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5.a High Voltage Gain DC-DC Converter Based On Three Winding
5.a High Voltage Gain DC-DC Converter Based On Three Winding
5.a High Voltage Gain DC-DC Converter Based On Three Winding
Abstract- This paper introduces a single-switch, high step-up, decrease the semiconductors voltage stress, and enhance the
DC-DC converter based on coupled-inductor (CL) with three conversion efficiency of the high step-up DC-DC converters
winding and voltage multiplier cell (VMC) to obtain a very high constitutes the major concerning issues.
voltage conversion ratio. A passive clamp circuit is applied in the Recently, most of the growths in the installed renewable
converter to recycle the energy of leakage inductance and reduce
voltage stress of the main power switch. This leads to utilize a
energy resources systems have been allocated to the grid-
power switch with low on-state resistance and low voltage-rating connected systems market compared to the off-grid market.
that decreases the conduction losses. Several advantages include Moreover, for example in PV systems, compared with either
low operating duty cycle, high voltage conversion ratio, low turn line frequency or high frequency transformers, the
ratio of the coupled inductor, leakage inductance reverse transformer-less PV system has typically a higher-efficiency
recovery, reduced voltage stress of semiconductors, alleviation of and reliability, as well as lower complexity and manufacturing
diodes reverse recovery issue and high efficiency make the cost. Besides, it is worth noting that, the PV module must be
presented topology appropriate for sustainable energy grounded in most standards in order to eliminate common
applications such as photovoltaic systems. The operation mode current. One convenient way to reach this goal is to
principle and steady-state analysis of the suggested topology in
continuous conduction mode (CCM) are expressed in detail. Also,
implement a common grounded transformer-less inverter. In
design procedure and theoretical efficiency analysis of the order to eliminate common mode current in grounded PV
proposed topology are presented. Moreover, a comparison study systems, the step-up DC-DC converter should allow a shared
is performed to demonstrate the superiority of the presented ground between the PV ground and the grid neutral line [2, 3].
converter over several similar recently proposed DC-DC In the actual systems having high voltage gain helps DC-
converters. Finally, the proposed DC-DC converter feasibility DC converters to operate in a very suitable duty cycle. It is
and performance are justified through fabricated 216 W important to note that when a DC-DC converter operates in
laboratory prototype at 50 kHz switching frequency. very large duty cycles, the conduction period of power
switches and diodes of the converter will be increased.
I. INTRODUCTION Therefore, the conduction losses of the switching devices will
be increased which results in high power losses in the actual
Nowadays, high step-up DC-DC converters have a
systems [4]. Thus, high step-up converters with high
significant role in sustainable energy applications include
efficiency are needed. Moreover, the large duty cycle not only
photovoltaic (PV) systems, wind power, fuel cells (FCs), etc.
induces very large voltage spikes and increases conduction
In order to decrease problems such as air and environmental
losses but also induces severe diode reverse-recovery problem
pollution and global warming that have been emerged by
[5].
using fossil fuels, sustainable energy resources are applied to
Recently, various step-up DC-DC converters with several
produce electric power. However, the produced DC voltage
techniques of voltage boosting have been presented [6].
level of resources such as PV and FCs are low so it is not
Isolated converters have a high voltage conversion ratio due to
suitable for connecting to the grid. According to the above
utilizing transformers with large turn ratio. However, too large
mentioned problem, high step-up DC-DC converters are
turn’s ratio leads to a large leakage inductance, which
required to increase the output DC voltage level of such
decreases the converter efficiency and increases the switch
resources [1]. How to step up voltage conversion ratio,
voltage stress [7, 8]. Moreover, when the galvanic isolation is
Manuscript received Apr 19, 2019; revised Jul 09, 2019 and Aug 25, not needed in the power grid, the conventional boost converter
2019; accepted Sep 22, 2019. (Corresponding author: Farzad Sedaghati) appears as a first choice in boosting the voltage gain due to its
M. Eskandarpour Azizkandi, F. Sedaghati and H. Shayeghi are with
the Department of Electrical and Computer Engineering, University of
low cost and simple structure. However, low voltage
Mohaghegh Ardabili, Ardabil, Iran (emails: conversion ratio, high voltage stress on semiconductors and
m.eskandarpour@student.uma.ac.ir; farzad.sedaghati@uma.ac.ir; reverse recovery issues are the basic problems of this
hshayeghi@gmail.com). converter in high power applications. Moreover, another
F. Blaabjerg is with the Department of Energy Technology, Aalborg
University, 9220 Aalborg, Denmark (email: fbl@et.aau.dk).
solution to boost voltage gain is the switched inductor (SI) and
switched capacitor (SC) DC-DC converters [9-10]. These
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(d) (e)
Fig. 2. Current flow path of presented converter in one period at CCM operation: (a) Mode 1, (b) Mode 2, (c) Mode 3, (d) Mode 4, and (e) Mode 5.
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In order to choose the proper power switch and diodes for ( peak ) 4 D (2n 2 n3 )(2 D ) 1 DV in
the suggested topology, current and voltage stresses of these I switch IO (21)
D (1 D ) 2 Lm f s
elements should be determined.
According to Fig. 3, based on capacitor C2 charge balance, the
A. Current Stress Analysis time transition of Mode 4, DC , is achieved as follows:
According to steady-state analysis, the current ripple of the DC [2(1 D ) / (2 2n2 n3 )] (22)
magnetizing inductance in CCM operation is determined as: Therefore, by using (22), the peak value of diode D1 current,
I Lm [DV in / Lm f s ] [DV inTs / Lm ] (16) I D( peak ) , is obtained as given in (23).
1
Where fs is the converter switching frequency.
Moreover, the average current of the magnetizing 2i D1 2I O (2 2n 2 n3 )I O
I D( peak ) (23)
inductance Lm is achieved as given in (17). 1 DC DC (1 D )
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B. Voltage Stress Analysis gain, besides that the component number of the suggested
According to the converter operation principle, the voltage converter is equal to the converters presented in [18-21], [27,
stress of semiconductor components are calculated as given in 28] and [30], the voltage gain of the suggested topology is
(24)-(26). higher than them. Moreover, it is worth noting that the voltage
1 1 gain of the converters suggested in [15-17], [24] and [31] is
V stress S1 V stress D1 V in V O (24) lower than the proposed converter with more numbers of
(1 D ) (3 2n 2 n3 )
power components. Although, the component number of the
(1 n 2 ) (1 n 2 ) converters presented in [9, 22, 23, 25, 26] and [29] is lower
V stress D 2,3 V in VO (25)
(1 D ) (3 2n 2 n3 ) than the proposed converter. However, their voltage gain is
(1 n 2 n3 ) (1 n 2 n3 ) remarkably lower than the presented structure. Moreover,
V stress D 4,O V in VO (26) between the input and output of the suggested structure, there
(1 D ) (3 2n 2 n3 ) is a common ground connection, which is a very important
factor for a step-up front-end DC-DC module of a
C. Magnetizing inductance design transformer-less grid-tied inverter.
In order to guarantee the operation of the suggested According to Fig. 5, the voltage gain of the suggested
converter in CCM, the average current through the magnetic topology is greater than the topologies presented in [9] and
inductance, ILm, must be higher than half of the current ripple [15-31] for all ranges of duty cycle with n2=2 and n3=1. This
of magnetic inductance, ∆ILm. The continuity of the advantage is due to the integration of a three-winding coupled
magnetizing current is also considered in the design of the inductor with the VMC in the suggested structure. As
magnetizing inductance. Therefore, by using (16) and (17), the indicated in Fig. 6(a), the main switch normalized voltage
magnetizing inductance minimum value for the presented stress in the presented topology is less than the other
converter is obtained as follows: topologies for any values of the duty cycle.
Lm [D (1 D )2 RO / 2fs (3 2n 2 n3 )2 ] (27)
According to (27), magnetizing inductance must be more than
15 µH. Thus, to guarantee CCM operation of the implemented
prototype, a coupled inductor that has a 100 µH magnetizing
inductance is applied.
D. Capacitors design
In order to suppress the capacitors voltage ripple, the
minimum capacitance should be determined. All capacitors
are designed by assuming the same voltage ripple. According
to (10)-(13), the voltages of capacitors C1-C4 for the proposed
topology are achieved. Since the charge absorbed or produced
by all capacitors are equal, and according to ∆Q = C∆VC =
IC∆T, the size of the capacitors are derived as given in (28)
and (29).
C i [V O / V Ci RO f S ] (28) Fig. 5. Voltage gain comparison of several boost converters. (n2=2, n3=1)
CO [DV O / V CO RO f S ] (29)
Moreover, Fig. 6(b) illustrates the normalized voltage stress
where i=1, 2, 3 and 4. across the output diode that has the maximum voltage stress in
Some power is dissipated when the equivalent series the high step-up converters. As indicated in this figure, the
resistance (ESR) of capacitor is considered. As the capacitance normalized output diode voltage stress in the presented
of an aluminum electrolytic capacitor increases, its ESR will converter is less than the topologies presented in Table I for
be smaller. So, in general, the capacitance is chosen to be any values of the duty cycle (even in [15-18] and [24]). Also,
much larger than the calculated value. The sizes of the converters in [15-18] and [24] have less normalized output
capacitors that are employed in the implemented prototype diode voltage stress than the suggested converter. However,
satisfy the equations derived in (28) and (29). they have also more components, higher switch voltage stress
and lower voltage gain than the suggested converter.
IV. COMPARISON OF THE PROPOSED CONVERTER Finally, according to the comparison study, the proposed
converter has a remarkably higher voltage gain over other high
To demonstrate merits of presented converter and confirm step-up converters due to integrating three-winding CL,
its performance, some comparisons are discussed in this voltage lift capacitor (C2) and VMC network. Also, utilizing a
section. The main features of the suggested converter and three winding CL in the structure of the converter results in
similar coupled inductor based converters using a single more flexible regulation of the voltage conversion ratio and
switch recently presented in [9], [15-31] are indicated in Table voltage stress on each semiconductor component. Having an
I. As demonstrated in this table, with considering the voltage ultra large conversion ratio causes to operate proposed
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TABLE I. COMPARISON OF THE PRESENTED DC-DC CONVERTER WITH SEVERAL OTHER SIMILAR TOPOLOGIES.
Number of Voltage Voltage stress Voltage stress C-
Reference Components gain on main switch of output diode(s) g
D C S CL+L
Proposed converter 5 5 1 13w +0 (3 2n2 n3 ) / (1 D ) V O / (3 2n2 n3 ) (1 n2 n3 )V O / (3 2n2 n3 ) Y
(3 n2 n3 ) / (1 D ) V / (3 n n ) (1 n n )V / (3 n n )
3w
Converter in [27] 5 5 1 1 +0 N
O 2 3 2 3 O 2 3
Converter in [28] 6 6 1 13w +0 (2 n2 n3 (2 D )) / (1 D ) V O / (2 n2 n3 (2 D )) (1 n2 n3 )V O / (2 n2 n3 (2 D )) Y
Converter in [29] 4 4 1 13w +0 (2 n 2 n3 (1 n 2 )D ) / (1 D ) VO / (2 n2 n3 (1 n2 )D ) (1 n2 )V O / (2 n2 n3 (1 n2 )D ) Y
(1 n2 n3D ) / (1 D ) V O / (1 n2 n3D ) (n2 )V O / (1 n2 n3D )
3w
Converter in [30] 5 5 1 1 +0 Y
Converter in [31] 6 5 2 23w +0 2( N 1) / (1 D) VO / 2( N 1) (2 N 1)VO / 2( N 1) Y
(4 n2 (2 D ) D ) / (1 D ) / (4 n2 (2 D ) D ) (n2 (2 D ) D )VO / (4 n2 (2 D ) D )
2w
Converter in [17] 8 8 1 1 +1 VO Y
Converter in [18] 5 5 1 12w+0 (2 n 2 (3 D )) / (1 D ) V O / (2 n 2 (3 D )) (1 n2 )V O / (2 n 2 (3 D )) Y
Converter in [19] 4 5 1 12w+1 (1 D n2 (2 D )) / (1 D ) V O / (1 D n2 (2 D )) (1 n2 )V O / (1 D n2 (2 D )) Y
Converter in [20] 4 5 1 12w+1 (2 n2 D ) / (1 D ) V O / (2 n2 D ) (1 n2 )V O / (2 n2 D ) Y
Converter in [21] 4 5 1 12w+1 (2 n2 (n2 1)D ) / (1 D ) V O / (2 n2 (n2 1)D ) (1 n2 )V O / (2 n2 (n2 1)D ) Y
Converter in [22] 2 3 1 12w+1 (1 n2 ) / (1 D) VO / (1 n2 ) VO Y
Converter in [23] 2 3 1 12w+1 (1 (n 2 1) D) / (1 D) VO / (1 (n 2 1) D) (1 n2 )VO / (1 (n 2 1) D) Y
Converter in [24] 6 6 1 12w+0 (2 n2 D 2n2 (1 D)) / (1 D) VO / (2 n2 D 2n2 (1 D)) (n2 )VO / (2 n2 D 2n2 (1 D)) Y
(BCISC(D)+VM)
Converters in [9 & 25] 4 4 1 12w+0 (2 n 2 n2 D) / (1 D) VO / (2 n 2 n2 D) (1 n2 )VO / (2 n 2 n2 D) Y
Converter in [26] 3 4 1 12w+1 (1 n2 ) / (1 D) VO / (1 n2 ) (n2 )VO / (1 n2 ) Y
Converters in [15&16] 6 6 1 12w+0 1 2n2 n2D / (1 D ) V O /1 2n2 n2D (n2 )V O /1 2n2 n2D Y
D=Diode; C=Capacitor; S=Switch; CL=Coupled Inductor; L=Inductor; 3w=3-winding; 2w=2-winding; C-g: Common grounded; Y: Yes; N: No
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A2 (0.5) f S I SVS (ton toff ) (33) 1.5 uH; N1: N2: N3=1: 2: 1; Capacitors type: Electrolytic
capacitor; C1-C4: 47 uF/250V; Cin: 470 uF/63V; CO: 220 uF/
where ton and toff are rise and fall times of the switch that are
450V; Power switch (S): IRFp260n [PD - 94004B] n-channel
given by device static characteristics provided by manufacture
MOSFET (VDSS=200 V, ID=50 A, RDS(on)=0.04 Ω); Diodes
datasheet information, IS is the switch current during the
(D1-D4 and DO): MUR1560 ultra-fast diode (VR=600 V,
switching time and VS is the switch maximum voltage stress.
IF(ave)=15 A, VF=1.2 V);
A3 is the diodes forward resistance loss of the converter and
Experimental measurement results of the converter
can be calculated as given in following:
2 operation in CCM are given in Fig. 7. As depicted in Fig. 7(a),
D (2 2n 2 n3 )I O 2I
2 2
2I (34)
A3 R FD 1 C (R FD 2 R FD 4 ) O (R FD 3 R FDO ) O the measured output and input voltage is about 418 V and 28
(1 D ) D 1 D V, respectively. According to this figure, the ripple of the
A4 is the diodes forward voltage loss and equals to: output voltage with the output capacitor of 220 µF is very low.
A4 V FD14,O I D14,O(ave ) I O (V FD1 V FD 2 V FD 3 V FD 4 V FDO ) (35) As illustrated in Fig. 7(b), the maximum voltage on the main
power switch is about 60 V and far lower than the output
A5 is the power losses of the capacitors of the converter, which
voltage (about 14% of the output voltage). Thus, a switch with
can be determined as given in (36).
low RDS(on) resistance can be utilized to enhance the overall
A5 rC 1,2,3,4,O (I rms
2
,C 1,2,3,4,O ) (36) efficiency. According to Fig. 7(b), the duty ratio of the main
A6 is the conduction loss of the primary, secondary and tertiary switch is close to 0.50. Fig. 7(b) demonstrates that the leakage
sides of the coupled inductor in the converter that can be inductance stored energy is recycled to the capacitor C1
formulated as: through diode D1 (ID1). Fig. 7(a) indicates the input current
waveform that is identical with leakage inductance current
A6 R LN 1 (I rms
2
,LN 1) R LN 2 (I rms ,LN 2 ) R LN 3 (I rms ,LN 3 ) (37)
2 2
without an input filter. The ripple of the input current is more
Finally, A7 is the core losses of the coupled inductor that can than other presented high step-up converters such as the
be determined with the Steinmetz equations and expressed as: topologies presented in [17], [19-23] and [26]. However, as it
A7 Kf ( Bmax ) Aclc (38) is depicted in Fig. 7(a) (ISource), a low pass filter can be utilized
where Ac is a cross sectional area of the core, lc is the mean to decline the input current ripple. According to Figs. 7(b) and
path length of the core and Bmax is the peak flux density. (d), the diodes D1, D2 and DO measured voltage stress are
Typically values of 𝐾, 𝛼, and 𝛽 are provided in the datasheet found to be about 60 V, 158 V and 218 V, respectively. It is
by the manufactures. obvious that the output voltage is far higher than the diodes
Moreover, the voltage gain of the suggested converter voltage stresses; hence, ultrafast diodes are employed to
including the conduction losses can be determined as follows: alleviate the reverse recovery current. The capacitors C1-C4
voltage waveforms are indicated in Fig. 7(c), which are in
MCCM [ (3 2n2 n3 ) / (1 D)] (39)
agreement with (10)-(13). The current in the diodes D1, D2 and
DO and switch S are shown in Figs. 7(a) and (d). The obtained
VI. EXPERIMENTAL RESULTS ANALYSIS results confirm the theoretical waveforms, given in Fig. 3.
Fig. 8(a) shows the measured efficiencies of the suggested
In order to justify the feasibility and verify the theoretical converter under several output powers for two different input
analysis of suggested converter, the experimental results of voltages while the output voltage (VO) is regulated at 418 V in
216 W implemented power circuit of the suggested topology both conditions. The peak value of the efficiency is 96.2%
are presented. In all the figures, the time per division is set to which is obtained at 180 W when Vin=38 V and the measured
be 8 µs. The specifications of the implemented converter are efficiency of the converter at nominal power is about 94% (Vin
given as follow: = 28 V). It can be found that as the input voltage increases, the
Input voltage: 28 V; Output voltage: 418 V; Output power: efficiency of the converter is enhanced.
216 W; Duty cycle: 0.50; Switching frequency: 50 kHz; Fig. 8(b) shows the efficiency comparison of the proposed
Coupled inductor: EE-55/28/21 ferrite core; Lm=100 uH; Lk converter with other similar topologies while keeping the
Vo (100V/div)
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