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A ZVS BI-DIRECTIONAL DC-DC CONVERTER

FOR VEHICULAR ELECTRONICS


Huafeng Xiao,Donghua Chen, Shaojun Xie

College of Automation Engineering, Nanjing University of Aeronautics & Astronautics,


Nanjing, 210016, China

Abstract—A ZVS bi-directional dc-dc converter for which is composed of an isolated boost converter and a bridge
vehicular electronics is analyzed in this paper. As a kind of converter. V1 side connected with battery or load is interlaced
current-voltage hybrid converter, the converter is boost topology consist of inductor L1 and L2, and switch S1
composed of an isolated boost converter and a bridge and S2(including their body diodes D1 and D2, and their
converter. The principle of soft switching is presented in intrinsic capacitors), which can be defined as low voltage side.
detail. The boost inductor is designed appropriately to V2 side connected with high voltage supply or load is bridge
satisfy the ZVS for all power devices. A control scheme topology consist of switch S3, S4, S5 and S6(including their
adopting one port voltage regulated and another port body diodes D3, D4, D5 and D6, and their intrinsic capacitors),
current regulated is proposed to realize the energy which can be defined as high voltage side. Flyback
conversion in bi-directional freely. A prototype rated 12 transformer NF1 NF2 and diode DF1 DF2 make up of the startup
V/42 V bi-directional dc-dc converter adopting the current restriction circuit.
proposed control scheme is tested. The simulation and
experimental results convince the high steady state and i1 D F1 i F1 DF2 i F2 D3 C3 D4 C4
dynamic state performance of the converter. L1 L2 S4
N F1 N F 2 S3
i L1 iL2
I. INTRODUCTION
V1 C11 C 22 V2
In future vehicles, 42 V dc bus power systems will be N1 N2
applied and become mainstreams gradually [1]. It is a long
D1 C1 D2 C2 D 5 C5 D6 C 6
time to alter the rated voltage of applications for vehicles from
S1 S2 S5 S6
current 14V to 42V, so 14V and 42 V dc power systems will
coexist in the next period of time. The 14 V/ 42 V dc-dc
converter using for vehicular electronics is required[2]. The
bi-directional dc-dc converters (BDC)[3,4] have to be Fig.1 main circuit topology
employed to accomplish the following functions: a) when the D is defined as the duty ratio of S1. The D of S1 and S2 is
integrated starter/generators operate in generator mode, the interlaced and phase shifted 180o. When D > 0.5 , the duty
BDC can charge 12V batteries, b) when the loads fluctuate,
ratio of S1 is inversion of the duty ratio of S3 and S6, and the
the BDC can control the direction of power flow to balance
duty ratio of S2 is inversion of the duty ratio of S4 and S5.
the loads, c) if the battery voltage is lower at start-up, the BDC
When D < 0.5 , S1 S4 and S5 switch at the same duty ratio, and
can realize the jump-start by the 12V battery on own or other
S2 S3 and S6 switch at the same duty ratio.
vehicles. The main technical requirements of the BDC are: 1)
As shown in fig.2, the drive signals are generated for all
larger rated power conversion, 2) realizing the energy
switches.
conversion in bi-directional freely, 3) adopting higher
switching frequency ( ≥ 100 kHz) to reduce bulk and weigh,
and with higher conversion efficiency.
In this paper, a ZVS BDC composed of an isolated boost
converter and a bridge converter is designed to work as
current-voltage sourced mode. The inductor current can flow
in bi-direction at the appropriate inductor value and all power
devices can satisfy the ZVS in any energy conversion
direction. Snubber capacitors connected with power devices in
parallel can limit the voltage surge. The boost inductor
designed as flyback transformer can restrain the surge current
when the converter operates at start-up. Fig.2. Generation of the drive signal

II. THE OPERATION PRINCIPLE OF THE ZVS BDC


B. Operation principle
Before the analysis, we can make the following assumptions:
A. Circuit configuration a).the flyback transformer can be equivalent to inductor and
Fig.1 shows the main circuit topology of the proposed BDC,

0-7803-9280-9/05/$20.00 ©2005 IEEE. 582


the value of inductor L1 = L2 ; b).the value of capacitors of Lσ and C1 .
(including the intrinsic capacitors of switches) C1 = C 2 , 1
During T1 ( T1 = 2π Lσ C1 ), the parallel resonance is
C 3 = C 4 = C 5 = C 6 ; c). all of power switches and diodes are 4
ideal. finished till t2, the current at N1 is I L1 max and the voltage of S1
1) Boost mode reaches maximum:
The operating waveforms can be divided into 24 stages in V2
one switching cycle in boost mode. Fig.3 shows the stable vC1 (t 2 ) = + I L1 max Z1 (4)
state waveforms in one switching cycle. Fig.4 shows the n
equivalent circuits corresponding to the former half cycle 12 π Lσ C1
stages. The equivalent circuits during latter half period are t12 covers .
2
similar.
Mode 3(t1-t3): From t1, the current on transformer
secondary N2 charges C 4 and C 5 , and discharges C 3 and
C 6 . At t3, the voltage on C 3 and C 6 are zero and the voltage
on C 4 and C 5 reach to V2, the mode finished.
The mode 2 and the mode 3 happen at the same time t1. The
time t12 can be longer or shorter than t13, even equal to t13.
When the time is equal, the expression (5) can be satisfied:
T1
1 V
∫ 4
i p (t )dt = 2C 3 2 (5)
0
2n 2
1 (π − 2)I
ω1 = = L1 max

Lσ C1 4nC 3V 2

When 1 (π − 2 )I , t12 is shorter than t13, which is


> L1 max

Lσ C 1 4nC 3V 2
shown in fig.3.
Mode 4(t3-t4): At t3, the voltage on S3 and S6 descend to
zero, D3 and D6 turn on. The voltage on S3 and S6 is clamped
Fig.3 Waveforms in Boost Mode
at zero. At t4, S3 and S6 turn on with zero voltage and the
mode finished.
Mode 1(t0-t1): Before t0, switch S1 and S2 turn on and the Mode 5(t4-t5): The current iL1 descends linearly to zero at
currents on L1 and L2 rise linearly. At t0, the current i L1 t5.
is I L1 max (the variation in the dead time is neglected) and it Mode 6(t5-t6): The current iL1 descends linearly from zero,
charges C1, the voltage on switch S1 increasing linearly. correspond to increase in the reverse direction. At t6, S3 and S6
I turn off.
v C 1 = L 1 max (t − t 0 ) (1) Mode 7(t6-t7): When S3 and S6 turn off, the inductor current
C1
i L1 charges C 3 and C 6 and discharges C 4 and C 5 , the
N1
When VC1 increases at V 2 ( n= , N 1 N 2 is the voltage on the capacitor vary in linear.
n N2 I L 1 min
vC3 = vC 6 = 2 n (t − t ) (6)
primary and secondary ratio of the transformer), mode 1 C3 6
VC
finished. It covers t 01 = 2 1 . I L 1 min
nI L1 max vC 4 = vC5 = V2 − 2 n (t − t ) (7)
6
C3
Mode 2(t1-t2): From time t1, the current begins to divert
from the snubber circuit to the transformer primary N1, the When the voltage on S3 and S6 reach to V 2 , mode 7
leakage of transformer begins to parallel resonant with C1, the 2
current in primary transformer and the voltage on C1 is: nV 2 C 3
finished. It covers t 67 = .
i p (t ) = I L1max[1− cosω1 (t − t1 )] (2) I L1 min
V2 Mode 8(t7-t8): At t7, the current of N2 decreases and the
vC1 (t ) =+ I L1 max Z1 sin ω1 (t − t1 ) (3) current of N1 decreases accordingly. Till t8, i s = I L1min =0. In
n n
Where ω 1 = 1 is the resonant angular frequency of this mode, C 3 , C 6 , C 4 and C 5 and the leakage inductor
Lσ C1
L'σ of N2 are resonant in series. The voltage on S3 and the
Lσ and C1 ; and Z 1 = Lσ is the characteristic impedance
C1 current of N2 are:

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V2 1 V2 1
v C 3 (t ) = + I L1 min Z 2 sin ω 2 t (8) vC 4 (t8 ) = − I L1min Z 2 (12)
2 2n 2 2n
1 The time of this mode is π L'σ C 3
i s (t ) =
I L1 min cos ω 2 t (9) t 78 =
2
n
Mode 9(t7-t9): From t7, the current of primary N1 decreases,
Where ω 2 = 1 is the resonant angular frequency of C1 discharges. Till t9, the voltage on C1 is zero.
L'σ C 3
The mode 8 and the mode 9 happen at the same time t7. The
'
L' σ and C 3 ; Z 2 = Lσ is the characteristic impedance time t78 can be longer or shorter than t79, even equal to t79.
C3 When the time is equal, the equation (13) must be satisfied:
of L' σ and C 3 . T2
V2
The voltage on the S4 can also be obtained as: ∫ 4
I L1min(1− cosω2t )dt = C1 (13)
0 n
V 1
v C 4 (t ) = 2 − I L1 min Z 2 sin ω 2 t (10) 1 n(π − 2 )
2 2n ω2 = = I L1 min
Lσ C 3
' 2C1V 2
1
After T ( T2 = 2π L'σ C 3 ), the resonance in series 1 n(π − 2 )
4 2 When > I L1 min , t78 is shorter than t79, which is
finishes and the current of secondary N2 is zero at t8. The '
Lσ C 3 2C 1V 2
voltage on S3 and S6 is: shown in fig.3.
V2 1
v C 3 (t 8 ) = + I L1 min Z 2 (11)
2 2n
The voltage on S4 and S5 is:
i1 D 3 C3 D4 C4
L1 L2 S3 S4
i L1 iL2
V1 C11 C 22 V2
N1 N2
D1 C1 D2 C2 D5 C5 D6 C 6
S1 S2 S5 S6

(a) (b) (c)

(d) (e) (f)

(g) (h) (i)

(j) (k) (l)


Fig.4 Equivalent circuits in Boost Mode

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Mode 10(t9-t10): At t9, the voltage on S1 descends to zero, i1 D F1 i F1 DF2 iF2

D1 is on. The voltage on S1 clamped at zero prepare for the L1 L2 S4 N F1 N F2


i L1 iL2
ZVS of S1. At t10, S1 turns on at ZVS and the mode finished.
V1 C11 C 22 V2 V1 C11 C 22 V2
Mode 11(t10-t11): When S1 turns on at zero voltage, the N1 N2
current iL1 rises linearly from negative value to zero at t11. S1 S5
Mode 12(t11-t12): The current iL1 rises linearly from zero.
At t12, S2 turns off. From t12, the next half cycle starts.
(a) (b)
2) Buck mode i1 D F1 i F1 DF 2 i F2
The energy transferred from V2 side to V1 side when the L1 L2 S3 N F1 N F2
circuit works at buck mode, the average value of inductor i L1 i L2
current is negative. Fig.5 shows the main operation waveforms V1 C11 C 22 V2 V1 C11 C 22 V2
N1 N2
of the converter in one period. The waveforms in buck mode
are similar as the waveforms in boost mode. S2 S6

(c) (d)
Fig.6 Equivalent circuits in startup Mode (D<0.5)

III. CONTROL STRATEGY


The BDC has the different operation mode in the different
energy direction. It is difficult to realize the stable control in a
set of controller because of the different small signal
equivalent circuit. The traditional controller with the
complicated control and drive circuit is to regular the voltage
in two sides, which restrain the bi-directional energy
conversion freely.
In this paper, a novel control strategy with one port voltage
regulated and another port current regulated is proposed.
Sampling the voltage of V2 side and the current of V1 side,
the double closed-loop control can realize the voltage
regulated and current regulated in the different energy
conversion, respectively. The control strategy unifies the
control system and simplifies the control circuit and makes the
Fig.5 Waveforms in Buck Mode
energy bi-directional conversion free.
3) Startup mode The schematic diagram of control circuit is shown in fig.7.
The inductor L 1 and L 2 are designed as flyback transformer When the voltage value on V2 side is higher than the reference,
the converter operates in buck mode and is controlled by
style[5,6]. The flyback winding N F1 and N F2 transfer the single current closed-loop. The current setting value for the
magnetizing energy to V2 side through D F1 and D F2 . In low voltage side is decided by the energy deposited and other
startup stage, the duty ratio of S1 and S2 increases from 0 condition of the battery. When the converter operates in boost
gradually. To simply the analysis, the leakage inductor of mode, it can be controlled by current and voltage closed-loop.
transformer and the parallel capacitors on power devices are This variable structure controller can improve the steady and
neglected, and all components are treated as ideal. dynamic performance by the appropriate control parameters.
When D < 0.5 , the operation in one cycle can be divided into
4 modes, the equivalent circuits of which are shown in fig.6. +15V
I1
Mode 1(t0-t1): S1 , S4 and S5 are on, S2 , S3 and S6 are off, the V2 Ve
energy is transferred from V1 side to V2 side.
Mode 2(t1-t2): All power devices are off. The energy in the +15V −15V

inductor charges C 22 by the flyback transformer, v2 rises.


Mode 3(t2-t3): S2 , S3 and S6 are on, S1 , S4 and S5 are off.
The operation is similar as in mode 1.
Mode 4(t3-t4): All power devices are off. This mode is
similar to mode 2. Fig.7 Control Scheme for BDC
When D > 0.5 , the energy in the inductors transfers to V2
side by the transformer, the flyback windings don’t operate.
The stages are same as in boost mode.

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IV. DESIGN OF THE BDC value is 42 V, L1 = L2 =3.7 µ F, main transformer ratio is
A. Duty ratio design n = 1, flyback transformer ratio nF = 7/6, C11 = 2000 µ F,
The steady voltage equation of converter is: C22 = 2200 µ F, C1 = C2 = 68 nF, C3 = C4 = C5 = C6 = 22
V2 n nF ,switching frequency is 100 kH Z .
= (14)
V1 1− D The prototype of the BDC is developed. The experiment
Where D is the duty ratio of S1 or S2 . When the circuit parameter is: V1 is six rated 2 V batteries in series, V2 rated
operate in steady state, the duty ratio should be satisfied value is 42 V, L1 = L2 =3.7 µ H, main transformer ratio is
D > 0.5 . In order to decrease the rated current of power n = 1, flyback transformer ratio nF = 7/6, C11 = 2000 µ F,
devices and decrease the ratio of the transformer, the duty
C 22 = 2200 µ F, C1 = C 2 = 68 nF, C 3 = C 4 = C 5 = C 6 = 22
ratio can be selected larger.
nF ,switching frequency is 100kH Z . Switches S1 and S2 are
B. Inductor design
IRFP2907 ( VDSS = 75 V, R DS( on) = 4.5 mΩ ) and switches S 3 ,
An appropriate value of inductor L1 = L2 can realize all
S 4 , S 5 , S 6 are IRFP150N( VDSS = 100 V, R DS(on) = 36 mΩ ).
power devices ZVS. The equation (15) must be satisfied:
V ⎛V 2 − V ⎞ Schottky diodes D F1 and D F2 are MBR20100.
⎜ ⎟
L1 <
1
⎝ n 1
⎠ (15)
V A. Boost mode
f I1 2
S n
Where I 1 is the average value of the inductor current at the Fig.8 shows the steady state simulation and experimental
waveforms in boost mode, in which from up to bottom are
maximum converter power and f S is the switching
inductor current i L1 , the gate drive signal of S1 , voltage
frequency.
across the drain and source on S1 , the gate drive signal of S 6 ,
C. Snubber capacitor design voltage across the drain and source on S 6 , respectively, at
In order to realize ZVS, the delay time t d 1 of the turn on low voltage port V1 =12 V, high voltage port V2 =42 V, high
time of S 3 and S 6 relative to the turn off time of S1 should voltage port power P2 =107 W.
be satisfied as: From fig.8, it can be seen that i L1 commutates between
t 01 + t 13 ≤ t d 1 ≤ t 05 (16) positive and negative, and the average value of it is larger than
zero, S1 and S 6 can realize ZVS. The simulation and
t 67 + t 79 ≤ t d 2 ≤ t 6 ,11 (17)
experimental results convince that all power devices can
where t d 1 depends on the current I [7] ull load in
'
L1 max realize ZVS at boost mode.
buck mode, and t d 2 depends on the current I L1 min at full
B. Buck mode
load in boost mode.
The directly paralleled snubber capacitor on switches can Fig.9 shows the steady state simulation and experimental
restrain the voltage spike caused by the transformer leakage waveforms in buck mode, in which from up to bottom are
inductance. The larger snubber capacitor value will increase inductor current i L1 , the gate drive signal of S1 , voltage
the current I L' 1 max and I L1 min to achieve ZVS, which leads across the drain and source on S1 , the gate drive signal of S 6 ,
to the increasing conduction loss. The parameters of voltage across the drain and source on S 6 , respectively, at
inductance and snubber capacitor can be designed low voltage port V1 =13.4 V, high voltage port V2 =48 V, low
synthetically according to the peak value of switch voltage voltage port power P1 =110 W.
and conduction loss.
From fig.9, it can be seen that i L1 commutates between
D. Flyback inductor design positive and negative, and the average value of it is less than
In startup stage, the flyback inductor supplies the zero, S1 and S 6 can realize ZVS. The simulation and
freewheeling circuit for the inductor. When the converter experimental results convince that all power devices can
works in steady state, the flyback inductor doesn’t operate. realize ZVS at buck mode.
The ratio of flyback inductor can be designed as: According to the theoretical analysis, we know that the
V 2 (18)
nF
< switches are relatively difficult to realize ZVS at full load.
V − V
2
n 1 Fig.8 and fig.9 show the converter operating waveforms at full
load, which illustrate that all switches can realize ZVS at any
operation state.
V. SIMULATION AND EXPERIMENTAL RESULTS
The simulation model of the BDC is built up in Saber. The
simulation parameter is: V1 rated value is 12 V, V2 rated

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(a)simulation waveforms (b)experimental waveforms
Fig.8 Waveforms of Boost Mode

(a)simulation waveforms (b)experimental waveforms


Fig.9 Waveforms of Buck Mode

bi-directionally and has the high steady and dynamic


C. Mode altering process performance.
Fig.10 shows the dynamic state simulation and Fig.11 shows the simulation and experimental waveforms
experimental waveforms of the energy bi-directional of startup, in which from up to bottom are voltage v2 and
conversion process, in which from up to bottom are voltage current i1. In fig.11, during [t0,t1], the converter operates in
v2 and current i1.When the voltage on V2 port is higher than startup mode, the startup circuit is working, the duty ratio D
the reference value, the BDC is charging V1 port. When the increases in open-loop control; at t1 the duty ratio D reaches
voltage on V2 port drops, the battery port is turning to to 0.5; during [t1,t2], the converter operates in boost mode,
discharge and supplying V2 port. As is shown in fig.10, the the startup circuit stop working, the input current i1
BDC operates in boost mode and supply V2 port a regulated
increases, during [t2,t3], the input works as a constant
voltage; at t1, the BDC operates in buck mode and supply
current source and at t3, the V2 port voltage is regulated at
V1 port a regulated charging current; and at t2, the BDC
reference value. From the simulation and experimental
returns to boost mode and supplies V2 port a regulated
results, the startup circuit can restrain the startup current
voltage. The dynamic state simulation and experimental
surge efficiently in [t0,t1] period.
results convinced that the novel control strategy for the
ZVS BDC can control the energy conversion

(a)simulation waveforms (b)experimental waveforms

Fig.10 Waveforms of BDC Conversion

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(a)simulation waveforms (b)experimental waveforms
Fig.11 Start up process of Boost Mode

VI. CONCLUSION
A ZVS BDC is proposed in this paper. Designed appropriate
inductor value and dead time, the converter can realize all
power devices ZVS. A startup circuit adopting flyback
inductor can restrain the startup current surge in boost
converter efficiently. A novel control strategy adopting one
port voltage regulated and another port current regulated can
realize energy conversion in bi-directional. The control
strategy unifies the control system and simplifies the control
circuit and makes the energy bi-directional conversion free.
Simulation and experimental results convince the high
performance of the ZVS BDC. The converter is suitable for
the applications for the vehicular power conversion.

VII. REFERENCES
[1] Norman Traub.42 V activities at SAE.
http://www.sae.org/42volt/cong02_traub.pdf 2002.3
[2] Arthur Pfaelzer, Maurice Weiner, Art Parker, Bi-directional automotive
42/14 volt but DC/DC converter[C], SAE Future Technology
Conference and Exposition, California, USA.2000:1-14.
[3] John M. Miller, Power Electronics in Hybrid Electric Vehicle
Application[C], IEEE APEC2003:23~29.
[4] Bojrup M,Karlsson P, A lakula M. A dual-purpose battery charger for
electric vehicles[C], IEEE PESC 1998:565-570.
[5] Wang Kunrong, Lee F. C, Lai J. Operation Principle of bi-directional
full-bridge DC/DC converter unified soft-switching scheme and
soft-starting capability[C], IEEE APEC 2000: 111~118
[6] Lizhi Zhu, Kunrong Wang, Fred C Lee, Jih-Sheng Lai, New Start-up
Schemes for Isolated Full-Bridge Boost Converters[J], IEEE Trans.
on PE vol.18 No.4, 2003: 946~951
[7] Gu Yi-lei,Chen Shi-jie, Lv Zheng-yu, et al, Strategy for single switch
DC/DC converters to achieve soft switching[J], Proceedings of the
CSEE, vol.24 No.11, 2004: pp130-133

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