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MMC Based Hybrid Switched Capacitor DC-DC Converter
MMC Based Hybrid Switched Capacitor DC-DC Converter
ABSTRACT Aiming to address the growth and the integration of renewable sources and electronic loads,
different types of dc-dc topologies with specific features have been proposed, going from medium frequency
isolated Modular Multilevel Converter to Switched Capacitor and Hybrid Switched Capacitor topologies. In
this paper, a bidirectional Modular Multilevel Converter based Hybrid Switched Capacitor dc-dc converter
is presented, featuring transformerless structure, automatic total arm voltages clamping/balancing, voltage
static gain independent of the submodules quantity and efficiency with reduced duty cycle influence. The
topology operates with a Quasi-Two-Level modulation, which provides passive components volume/weight
reduction, a degree of freedom regarding the dv/dt applied on the magnetic windings and basis to perform
the submodule capacitor voltages equalization within each arm. The topology operating principles are
approached by an average value static analysis, while an instant value static analysis is used to estimate
the operating current spike worst case. A 1.17 kW, 350/200 V laboratory scale prototype using IGBTs is
implemented to experimentally confirm the theoretical approaches.
INDEX TERMS Switched Capacitor, Modular Multilevel Converter, MMC, Hybrid Switched Capacitor,
Non-Isolated DC-DC Converters.
This work is licensed under a Creative Commons Attribution 4.0 License. For more information, see https://creativecommons.org/licenses/by/4.0/
142 VOLUME 3, 2022
voltage balancing between the upper and lower arms. How-
ever, when the difference between the input and output volt-
ages is significant, a high ac current and/or bulky arm passive
components are needed to achieve this balance, leading to
low efficiency and bad use of the components capacity in
these cases. This drawback is addressed in [14], [15], where
different current source modules are used to intermediate the
energy transfer between the dc terminals. Since the increase of
the SMs quantity takes to a decrease of the maximum output
voltage, these topologies covers applications that demand high
voltage ratio between dc input and output.
Another category of transformerless dc-dc converters is
composed by the Switched Capacitor (SC), Switched Inductor
(SL) and Hybrid Switched Capacitor (HSC) topologies [16]–
[22]. The operating principle of these converters consists in FIGURE 1. DC-DC converter.
parallel/series connecting groups of capacitors/inductors to
process the energy, which results in high voltage ratio ca-
pability and converters with high power density. Moreover,
self-voltage clamping and balancing of some components is analysis; a peak current estimation method that takes into
achieved on SC and HSC converters. On the other hand, the account the Q2L transitions and the SM capacitance effects;
efficiency dependence on the operating duty cycle, the large and experimental results to compare with the analytical data.
components count, the voltage ratio variation with the number This text is divided in a general topology overview, ap-
of cells and the current/voltage spikes concern can impose proaching the topological states and the applied modulation
some limitations or add complexity to these topologies. technique; an average value static analysis, to define the con-
This paper is aimed to present a bidirectional MMC based verter equivalent output resistance characteristic and the volt-
Hybrid Switched Capacitor (MMC-HSC-DC) dc-dc topology. age static gain; an instant value static analysis, to address the
It is a transformerless converter, that structurally differs from SC current spikes; and the laboratory scale prototype experi-
those in [6], [11] and [12] by the absence of the arms in- mental results along with discussion. Variables defined with
ductors. It provides a new strategy to balance the arms total small and capital initial letters represent ac plus dc signals
voltages, which become automatically clamped by the flying and signal average or RMS value, respectively. Matrices are
capacitor C f . Consequently, it is not necessary to generate defined by bold and initial capital letter variables.
an ac power flux through the arms to achieve the voltage
balance, unlike the mentioned topologies. Additionally, the II. PROPOSED DC-DC TOPOLOGY
converter acquires a switched capacitor operational behavior, The topology presented in this paper is a transformerless
demanding a new approach regarding the topology design, bidirectional dc-dc converter based on the integration of the
since issues like current spikes and equivalent output resis- Three-Level Buck converter (or dc-dc Flying Capacitor con-
tance must be addressed. verter) and the MMC. The representative diagram of the
On the other hand, when compared to other HSC convert- topology is presented in Fig. 1, which is composed by four
ers, the number of SMs in the MCC-HSC-DC arms can be series connected sets of N SMs, here defined as arms (Aa , Ab ,
changed without leading to output voltage range restrictions. Ac and Ad ), a flying capacitor (C f ) and an output LC filter
Furthermore, due to the topology operational symmetry, it can composed by Lo and Co. The LC filter input voltage is defined
be designed to reduce the duty cycle influence on the converter as vLC = vLo + vo. All the analysis presented in this paper
conduction losses. Hence, better efficiency behavior can be considers the topology operating in Buck mode, but can be
achieved in closed-loop operation. similarly applied to obtain the Boost mode equations.
The Quasi-Two-Level (Q2L) modulation [23] is used to The SM configuration can be chosen according to some
reduce the passive components size, to create a degree of desired features. For example, HB SMs will provide a low
freedom regarding the dv/dt applied on the magnetic, by account of semiconductors, reducing the converter complexity
limiting the voltage steps on the windings [24], and to provide and losses. On the other hand, the use of Full-Bridge (FB)
a voltage equalization method to balance the SM capacitors SMs in the upper arms (Aa and Ab ) provides bidirectional
within each arm. short-circuit interruption capability to the topology, improving
The step-down unidirectional variant of the proposed con- safety and robustness. All the analysis presented in this paper
verter is introduced in [25], where more superficial and gen- considers equal HB SMs composing the proposed converter.
eral topology analyses are developed. The current paper is
conceived to provide a broader and more detailed mathemati- A. TOPOLOGICAL STATES
cal approach regarding the topology operation, covering: two Initially, it is considered that all the SMs within an arm op-
operation modes; an equivalent output resistance thorough erate equally, always changing to the same requested state
FIGURE 2. Proposed converter topological states. (a) Topological state 1. (b) Topological state 2. (c) Topological state 3. (d) Topological state 4.
at the same time. Therefore, the N SMs of each arm can be Vo < VH /2. C f exchanges charges with Ceq,b . VH , C f and
represented by an equivalent SM, where Ceq,i = Csm /N and Ceq,d also exchange charges among themselves;
i ∈ {a, b, c, d} identifies the arms. Additionally, it is defined r State 3 (Aa = Ad = 0; Ab = Ac = 1): C f transfers en-
that an arbitrary arm assumes the state Ai = 1 when the cor- ergy through Lo to the output, decreasing vC f . The cur-
responding equivalent SM upper switch is off and the lower is rent iLo decreases if Vo > VH /2 and increases if Vo <
on, bypassing Ceq,i . On the other hand, Ai = 0 when the upper VH /2. C f exchanges charges with Ceq,c . VH , C f and Ceq,a
switch is on and the lower is off, connecting Ceq,i to the SM also exchange charges among themselves;
output. r State 4 (Aa = Ad = 0; Ab = Ac = 0): only Lo transfers
Considering that Aa = Ad and Ab = Ac , in order to avoid energy to the output on a free-wheeling behavior, de-
short circuits and high voltage differences when the switched creasing iLo. C f exchanges charges with Ceq,b . VH , C f
capacitor parallel connections are performed, four fundamen- and Ceq,a also exchange charges among themselves.
tal topological states, depicted in Fig. 2, can be obtained from
the arms configuration.
The converter behavior during each topological state can be B. MODULATION
described as follows: To operate the converter, the Q2L PWM modulation is cho-
r State 1 (Aa = Ad = 1; Ab = Ac = 1): VH transfers en- sen. Basically, it is composed by one triangular carrier with
ergy through Lo to the output, increasing iLo. C f ex- peak value Vp and by 4 N modulation signals, one for each
changes charges with Ceq,c . VH , C f and Ceq,d also ex- SM. Since Aa = Ad , there is always one modulation signal of
change charges among themselves; Aa equivalent to another of Ad . The same can be applied to
r State 2 (Aa = Ad = 1; Ab = Ac = 0): VH transfers en- the pair Ab and Ac . These definitions are represented by the
ergy through C f and Lo to the output, increasing vC f . modulation signals vm a,d and v b,c , respectively, where v b,c =
m m
The current iLo decreases if Vo > VH /2 and increases if Vp − vm . The implemented comparison logic between the
a,d
duty cycle regarding the time interval that Aa = Ad = 1. Each The initial values in (3) can be obtained by recursively
transition duration time is defined as t12 = t23 = t34 = equaling each vCα f 0 to the respective previous state final value.
t41 = ttr . The variable hC f = NRC f fs is a dimensionless parameter that
relates the time constant of the RC meshes composed by NR where Reqo is a function of hC f and D that represents the
and C f to the switching frequency fs (or switching period Ts ). topology equivalent output resistance. Since Reqo (hC f , D) is a
The longer is NRC f regarding Ts , the lower are the current quite large exponential equation, that do not provide a clear
spikes. idea of the responses caused by varying hC f and D, it is
Obtaining iat1 , iat2 and iat4 from the circuit analysis and decided to present an abacus to illustrate Reqo.
knowing that Iat1 = ILo, the following relation is achieved The lowest Reqo (hC f , D) value is 2NR, which is obtained
DTs when hC f → ∞. This value can be used to normalize Reqo, as
1
iat1 (t ) dt = ILo. (5) follows
DTs 0
Reqo Reqo
Solving (5) leads to Reqo (hC f , D) = = . (17)
lim Reqo 2NR
D −VH + 2VCeq,c + 2NRILo kr2 hC f →∞
VCeq,a = VCeq,c + , (6)
hC f kr1 − Dkr2
Sweeping (17) for different values of hC f and D results in
where the abacus presented in Fig. 4(a), which is intended to be used
1+4D 1+2D 1 1+D 2D D 1 as a design guideline to find C f or the switching frequency fs .
kr1 = e 2hC f − 2e 2hC f + e 2hC f + e hC f − e hC f + e hC f − e hC f As typical for SC converters, the increase of hC f leads the con-
(7) verter to operate in Partial Charge (PC) and No Charge (NC)
and modes [26], where Reqo and, consequently, the conduction
D
1 losses are both reduced, because of the lower current spikes
kr2 = e hC f
− 1 e hC f . (8) caused by the capacitors parallel connections. However, it
also makes Reqo to be more independent of D, which is an
On the other hand, ibα = iaα − iCα f average value is zero interesting characteristic in terms of the converter efficiency
within the interval from the beginning of t4 until the end when it is operated in closed-loop, since duty cycle variations
of t2 and the following relation is achieved will not significantly increase the conduction losses.
Ts In order to reduce the conduction power losses and its duty
1 2
ibα (t ) dt = 0. (9) cycle dependence, it is considered, from now on, that the con-
(1 − D)Ts −(1−D)Ts verter operates with hC f ≥ 0.5. Within this region, the maxi-
Solving (9) leads to mum value that Reqo can assume is 1.04, approximately, which
VH leads to an acceptable conduction loss penalty. Moreover, the
VCeq,c = − NRILo [1 − (1 − D) kr3 ] (10) Reqo variation with D is not significant. However, it must be
2
considered that the reduction rate of Reqo decreases for higher
and, replacing (10) in (6), takes to hC f values. In other words, the reduction in conduction losses
VH tends to not worth regarding the switching frequency and/or
VCeq,a = + NRILo (1 − Dkr3 ) , (11) C f increase, which is necessary to achieve such high hC f . In
2
this case, the switching losses and/or capacitor volume/weight
where
tend to be the converter limitation.
2 hC f kr1 + Dkr2 Taking into account that additional resistances and induc-
kr3 = . (12)
hC f kr1 − D (1 − 2D) kr2 tances will be part of the converter, due to the actual compo-
nents and PCB characteristics, a better damp of the current
The LC filter input voltage during t1 and t2 can be
spikes tends to be achieved in real operation. Therefore, to
described by
simplify the converter design, it is assumed that this additional
t1
vLC = VH − VCeq,b − NR iat1 + ibt1 (13) impedance sufficiently increases the total loop resistance, so
that the definition of R as the highest conduction resistance
and between the used switch and diode results in a good trade-off
between current spikes and component design.
t2
vLC = VH − VCeq,a − VCeq,b − NR iat2 + ibt2 , (14) Continuing the average value analysis, from (2) is also
which results in possible to obtain the following average value matrix
VH (1 − 2D) (1 − 2D)
Vo = VLC = − VCeq,a (1 − D) + VCeq,d D − NRILo. (15) A = A2 · D + A4 · + A3 · D + A4 · .
2 2 2
It is shown in the subsequent analysis that VCeq,a = VCeq,b (18)
and VCeq,c = VCeq,d . Therefore, replacing (10) and (11) in (15) The matrix B is similarly obtained.
leads to In steady state, ẋ = 0. Therefore, the state-space variables
average values are calculated by
Vo = DVH − 2NR [1 − D (1 − D) kr3 ] ILo, (16)
T
Reqo X = −A−1 · B · VH V f Vsat , (19)
VCo + kdr
out
DRo
MV DC = = . (22) D. INSTANT VALUE STATIC ANALYSIS
VH 2NR + Ro
This analysis basically consists in obtaining Ceq,i voltages and
Replacing (20) in (2) for the used set of topological states, currents equations as functions of time by solving (2). Once
average value representations of C f and Ceq,i currents (ICα f the analyzed system is composed by seven state variables, it
α , respectively) are achieved for each time interval α.
and ICeq,i is considered that, for simplification purposes, Vsat = V f = 0
Therefore, applying the RMS mathematical definition to ICα f and vC f is defined by (3). Additionally, iLo time equations
along Ts , the RMS values of C f currents for BM1 and BM2 are can be defined using (20) to find vLo for the used topological
respectively defined as states, since hC f ≥ 0.5.
√ At first, considering only BM1, the transition states in-
f ,BM1 = ILo 2D
ICrms (23)
fluence on this analysis has to be addressed. During ttr , an
and equivalent SM capacitor per arm is defined as follows
Csm
f ,BM2 = ILo 2 (1 − D)
ICrms (24) Csm + N−1 NCsm
tr
Ceq,i = = . (25)
Similarly, the average and RMS values of the equivalent 2 2 (N − 1)
SM lower switches (Si,L ) currents, shown in Table 2., can be Analyzing the interval from the beginning of t41 until the
obtained. These equations are valid for BM1 and BM2. end of t12 , it can be stated that Id = 0 and the Lo current
{α,β} {α,β}
TABLE 3 Values of the Constants Used in vCeq,a and vCeq,d resulting in
iC f ,p t1 t1 t1
iC f ,p = = iLo0 + iCeq0,d − iCeq0,a . (31)
ILo
FIGURE 6. iCf (Ch 1 - 5 A/div), vCf (Ch 2 - 100 V/div), vLC (Ch 3 - 100 V/div) and vo (Ch 4 - 50 V/div) steady state waveforms (20 μs/div) with: (a) D < 0.5
(b) D = 0.5 and (c) D > 0.5.
FIGURE 7. iLo (Ch 1 - 2 A/div), vCf (Ch 2 - 100 V/div), vLC (Ch 3 - 50 V/div) and vo (Ch 4 - 50 V/div) steady state waveforms (20 μs/div) with: (a) D < 0.5 (b)
D = 0.5 and (c) D > 0.5.
FIGURE 8. Detailed waveforms of: (a) iCf (Ch 1 - 5 A/div) and vCf (Ch 2 - AC coupling - 1 V/div) for D > 0.5 (20 μs/div) (b) iCf (Ch 1 - 5 A/div) and vLC (Ch 3
- 50 V/div) for D > 0.5 (1 μs/div) and (c) iCf (Ch 1 - 5 A/div) and vLC (Ch 3 - 50 V/div) for D = 0.5 (1 μs/div).
decreasing from 100% to 0% of the rated output power. The Applying the same mentioned load step, Vo converges and
disturbance behavior of the Aa SM capacitors voltages is stabilizes to the rated value after the transition period, as
presented in Fig. 9(b), where the proper equalization pro- depicted in Fig. 9(c). This behavior also indicates the power
cess can be noticed, with small deviation during the transient flux reversion. When the load is removed, vo increases. Con-
period. sequently, the inductor voltage assumes a negative average
With the converter operating in closed-loop for Vo, VC f value and ILo starts to decrease. When the direction of ILo
and ILo, the zero load operation stability and the topology is changed, i.e. ILo < 0, the topology boost operation begins
bidirectional characteristic are verified. The prototype is de- and energy starts to be processed from the low to the high
signed with a low Co value, in order to assess the converter voltage dc bus. Therefore, the output capacitor surplus charge
performance during considerable vo undershoot and overshoot is sent back to the converter input source after the load step. If
conditions. the bidirectional feature was not available, the output voltage
the semiconductors switching speed attached to the number [16] B. Axelrod, Y. Berkovich, and A. Ioinovici, “Switched-
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