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A High Step-Up Isolated DC-DC Converter Based On Voltage Multiplier Cell
A High Step-Up Isolated DC-DC Converter Based On Voltage Multiplier Cell
A High Step-Up Isolated DC-DC Converter Based On Voltage Multiplier Cell
Abstract—Generating sources of renewable systems, like
photovoltaic module or fuel cell, have a low output voltage that has
to be boosted for most of applications, such as grid-tie inverters.
To accomplish this, an isolated dc-dc high step-up SEPIC (single
ended primary inductor converter) with a Greinacher voltage
doubler cell is presented. It has the advantage of continuous input
current, high efficiency, high voltage gain, isolation and demands Fig. 1. MIC converter with emphasis on first stage.
a single switch, being suitable for low power grid-tie photovoltaic
systems. The operating principles and steady-state analysis are side. These VMCs used on secondary side are based on
presented, including the detailed analysis of resonant stage and the switched-capacitor techniques and the most commonly used are
effects of transformer winding capacitances on converter known as voltage doubler (VD) and voltage tripler (VT), with
operation are investigated. Moreover, the effects of resonance the possibility of expansion to raise voltage gain, although
frequency variations on converter efficiency is experimentally
investigated. Experimental results on a 50 kHz, 200 W prototype
increasing the number of converter components [4].
are presented to validate the proposed concept. Many authors have proposed new topologies with high
voltage gain without using transformer, combining voltage
Index Terms—Isolated SEPIC, Resonant stage, Voltage boosting techniques and the use of snubber circuit to reduce
multiplier cell. voltage spikes across the switch [5], or replacing diodes with
synchronous switches, achieving soft-switching and reducing
I. INTRODUCTION EMI issues [6]. Despite of its advantages, non-isolated
converters require additional circuits or techniques to mitigate
H IGH step-up converters are often used in renewable
systems, specifically in low power grid-tie systems with
two converters, where the output voltage of the photovoltaic
leakage current.
Galvanic isolation is desirable for this application in order to
module is low and has to be boosted, making the high-step up maintain security of the whole system, besides mitigating
dc-dc converter very attractive [1]. These systems, as shown in leakage current and electromagnetic interference (EMI)
Fig. 1, are also known as ac photovoltaic modules (module- problems [7]. Therefore, regarding isolated converters, in [8] a
integrated-converter – MIC), where a high step-up converter, in high voltage gain converter with a lower transformer turn ratio
first stage, provides a high voltage gain and is connected to a is obtained, through the integration of cascading boost with an
grid-tie inverter [2]. A great number of isolated and non- isolated buck-boost converter and mitigating voltage spike
isolated topologies have been proposed for this application. caused by leakage inductance. Despite of its advantages, this
Several classic non-isolated step-up converters can be used, converter has a large number of switches, which significantly
however, as many of them present reduced voltage step-up ratio increases the cost of whole system and, besides that, maximum
[3], methods to increase voltage gain are needed, such as efficiency obtained is not attractive for this application. There
cascade boost converters, coupled-inductor based boost are other options to increase maximum efficiency and obtain
converters, switched capacitor, switched inductor, voltage high voltage gain, with the use of a resonant full-bridge
multiplier, among others [4]-[5]. Voltage multiplier cells converter, replacing the secondary diodes with active switches,
(VMCs) applied on secondary side provide the advantages of obtaining soft-switching conditions for diodes and switches [9]
increased converter static gain, in some cases clamping the or with addition of a voltage multiplier on secondary side,
voltage spikes on diodes, without elevating voltage stress over reducing turn ratio of transformer [10]. Although these
the switch, unlike voltage boost techniques applied on primary advantages were experimentally validated, those converters still
This work was supported by Coordenação de Aperfeiçoamento de Pessoal Electrical Engineering, Federal University of Santa Maria, Santa Maria
de Nível Superior – Brasil (CAPES/PROEX) – Financial Code 001, INCTGD, 97015900, Brazil. (e-mails: adoandres, Leonardo.romitti, roggia, schuch.prof
CNPq (465640/2014-1), CAPES (23038.000776/2017 – 54), FAPERGS {@gmail.com})
(17/2551-0000517-1). Fabrício Hoff Dupont is with Technology Development Group, Community
Bernardo Andres, Leonardo Romitti, Leandro Roggia and Luciano Schuch University of Chapecó Region, 89809-900, Chapecó. (e-mail:
are with Power Electronics and Control Research Group, Department of fhdupont@gmail.com)
2
Fig. 2. Isolated SEPIC derivation: (a) Classic SEPIC; (b) Isolated SEPIC using cantilever model; (c) Isolated SEPIC with VMC on secondary side.
have the same problem of excessive number of active switches converter is presented in Section II. In [19] a similar topology
for a low power application. is presented, however, some notables differences in our work
In this low power application, some authors have proposed are: reduced leakage inductance and higher magnetizing
a single switch converter, using coupled inductor for isolation inductance, no use of snubber circuit with low voltage stress
and VD circuit on secondary side to increase voltage gain [11]. across the switch and, besides that, primary capacitor C is taken
Despite of these advantages, this topology has a large leakage into account on resonance analysis and effects of winding
inductance, due to coupled inductor, which requires an transformer capacitance are investigated.
additional snubber circuit. Furthermore, maximum efficiency is The converter has the following features: 1) quasi zero-
obtained in a very low power, while in the full-load condition current switching (qZCS) turn-on of switch disregarding the
this value is considerably lower. Similar to this, a current-fed use of snubber circuit; 2) ZCS turn-off of all diodes, mitigating
converter with high voltage gain also uses a voltage multiplier losses associated with diode reverse recovery; 3) Clamp of
on secondary and a snubber circuit on primary, mitigating voltage spikes across the diodes; 4) Small input current ripple
voltage spikes across the switch [12]. Once again, the problems due to input inductor; 5) Reduced voltage spikes across the
are low maximum efficiency in the full-load condition, besides switch, without use of snubber circuit, due to low leakage
the requirement of using a snubber circuit due to high leakage inductance of transformer; 6) High efficiency with low cost,
inductance. Some other works proposed different snubber achieving high voltage gain. Experimental results on a 50 kHz,
circuits that can be used in single switch converters with high 200 W prototype are presented to validate these features.
leakage inductance [13]-[14], but, even with the improvements, In Section II, the derivation of converter is presented,
in general the results are unattractive, without reaching a high showing some cells used on secondary and its influence on
efficiency, considering the addition of an auxiliary circuit. magnetizing current, justifying the choice of VD cell. In Section
Therefeore, single switch converters are more suitable for III, theoretical analysis of proposed converter is presented, with
lower power applications, reducing volume, costs and emphasis on resonant stage and effect of winding transformer
complexity. Basic single switch isolated topologies are: capacitance on converter operation. Experimental results are
flyback, ZETA, SEPIC and Ćuk. Flyback converter is suitable shown in Section IV, validating the proposed concept and
for low power applications, however, it has low efficiency verifying the effects shown on previous section. Section V
because of the high voltage and current stresses on the concludes the paper.
components [15]. Moreover, it presents problems regarding to
high leakage inductance, due to its coupled inductor, which II. DERIVATION OF CONVERTER
causes several voltage spikes across the switch and rectifying From the classic SEPIC topology, shown in Fig. 2a, the
diode, and discontinuous input current, requiring a large input iSEPIC is obtained substituting the inductor Lo by a coupled
capacitance [16]. Isolated ZETA converter has the same inductor, using the Cantilever model, which is an interesting
problem of discontinuous input current and high leakage option to represent the magnetic element (transformer or
inductance. Those two converters always require a coupled coupled inductor) on isolated converters [20], as shown in Fig.
inductor for isolation, even with the use of different cells to 2b. In order to increase the voltage gain without increasing the
increase its voltage gain. Among these options, isolated SEPIC voltage stress over switch, the VMC is added on secondary side,
and Ćuk converters are a good option for this application, since as shown in Fig. 2c. Greinacher VD cell, Dickson and Ladder
they provide continuous input current, however, Ćuk has a VT cells, shown in Fig. 3, are interesting options that can be
higher component count, in standard version and with increase used on secondary side [21]-[23]. Besides the increase of
of cells, as shown in [17]. Hence, isolated SEPIC (iSEPIC) is a voltage gain, the circuit of these cells mitigates the voltage
very good choice, with low component count, and significantly spikes over the diodes. As aforementioned, an appropriate
reducing the dc magnetizing current with the appropriate choice choice of VMC can significantly reduce the dc magnetizing
of voltage multiplier cells (VMCs), allowing to use a current, guaranteeing that the magnetizing inductance, Lmag¸
transformer instead of coupled inductor [18], besides increasing does not store energy. Thus, a transformer is used for galvanic
voltage gain.
Therefore, this paper proposes an isolated single switch dc-
dc converter achieving high voltage gain and high efficiency
using a transformer for galvanic isolation without using a
snubber circuit, which significantly reduces volume and cost of
the whole system. To achieve this, a VD cell is used on
secondary side of an iSEPIC. The derivation of proposed Fig. 3. Cells applied on secondary to increase voltage gain.
3
shown in Fig. 5.
The main advantage of this feature is the use of a transformer
instead of a couple inductor. Besides the aforementioned
advantage of better utilization of BxH curve, leakage flux on
transformer is intrinsic and results of its design, while in
coupled inductor this is necessary to store energy, resulting in a
dc component on magnetizing current [24]. Leakage inductance
effects on power converters are well known and the main
concern is voltage stress across the switch, due to large spikes,
requiring a snubber circuit. Therefore, Greinacher voltage cell
applied on secondary of isolated SEPIC increases converter
static gain and efficiency while reduces volume and cost.
Fig. 9. Current flow path in four stages during one switching period in CCM
operation: (a) stage I; (b) stage II; (c) stage III; (d) stage IV.
vc
vC (t ) Vin vC max , (5)
2
V
iLin t iLin t0 in t, (6)
Lin
vCr min Vo
vC max
Fig. 8. Key waveforms of VDiSEPIC in CCM operation. i1 t ni2 (t ) niD 2 i1 (t0 ) n t, (7)
Lr
mode. This will receive more attention during the description
of operation stage II and in experimental results. vC max
iLmag t iLmag t0 t, (8)
Fig. 8 shows the key waveforms of the converter in one Lmag
switching period, in continuous-conduction-mode (CCM). It is
is (t ) iLin t iLmag t i1 t . (9)
important to mention that these waveforms are obtained for
operation below resonance frequency. The converter has four
operation stages in one switching period, as shown in Fig. 9. Stage II (t1 – t2): This stage begins when current i1 changes
The converter operation is given as follows: its direction, therefore, the diode D1 is turned on. A resonance
occurs among Lr and the equivalent capacitance, obtained from
Stage I (t0 – t1): This stage begins when switch S1 is turned a series association of Cr and C reflected to secondary. Hence,
on. For a short period, the current i1 has a linear decreasing, due during this stage, the current through D1 is sinusoidal, while the
to the negative voltage over the leakage inductor, current through the switch is a combination of this sinusoidal
demagnetizing it. This also happens with iD2, that has a linear current, from the resonance, with a trapezoidal current, from
decreasing, with the same rate of i1 reflected to secondary side. input inductor, Lin. Currents through Lin and Lmag are increasing
On the other hand, the switch current, iS, has a linear increasing, linearly, since the voltage across Lin is equal to Vin and voltage
with the same rate of i1. This results in a quasi-ZCS turn on of across Lmag is equal to vC. During this stage, the capacitor C is
the switch. This stage ends when current i1 reaches 0 A and discharged, while the capacitor Cr is charged. The equivalent
diode D2 is turned off under ZCS condition. The duration of this circuit, used to analyse the resonance and obtain the resonant
stage is considerably smaller than stage II and, moreover, the parameters, reflecting Lr and C to secondary, is shown in Fig.
voltage ripple over the capacitors ideally is small, therefore, 10.
because of this, the voltages across capacitors are constant on Taking into account that magnetizing inductance is
this stage. The main equations of this stage are given by significantly higher than leakage inductance, this element can
v be neglected in resonance analysis. In Fig. 10, leakage
vCr (t ) nVin Cr vCr min , (4) inductance Lr is referred to secondary multiplying its
2
inductance by square of turn ratio, n², and C is referred to
secondary as CS, dividing its capacitance by n². The equivalent
5
vc
vC (t ) Vin vC min , (18)
2
Vin T
iLin t iLin t 2 t R =iLin max , (19)
Lin 2
Fig. 10. Converter equivalent circuit of resonant stage. vC min T
capacitance is composed by a series association of Cs and Cr.
iLmag t iLmag t2 t R =iLmag max , (20)
Lmag 2
Therefore, Ceq, resonance frequency, fr, and resonant
is (t ) iLin t iLmag t . (21)
impedance, Zr, are given by
Vin V
VDS o. (28)
1 D n
For diodes D1 and D2, the voltage stresses are given by
nVin
VD1 VD 2 Vo (29)
1 D
voltage stress over switch. On the other hand, low values of TABLE I
duty cycle increase the required turn ratio, which causes more Main Parameters and Component Rating
transformer losses. Therefore, turn ratio has to be equal to six Parameter/Component Specification/Value
Input Voltage 37.4 V
to obtain the specified output voltage. Finally, switching Duty Cycle 0.44
frequency is equal to 50 kHz. Output Voltage 400 V
1) Transformer Switching Frequency 50 kHz
Switch S IPP051N15N5 (150 V/120 A, 5.1 mΩ)
The transformer was acquired through a local supplier of
Diodes D1, D2 MUR860 (600 V/8 A, vf = 0.9 V)
magnetic materials, called Magmattec – Technology in Transformer
500 nH, 1 mH, 8:48, 2xMMT520T40.31.10B [30]
Magnetics Materials. The design of this component was made Lr, Lm, N1:N2, Core
9 mΩ (3x20 AWG), 318 mΩ (1x25 AWG)
considering a maximum flux density of 0.51 T, using two DCR N1, DCR N2
Input Inductor Lin 220 µH/ 77090 [33]/ DCR: 38 mΩ (1x18 AWG)
nanocrystalline cores, model 2xMMT520T40.31.10B [30], in 4x10 µF/100 V Electrolytic ESK106M063AC3 (32 mΩ)
Input Capacitor C
parallel. These cores have positive characteristics that provide 3x3.3 µF/100 V film BFC246804335 (10 mΩ)
low leakage flux and consequently a small leakage inductance. Resonant Capacitor Cr 3x470 nF/250 V film BFC246817474 (8 mΩ)
Output Capacitor Co 1x100 µF/450 V Electrolytic B43505C5107M000 (960 mΩ)
The primary coil is composed of three AWG 20 wires in
parallel, resulting in a copper wire resistance of 9 mΩ. The resonate with Lr, this intrinsic capacitance cuts off part of the
secondary coil is composed of one AWG 25 wire, resulting in a resonant current in the beginning of stage II. Therefore, the
copper wire resistance of 318 mΩ. The leakage inductance is converter was initially tested with the capacitance C equal to 33
500 nH, while the magnetizing inductance is 1 mH. µF and the capacitance Cr equal to 1 µF. According to (11),
2) Capacitors considering theses capacitances, the leakage inductance, the
The input capacitor and resonant capacitor are defined by switching period and duty cycle, half of the resonant period has
two conditions: maximum voltage ripple of 5% and an a closer value to the period that switch is ON, being equal to 8.8
µs. However, in the experimental test, half of resonant period
equivalent capacitance Ceq that guarantee converter operation
has an approximate value of 7 µs. Taking this into account, both
below resonance operation, according to (10)-(11). From (32),
capacitances were increased until Tr/2 has a close value to DTs.
the minimum capacitance obtained is equal to 32 µF. From (33),
This condition is obtained for C = 50 µF and Cr = 1.4 µF.
the minimum capacitance obtained is equal to 890 nF. It is According to (29) and (30), the ripple of vC is equal to 3.2%,
important highlight that the winding transformer capacitance while ripple of vCr is equal to 3.18%. Due to the low availability
has a significant impact on resonant waveforms. Briefly, the of capacitors in the laboratory, to achieve the required
discharge of this capacitance directly affects the resonant stage capacitances, C is composed of a parallel association of
II, therefore, a linear current cuts off part of resonance, reducing electrolytic and film capacitors, while Cr is composed of a
its period. The experimental results in next section will show parallel association of film capacitors.
this effect. Therefore, the solution is to test the converter using Fig. 13 shows main waveforms of switch at full-load
capacitance values for C and Cr close to what was obtained with condition with a zoom on turn-on transition. iS waveform shows
(32) and (33), and slowly increase these values until converter that converter is operating near to second mode, since half of
is operating near the condition Tr/2 = DTs. As to the output resonant period is lower than the period that switch is on, and
capacitor, the maximum voltage ripple defined is equal to 0.1%, the effect of Ct can be seen, being in agreement with theoretical
therefore, according to (34), the minimum capacitance obtained analysis and waveforms of Fig. 12. Furthermore, the zoom on
is equal to 11.2 µF. turn-on transition shows that turn-on switching losses are
3) Input Inductor negligible. Finally, it can be seen there is a voltage spike across
The input inductor was chosen to guarantee a maximum switch due to leakage inductance of transformer, although, this
current ripple of 30%. From (31) the minimum inductance is not a concern, once that maximum voltage across switch is
obtained is 205 µH. Therefore, an inductor was made using a 95 V, while maximum voltage of switch S1 is 150 V and there
Kool Mu toroidal core, model 77090 [33], with an AC flux of is no need to use an additional snubber circuit. This happens
0.035 T. A single AWG 18 wire was used with 35 turns, because leakage inductance has a small value, a positive
resulting in a DCR equal to 38 mΩ. The obtained inductance is characteristic of well-designed transformers using
equal to 220 µH. nanocrystalline core.
4) Semiconductors Fig. 14 shows main waveforms of transformer. The
The choice of the semiconductors is based on maximum waveform of i1 confirms the converter operation in first mode,
voltage and current stresses over them. Therefore, the chosen
switch is the IPP051N15N5, while the chosen diodes are
MUR860.
10 V/div
10 µs
substantial difference to the theoretical due to the effect of
Fig. 13. Experimental waveforms of switch S1 with zoom on turn-on.
winding transformer capacitance. Different from C and Cr, that
8
20 V/div
vGS
10 A/div
i1
50 V/div
v n1
250 V/div
vn2 10 µs
20 V/div 20 V/div
v GS v GS
10 A/div 10 A/div
i1 i1
is is
10 A/div 10 A/div
(a) (b)
20 V/div 20 V/div
v GS vGS
10 A/div 10 A/div
i1 i1
is is
10 A/div 10 A/div
(c) (d)
Fig. 18. Experimental waveforms of vGS, i1 and is using: (a) C1 = 0.43 µF; (b) C1 = 0.9 µF; (c) C1 = 7.97 µF; (d) C1 = 10.33 µF.