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Jih-Sheng Lai*, Seung-Ryul Moon, Raeyoung Kim, Feng-Yuan Lin, Yu-Hsuan Liu, and
Ming-Hsien Lin
ABSTRACT
Multiphase dc-dc converters allow current sharing among phases and high-fre-
quency ripple cancellation and are very desirable for low-voltage high-power fuel
cell applications. In this paper, a versatile three-phase dc-dc converter circuit as a
building block is proposed for different output voltage levels including non-isolated
48 V for telecom and isolated 400 V for subsequent stage dc-ac inverter applications.
For either type of application, the proposed three-phase converter circuit is controlled
by the same complementary gating control that allows synchronous rectification for
the non-isolated version and zerovoltage soft switching for the isolated version. Two
sets of 5-kW converters have been built and tested with a fuel cell simulator. Experi-
mental results are given to show the superiority of the efficiency performance in two
different applications.
I. INTRODUCTION (Liu et al., 2005, and Liu et al., 2006) has demon-
strated a desired high efficiency for fuel cell voltage
For stationary applications, fuel cells were mostly less than 25 V or current higher than 200 A, the
found with low voltages such as 20 to 60 V and high threephase three-leg (V3) dc-dc converter circuit in
powers such as 3 to 10 kW. The load may be 48-V is more versatile when it comes to different applica-
dc for telecom applications or 110/220-V ac for house- tions that involve both isolated and non-isolated dc-
hold applications. For 48-V dc output, isolation is dc power conversions. The V3 converter circuit can
normally unnecessary, but for 110/220-V ac output, be used for non-isolated applications, while V6 con-
an isolated dc-dc converter is needed to serve as the verter is only limited to isolated applications.
first-stage voltage boost and galvanic isolation. For Intuitively an isolated dc-dc converter can be
a typical 5 kW stationary fuel cell power plant, the universally used for versatile applications. Fig. 1
dc-dc converter input inevitably sees more than 100 shows block diagrams of stationary fuel cell power
A for fuel cells with voltage level lower than 50 V. plant using an isolated dc-dc converter for 48-V dc
Such a high-current dc-dc converter requires multiple output and 110/220-V ac output conditions. The iso-
phases to achieve high efficiencies (Liu et al., 2005, lated dc-dc converter consists of a bridgetype con-
Liu et al., 2006, Oliveira et al., 2003, Moon et al., verter that converts dc to low-voltage high-frequency
2007, Prasad et al., 1992, and De Doncker et al., 1991). ac, a high-frequency transformer that converts low-
Although the 3-phase 6-leg (V6) dc-dc converter in voltage high-frequency ac to high-voltage high-fre-
quency ac, and an ac-dc rectifier plus a filter circuit
*Corresponding author. (Tel:(540)2314741; Fax: (540)2313362; to smooth the dc output. For 48-V dc load, the out-
Email: jslai@vt.edu) put side can be isolated from fuel cell ground or ty-
J. S. Lai, S. R. Moon, and R. Kim are with the Future Energy ing either positive or negative to the ground. For 110/
Electronics Center (FEEC), Virginia Polytechnic Institute and State 220V ac load, a high voltage conversion ratio is re-
University, Blacksburg, Virginina 24061-0111, USA.
F. Y. Lin, Y. H. Liu, and M. H. Lin are with the Tatung System
quired to boost the output voltage up to 400 V for the
Technologies, 22, Chungshan N. Rd., 3rd Sec., Taipei 104, Taiwan, dc-ac inverter to produce 220 V ac output.
R.O.C. The main problem with isolated design is the
1146 Journal of the Chinese Institute of Engineers, Vol. 30, No. 7 (2007)
48V DC
AC-DC
Fuel Bridge Rectifier a a a
Cell Vin Converter + Vdc Vdc Vdc
Filter
(a)
AC
(a) (b) (c)
AC-DC DC-AC
Fuel V Bridge Rectifier Inverter 110V220V Fig. 2 Phase-leg circuit configurations: (a) buck switch, (b) boost
Cell in Converter + + 110V
Filter Fiter switch, and (c) general-purposed half-bridge circuit.
(b)
L iL
S1 S3 S5
V 1:n D1 D3 D5
Fuel fc A a
cell iA ia
Inverter
input Cf b
Vfc B Co Vdc
37-57V
C c
S4 S6 S2 D4 D6 D2
Vo –48V
Fig. 5 Circuit configuration of a three-phase two-stage boost-cas- is difficulty to maintain smooth transition from one
caded with buck converter for positive output mode to the other mode.
Auxiliary power
Fig. 8 Conversion ratio and operating mode for V3
Inductors 40
20
Magnitude (dB)
0
-20
Boost stage
-40 G.M.: 29.4 dB
-60 Freq: 1.39e+004 Hz
Stable loop
Control -80
settings 315
Phase (deg)
270
Buck stage 225
180
Fig. 12 Photograph of a two-stage boost buck converter using the 135
proposed converter building block 90 P.M.: 76.5 deg
Freq: 884 Hz
45
101 102 103 104 105
Frequency (Hz)
being one switching cycle, this error represents 0.1%,
Fig. 14 Frequency response of the boost stage control loop
which corresponds to the ratio of the FIFO clock pe-
riod and the switching period.
A. The individual phase current has a peak to peak
V. APPLICATION TO A NON-ISOLATED current ripple of 5A, but the total current ripple is
BOOST-BUCK CONVERTER much reduced because of current interleaving.
The circuit diagram shown in Fig. 5 has been With two-stage power conversion, the control
implemented using the proposed three-phase con- stability and interaction are major concerns. In or-
verter building block for a 5-kW boost-buck converter der to avoid mid dc bus voltage overshoot during load
with 37 – 57 V fuel cell input and 48-V nominal transient, a voltage loop control is needed for the boost
output. Fig. 12 shows the photograph of the entire converter, which has a transfer function shown in (1).
assembly. The only added components are input and
output inductors and control setting interface board. – 0.6575(s – 2.567 × 10 5)(s + 2128) (1)
G vd =
In this test setup, both input and output inductors are s 2 + 3006s + 4.059 × 10 6
29 µH, which allows each phase current to have 10%
By selecting a crossover frequency slightly below 1
ripple at the full load.
kHz, a proportional-integral (PI) controller can be de-
Figure 13 shows experimental results of the
signed as follows.
three inductor currents running at 90% duty cycle
under buck mode condition. Due to a high core 35882(s + 1700)
tolerance, the inductor currents are not quite balanced. C(s) = (2)
s(s + 6.1 × 10 4)
With average a little more than 25-A in each phase
inductor current, I L, the total current I total is about 76 Frequency domain plot of the entire loop gain is
1150 Journal of the Chinese Institute of Engineers, Vol. 30, No. 7 (2007)
40 99.0%
20
Magnitude (dB)
98.5%
0 98.0%
-20
Efficiency
97.5%
-40 G.M.: 30.6 dB 97.0%
-60 Freq: 2.2e+004 Hz 96.5%
-80 Stable loop
96.0%
-45 95.5%
Phase (deg)
-90 95.0%
0 1000 2000 3000 4000 5000
-135
Power (W)
-180 P.M.: 78.4 deg
Freq: 1.74e+003 Hz Fig. 17 Buck converter efficiency test results
-225 1
10 102 103 104 105
Frequency (Hz)
96%
Fig. 15 Frequency response of the buck stage control loop Vin = 57V
94%
Vin = 48V
Efficiency
92%
Vin = 37V
90%
88%
Vds (50 V/div) Vgs (10 V/div)
86%
0 1000 2000 3000 4000 5000
Power (W)
ILoad = 21A ILoad = 33A Vdc= 59V Fig. 18 Overall system efficiency with different input voltages and
both boost and buck converters operating in closed-loop
condition
t (10 µs/div)
Fig. 16 Dynamic response of the mid dc bus voltage under load the control loops are stable, and the mid dc bus voltage
step Vdc is well regulated when the load current ILoad is in-
creased from 21 A to 33 A condition. The device volt-
age vds and gate-source voltage vgs indicate a small and
shown in Fig. 14. The resulting loop gain bandwidth gradual duty cycle increase after the load current step.
is 884 Hz, and the phase margin is 76.5°.
Voltage loop control is also needed for the buck 3. Efficiency Measurement Results
converter because the output voltage needs to main-
tain constant at 48 V. The buck converter transfer For efficiency measurement, all the instruments
function is shown in (3). are high precision with 0.02% accuracy. The current
sensor is a high precision current viewing resistor with
3.1 × 10 5(s + 1333) (3) 0.2% accuracy. Fig. 17 shows the buck converter ef-
G vd =
s2 + 5187s + 6.897 × 10 6 ficiency test results. The peak efficiency occurs in
between 3 kW and 4 kW. High efficiency of 98%
To avoid interaction between two stages, a crossover
power conversion can be achieved if only one con-
frequency of higher than 1 kHz is selected for the buck
verter is used.
converter. The designed PI controller is shown in (4).
The buck converter duty cycle is almost con-
43342(s + 3800) stant throughout the entire fuel cell voltage range because
C(s) = (4) the boost converter runs in closed-loop condition that
s(s + 6.1 × 10 4)
regulates the mid dc bus voltage to a constant of 60V.
Frequency domain plot of the entire loop gain is shown Thus the buck converter can have very high efficiency
in Fig. 15. The resulting loop gain bandwidth is 1.74 in a wide load range. The boost converter, however,
kHz, and the phase margin is 78.4°. Note that a volt- needs to deal with different input voltages, and its
age sensor was included in the both boost and buck efficiency will depend on the input voltage condition.
converters. The scaling factor and the cut-off frequency If the seamless transition is needed, then both boost
of the voltage sensor are 0.05 and 50 kHz, respectively. and buck converters need to operate in closed-loop
Figure 16 shows voltage and current waveforms condition, and the total system efficiency will be lower.
under dynamic load step test. Test results verify that Fig. 18 shows the overall system efficiency with
J. S. Lai et al.: A Versatile Three-Phase DC-DC Converter Circuit for Fuel Cell Applications 1151
vds1 vgs1
Rectifier 20 V/div 5 V/div
stage
vds4 vgs4
20 V/div 5 V/div
Transformer 5 µs/div
stage Zoome-in
Upper Device
ZVS
Zoom-in
Three-phase
converter Lower Device
building block ZVS
200 ns/div
Fig. 21 ZVS for V3 at high duty cycle and heavy load condition
V fc = 50 V, V dc = 400V, 50% duty cycle, 3 kW load
Fig. 19 Photograph of the V3 converter using the three-phase con-
verter building block
vgs1
5 V/div
vds1 vgs1
vgs4
20 V/div 5 V/div
5 V/div
iA
vds4 vgs4
5 V/div 10 A/div
20 V/div
5 µs/div iB
Zoome-in 10 A/div
iC
Upper Device
ZVS 10 A/div
Zoom-in t: 5 µs/div
Lower Device
ZVS Fig. 22 Gate drive signals and output phase currents of V3 con-
200 ns/div verter
Fig. 20 ZVS for V3 at low duty cycle and light load condition V fd
= 50 V, V dc = 300V, 25% duty cycle, 1 kW load 98%
97%
96%
95%
Efficiency
different input voltages and both boost and buck con- 94%
verters operating in closed-loop condition. The peak 93%
92%
efficiency drops to about 95.5%. The efficiency is
91%
generally higher with higher input voltage. 90%
89%
VI. APPLICATION TO THE V3 ISOLATED 0 1000 2000 3000 4000 5000 6000
DC-DC CONVERTER Power (W)
results of the V3 converter. Again, in the test setup, voltage, and the isolated dc-dc converter efficiency
all meters and current sensors have been selected to peaks at 96.8%. Stable control loop designs are also
be 0.02% precision or better. The results indicate that shown for a two-stage power conversion. It can be
the V3 converter maintains efficiency between 95 and concluded that the proposed versatile three-phase
97% from 1 kW to 5 kW and peaks at 96.8% at 2 kW. converter building block is very well suited in low-
voltage high-power fuel cell applications.
VII. CONCLUSION
REFERENCES
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isolated dc-dc converter has the peak efficiency Manuscript Received: Mov. 19, 2007
between 94% and 96% depending on the fuel cell and Accepted: Mov. 19, 2007