DC-DC Conversion Techniques and Their Circuit Analysis

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UNIVERSITI TEKNOLOGI MALAYSIA
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SEE 4433 Power Electronics And Drives

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Chapter 3:
DC to DC Conversion (Choppers)
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General
Overview
Buck converter Boost converter Buck-Boost converter
Switched-mode power supply (SMPS)

- fly back converter - forward converter - bridge converter
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DEFINITION
DEFINITION: Converting the unregulated DC input to a controlled DC output with a desired voltage level. General block diagram:
Applications: High-frequency switched-mode power supply (SMPS), DC motor control (traction, forklift, electric vehicles, trams, battery chargers, capacitor chargers)
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Linear Regulator
Transistor is operated in linear (active) mode. Output voltage:
The transistor can be conveniently modeled by an equivalent variable resistor, as shown. Power loss is high at high current due to:
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Switching Regulator
Transistor is operated in switched-mode: Switch closed: Fully on (saturated) Switch opened: Fully off (cut-off)
When switch is open, no current flow in it When switch is closed no voltage drop across it. Since P=V.I, no losses occurs in the switch. Power is 100% transferred from source to load. Power loss is zero (for ideal switch):
Switching regulator is the basis of all DC-DC converters

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Duty cycle D: 0D1 complement D: D = 1 - D
Buck (Step-Down) Converter
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Switch is turned on (closed)
Diode is reversed biased. Switch conducts inductor current This results in positive inductor voltage, i.e:
It causes linear increase in the inductor current

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Switch turned off (opened)
Because of inductive energy storage, iL continues to flow. Diode is forward biased Current now flows (freewheeling) through the diode. The inductor voltage can be derived as:
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Analysis
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Analysis
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Realization using power MOSFET and diode Vg + -
Steady-state Operation
+ L
ic(t) R
iL(t)
+
DTs Ts t
VL(t) D1
Unstable
Steady-state
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Average, Maximum and Minimum Inductor Current
Average inductor current = Average current in RL
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Continuous Current Mode (CCM)
From previous analysis, For continuous operation, This is the minimum inductor current to ensure continous mode of operation. Normally L is chosen to be >> Lmin
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Output Voltage Ripple
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Output Voltage Ripple
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Basic Design Procedures
Calculate D to obtain required output voltage. Select a particular switching frequency (f) and device preferably f >20 kHz for negligible acoustic noise higher fs results in smaller L and C. But results in higher losses. Reduced efficiency, larger heat sink. Possible devices: MOSFET, IGBT and BJT. Low power MOSFET can reach MHz range.
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Calculate Lmin. Choose L >>10 Lmin Calculate C for ripple factor requirement. Capacitor ratings: must withstand peak output voltage must carry required RMS current. Note RMS current for triangular waveform is Ip/3, where Ip is the peak capacitor current given by iL/2. Electrolytic Capacitors (E-CAPs) can be used. Wire size consideration: Normally rated in RMS. But iL is known as peak. RMS value for iL is given as:
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Examples
Question 1. A buck converter has an input voltage of 12 V. The required average output voltage is 5 V and peak-to-peak output ripple voltage is 20 mV. The switching frequency is 25 kHz. If the peak-to-peak ripple current of inductor is limited to 0.8 A, determine i. duty ratio, D ii. filter inductance, L iii. output filter capacitor, C (0.42, 148 mH, 197 uF) Question 2. A buck converter is supplied from a 50V battery source. Given L = 400 H, C=100 F, R=20 , f =20 kHz and D = 0.4. Calculate: (a) output voltage (b) maximum and minimum inductor current, (c) output voltage ripple.
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Examples
Question 3. A buck converter has an input voltage of 50V and output of 25 V. The switching frequency is 10KHz. The power output is 125 W. (a) Determine the duty cycle, (b) value of L to limit the peak inductor current to 6.25 A, (c) value of capacitance to limit the output voltage ripple factor to 0.5 %.
Question 4. Design a buck converter such that the output voltage is 28 V when the input is 48V. The load is 8 . Design the converter such that it will be in continuous current mode. The output voltage ripple must not be more than 0.5 %. Specify the frequency and the values of each component. Suggest the power switch also.
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Buck Converter Conclusion
The output voltage may be controlled by the dutyratio, but cannot be larger than input voltage
The voltage conversion ratio depends solely on dutyratio, and is independent of load condition The capacitor ripple current is independent of load current
The off-state voltage across device is supply voltage
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Boost (step-up) converter
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Steady-state Operation
Boost converter produces output voltage that is greater or equal to the input voltage. Alternative explanation: when switch is closed, diode is reversed. Thus output is isolated. The input supplies energy to inductor. When switch is opened, the output stage receives energy from the input as well as from the inductor. Hence output is large. Output voltage is maintained constant by virtue of large C. The off-state voltage impressed across power device is Vo
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Average, Maximum, Minimum Inductor Current
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L and C Values
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Boost Converter Conclusion
The output voltage is always greater or equal to the input voltage The voltage conversion ratio depends solely on dutyratio, and always greater than or equal to one Theoretically the output voltage tends to infinity as D tends to 1, but in practice the maximum output voltage will be limited to conduction loss The capacitor ripple current is severe and depends directly on the load current level The off-state voltage impressed across device is output voltage
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Example :
A boost converter has an input voltage of 5 V. The average output voltage is 15 V and the average load current is 0.5 A. If fs = 25kHz, L = 150 H and C = 220 F, determine (a)duty cycle (b) inductor ripple current (c) inductor peak current (d) output ripple voltage The boost converter has the following parameters: Vd = 20V, D = 0.6, R = 12.5, L = 65 H, C = 200 F, fs= 40 kHz. Determine (a) output voltage, (b) average, maximum and minimum inductor current, (c) output voltage ripple. Design a boost converter to provide an output voltage of 36V from a 24 V source. The load is 50 W. The voltage ripple factor must be less than 0.5%. Specify the duty cycle ratio, switching 29 frequency, inductor and capacitor size, and power device.
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Buck-boost Converter
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Buck-boost Analysis
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Buck-boost Analysis
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Output Voltage
NOTE: Output of a buck-boost converter either be higher or lower than input. If D > 0.5, output is higher than input If D < 0.5, output is lower input Output voltage is always negative.
Steady state operation :
Note that source is never directly connected to load. Energy is stored in inductor when switch is closed and transferred to load when switch is opened. Off-state voltage across power switch is ( Vd Vo )
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Average Inductor Current
Assuming no power loss in the converter, power absorbed by the load must equal power supplied the by source, i.e.
But average source current is related to average inductor current as :
Substituting for Vo ,
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L and C values
Ripple Factor, r
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Example :
A buck-boost converter has input voltage of 12 V. The duty cycle is 0.25 and the switching frequency is 25 kHz. L = 150 H and C = 220 F. The average load current is 1.25 A. Determine: (a)average output voltage (b)peak-to-peak output voltage ripple (c)peak-to-peak inductor ripple current (d)peak current transistor (-4 V, 56.8 mV, 0.8 A, 2.07 A)
A buck-boost converter has the specification as follows: Vd = 18 V, D = 0.6, fs = 40 kHz, R = 10 , L = 50 H, C = 200 F Consider all components are ideal, determine (a)output voltage (b)average, maximum, and minimum inductor current
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(-27 V, 6.75 A, 9.45 A, 4.05 A)
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Buck-Boost Converter conclusion
The voltage conversion ratio depends solely on dutyratio and less than unity for D < 0.5. For D > 0.5, the conversion ratio greater than unity. The maximum conversion ratio is limited in practice by circuit losses Similar to boost, the capacitor current ripple is severe and depends on load current The off-state voltage impressed across the device is the sum of supply and output voltage
The average inductor current is the sum of average input and output current
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Converters in CCM: Summary
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Control of DC-DC Converter: Pulse Width Modulation (PWM)
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Purpose of control: To regulate the output voltage so that it is maintained within a specified tolerance band (e.g. 2% of output DC voltage) Basic block diagram for converter control
DC-DC Converter Control
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Isolated DC-DC Converter
Isolated DC-DC requires isolation transformer Two types: Linear and Switched-mode Power Supply (SMPS) Advantages of switched mode over linear power supply -Efficient (70 95%) -Weight and size reduction Disadvantages -Complex design -EMI problems However above certain ratings, SMPS is the only feasible choice Types of SMPS -Flyback -forward -Push-pull -Bridge (half and full)
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Linear and SMPS Block Diagram
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Linear and SMPS Block Diagram
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High Frequency Transformer
Basic function: 1) Input - output electrical isolation 2) Step up/down time - varying voltage Basic input - output relationship
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Flyback Converter
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Operation: Switch Closed
Flyback Converter
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Operation: Switch Closed
Flyback Converter
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Operation: Switch Opened
Current flows in different direction at the Primary..
Flyback Converter
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Operation: Switch Opened
Flyback Converter
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Output Voltage
Input output relationship is similar to buck-boost converter. Output can be greater of less than input, depending upon D. Additional term, i.e. transformer ratio is present. Positive output voltage polarity
Flyback Converter
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Flyback Waveforms
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Average Inductor Current
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Max., Min. Inductor Current
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Max., Min. Inductor Current
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Example :
The Flyback converter has these specifications: DC input voltage: 40 V Output voltage: 25 V Duty cycle: 0.5 Rated load: 62.5 W Max peak-peak inductor current ripple: 25 % of the average inductor current. Maximum peak-peak output voltage: 0.1 V Switching frequency: 75 kHz Based on the abovementioned specifications, determine a) Transformer turns ratio b) Value of magnetizing inductor Lm. c) Maximum and minimum inductor current. d) Value of capacitor C.
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Example :
The Flyback converter has the following: Input voltage: 24 VDC Output voltage: 5 V Transformer turn-ratio (N1/N2): 3 Load resistance: 5 Magnetising inductance: 500 H Output capacitor: 200 F Switching frequency: 40 kHz Based on the abovementioned specifications, determine a) duty ratio b) average inductor current in Lm. c) maximum and minimum inductor current. d) output voltage ripple.
0.39, 540 mA, 770 mA, 310 mA, 48 mV
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Example :
For a Flyback converter, consider all components are ideal. The parameters are shown as follows:
Based on the abovementioned specifications, calculate a) The range of duty ratios, D b) The minimum value of Lm , to ensure continuous current if the input voltage varies from 10 V to 40 V. c) The required capacitor if output voltage ripple is 0.2 V p-p.
0.123<D<0.4, 4.08 uH, 57.12 uF
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Forward Converter
Derived from Buck Converter, but Dmax = 0.5 Transformer magnetizing current must be taken into account Assume transformer ideal, when switch ON, D1 forward biased and D2 reversed biased, VL positive and iL increases linearly
When switch OFF, D1 reversed biased and iL circulates through D2 . VL negative and iL decreases linearly
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Forward Converter
Equating the integral of inductor voltage over one time period to zero,
It shows that the output voltage is proportional to the duty ratio, D, similar to buck converter Practically transformer magnetization current must be considered in converter operation to avoid converter failure due to energy stored in its core. A third/reset/demagnetizing winding is required so that energy in transformer core can be transferred back to the supply when switched turned OFF.
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Forward Converter
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Forward Converter
When switch ON,
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Full-bridge Converter
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Full Bridge: Basic Operation
Switch pair: [S1 & S2]; [S3 & S4]. Each switch pair turn on at a time as shown. The other pair is off. AC voltage is developed across the primary. Then transferred to secondary via high frequency transformers. On secondary side, diode pair is high frequency full wave rectification. The choke (L) and (C ) acts like the buck converter circuit. Output Voltage
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Half-bridge Converter
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Half-bridge Converter
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Industry Favorites SMPS
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Example :
Q1 Referring to Figure Q1, a) Sketch the waveforms for the inductor voltage and current (per cycle) with fs = 25 k Hz. (5 marks) b) With the assumption that the switching device operates as a fixed frequency switch with a duty ratio D and the inductor current is continuous, show that the output voltage Vo = Vd / (1 D).
(10 marks)
c) If the switching device operates at a duty ratio of 0.4, calculate the output voltage and the average inductor current when the input voltage is 60 V and the resistive load is 10 . Determine the inductor value such that peak to peak inductor ripple current is 4 A.
(10 marks)
Ans: 100 V, 16.67A, 240 uH

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Example :
Q2 Referring to Figure Q2, and assuming converter operates in CCM a) Sketch the waveforms for the inductor voltage ,inductor current and capacitor current(per cycle). b) Prove that the peak-to-peak output voltage ripple c) The converter in Figure Q2 required to provide a 400V regulated output from a variable DC source, ranges between 150 V < Vd < 300 V. The output power varies over the range of 100 W to 1 kW and the switching frequency is 50 kHz. If the converter operates in CCM, i) Calculate the range of the duty ratio, D ii) Determine the capacitor value that results in the maximum peak-to-peak ripple voltage of 3 V iii) Determine the minimum value of inductance to ensure CCM of current over all condition
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Ans: 0.25<D<0.63, 10.4 uF, 2.37 mH
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Example :
Q2 (a)Draw and label a block diagram of a switched mode power supply (SMPS).Briefly state the function of each element in the diagram. (8 marks) (b) Figure Q3 shows a boost converter with the inductor current waveform in steady state. The key quantities of the waveforms are labeled. The circuit uses a feedback controller to regulate the output voltage at 12V by varying the duty cycle, D. It was found that, for this condition, the peak-peak output voltage ripple, vo, is 0.08V. Based on the circuit condition and its waveform determine: (i) The duty cycle D and the input voltage, Vs. (3 marks) (ii) The values of R, L and C. (6 marks) (iii) The maximum value of R to keep the converter operation in a continuous conduction mode. All other parameters are kept constant. (3 marks) (iv) Draw the voltages across MOSFET, vm and diode, vd. Suggest the minimum voltage rating for the diode and MOSFET. (3 marks)
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Ans: i)0.4, 7.2V, ii)2.5 , 7.2u, 240uH, iii)10
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The End of Chapter 3
Thank You
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DC-DC Conversion Techniques and Their Circuit Analysis

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UNIVERSITI TEKNOLOGI MALAYSIA

SEE 4433 Power Electronics And Drives

UNIVERSITI TEKNOLOGI MALAYSIA

UNIVERSITI TEKNOLOGI MALAYSIA

Buck converter Boost converter Buck-Boost converter

Switched-mode power supply (SMPS)

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Transistor is operated in linear (active) mode. Output voltage:

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Switching regulator is the basis of all DC-DC converters

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Buck (Step-Down) Converter

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Switch is turned on (closed)

It causes linear increase in the inductor current

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Switch turned off (opened)

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Average, Maximum and Minimum Inductor Current

Average inductor current = Average current in RL

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Continuous Current Mode (CCM)

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Output Voltage Ripple

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Output Voltage Ripple

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Basic Design Procedures

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Buck Converter Conclusion

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Boost (step-up) converter

UTM Boost Analysis: Switch Closed

UTM Boost Analysis: Switch Opened

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Average, Maximum, Minimum Inductor Current

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Boost Converter Conclusion

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Steady state operation :

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Average Inductor Current

But average source current is related to average inductor current as :

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(-27 V, 6.75 A, 9.45 A, 4.05 A)

Buck-Boost Converter conclusion

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Converters in CCM: Summary