HIGH GAIN DC-DC BOOST CONVERTER WITH A COUPLING INDUCTOR

Felinto S. F. Silva1, Antnio A. A Freitas2, Srgio Daher2, Saulo C. Ximenes2, Sarah K. A. Sousa2, Edilson M. S. Jr.3 , Fernando L. M. Antunes2, Ccero M. T. Cruz2.
IFPI Instituto Federal de Educao, Cincia e Tecnologia do Piau CAMPUS/Picos 2 Universidade Federal do Cear 3 IFCE Instituto Federal de Educao, Cincia e Tecnologia do Cear CAMPUS/Sobral Av. da Universidade, 2853 Benfica fantunes@dee.ufc.br Abstract This paper presents a design, mathematical modeling, simulation results and laboratory implementation of a 300W high gain dc-dc boost converter with a coupled inductor, to step up the 24V of a battery bank to 311Vdc, aiming to supply residential loads with dc voltage in an off-grid PV system. The converter can supply most of the residential ac loads which input stage is a single-phase rectifier. Laboratory tests with the 300W converter supplying electronic lights, mobile charger and audio-video system ac showed the viability of the proposed idea. Keywords DC-DC converter, PV system, Battery charger. I. INTRODUCTION The necessity of off-grid electric systems to supply remote areas rural loads led the Brazilian Electricity Regulatory Agency ANEEL to establish guidelines for intermittent electric energy systems such as wind and PV systems. In that sense, in September of 2004 it was issued by ANEEL the guideline 83 which states that the electric energy supplied by Electric Energy Production Units should have a sinusoidal output voltage waveform with magnitude and frequency compatible with the utility grid. However, aiming to boost the production of electric energy from renewable sources, in Brazilian remote areas with difficult access, ANEEL has authorized, throughout the Resolution 927 of May 2007, the development of a pilot project with the option to supply remote low consumption areas not in ac, but in dc voltage. In the context of the Resolution 927, this paper presents the design, the mathematical modeling, the simulation and the laboratory implementation of high gain coupled inductor dcdc boost converter, to step up the 24V of a battery bank to 311Vdc, as part of an off-grid PV system suitable for isolated areas, where the cost to extend the electric utility is prohibitive. The converter can supply most of the residential ac loads which input stage is a single-phase rectifier. Laboratory tests with the 300W converter supplying electronic lights, mobile charger and audio-video system ac showed the viability of the proposed idea. Figure 1 shows the proposed PV system, highlighting in a dashed circle the high gain dc-dc boost converter discussed in this paper.
PV BATTERY CHARGER

II. BOOST CONVERTER TOPOLOGY SELECTION Considering the cost of the electricity produced from PV conversion, it is mandatory the search for efficient converters. In relation to the efficiency of dc-dc converters, the non-isolated can be more efficient than the isolated ones. The literature about non-isolated dc-dc converters presents some topologies as: classical boost, modified boost, high gain boost, cascade, interleaved boost, high gain interleaved boost and classic boost converter.
PROPOSED SYSTEM
BOOST CONVERTER
CONTROLLER 311 Vdc AC LOADS ELECTRONIC LIGHTS MOBILE CHRAGER HI FI RADIO

DC

24 Vdc

BATTERY BANK

Fig. 1. Block diagram of the whole PV system (boost converter highlighted).

It can be seen in Figure 1 that the discussed boost converter (in the dashed circle) requires a static gain of 13. For this level of gain, the classical converters are not appropriate, due to the fact that the power switches operate with high input current and high output voltage [1]. This is unfavorable, regarding the practical implementation and efficiency. On the other hand, non-isolated high gain topologies are adequate for this kind of application, using associated switches and inductors. Figure 2 presents some high gain, non-isolated topologies. Comparing the topologies presented in figure 2 it can be observed that topologies C) and D) employ two switches, while A) and B) only one switch. So, as far as efficiency is concerned, topologies A) or B) are more suitable for the application. Looking to the polarity of both topologies it can be concluded that the topology B) is an inverting polarity topology which makes difficult the practical implementation of the control circuit. Therefore, the high gain boost with coupled inductor topology has been chosen.

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L1

L2
S1

Vin

D1 C1
CARGA

L1
Dg

L2

D1 C1
LOAD

Vin

S1

Cg

A) High gian boost - converter

a) Complete circuit

S1

L2 L1

D1 C1
load

I1 L2

ID

Vin

IL

L1

V in
B)High gain buck-boost -

VS

C 1 LOAD

Vo

L1

L2
S1 C1 S2

D1 C2
CARGA

b) Simplified circuit

Vin

Fig. 4. a) Proposed converter complete circuit; b) Proposed converter simplified circuit.

C) Cascade boost
D3 T3 T1 D2 D1 D4 C3 C2

Lb

Load

T2

The operation principle of the high gain boost converter is illustrated in stages in Figure 5. It is important to note that the presented analysis was done considering the continuous conduction mode of operation. In this case, due to the coupled inductors, abrupt current variation may occur in each inductor, while the stored energy is still continuous. This fact explains the abrupt current variations in IL1 and IL2 waveforms.
I1 IL

Vin

C1 S1 S2

D) High gain interleaved boost - converter

L1
Vin V S IS IC C1 LOAD Vo

Fig. 2. High gain, non-isolated and modified topologies.

A. Basic circuit of the dc-dc high gain boost topology with a coupling inductor Figure 3 presents the basic topology from which the topology presented in Figure. 2.A) is based on.

a) Stage I( 0 < t < t1)

I1 L1 L2 V L1 V in V S IS IC C1 ID IL

LOAD

V o

b) Stage II( t1 < t < T)

Fig. 5. Operating stages.

Fig. 3. High gain boost converter with clamped circuit.

The difference between the topologies of Figure 2.A) and the one of Figure 3 is the snubber circuit to minimize possible overvoltages, due to the non-ideal coupling between inductors L1 and L2 [2]. III. OPERATION STAGES OF THE DC-DC HIGH GAIN BOOST TOPOLOGY WITH COUPLING INDUCTORS Figure 4 presents the complete and simplified circuits for the converter. The simplified version presented in figure 4.b), is used to make the converter analysis.

In Figure 5, from the first operation stage (switch is closed), it can be observed that the input energy source delivers energy to the inductor L1, while the load is supplied by the energy stored in the output capacitor C1 [4], [5]. In the second operation stage, the energy stored in the coupled inductor is then transferred to the output (added to a component directly supplied by the input source, which is in series). In this stage, the current that flows through the output diode, charges the output capacitor and also supplies the load. The main voltage and current waveforms are presented in Figure 6. It is possible to observe that the maximum voltage across the power switch is equal to the input voltage added by the voltage across L1. Since the voltage across L1 is just a fraction of the output voltage, the voltage stress in the power switch is strongly limited (in this case, around twice the input voltage). In fact, compared to

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the classical boost topology, this is the most important advantage presented by the proposed topology.
T Stage - I (t1) Drive signals to S VS 0 t1 Vi + V L1 Vi Stage - II (t2) t T t

discharged through an ideal transformer transformation ratio is a function of L1 and L2.

whose

IS

I L1

I L2 IC Io

Fig. 7. Obtaining the model for equating: a) simplified circuit; b) equivalent model in the range of loading; c) equivalent model during unloading.

For the equation, it is preferable use the transformation relation of the equivalent model k, given by (1).

Fig. 6. Converter of main voltage and current waveforms.

During the interval where the power switch is closed, it is possible to see the linear variation of the current through L1, since the voltage across it is approximately constant. It is also important to notice that the current through the power switch does not starts at zero, but presents an offset value, revealing that the converter is operating on the continuous mode (for the continuous operation mode, the stored energy never reaches zero). The continuous current operation mode can also be observed over the continuity of the inductor L1 current, IL1. However, in opposition to the operation principle of the classical boost where the current variations I in the inductor are equal in amplitude for both the charge and the discharge stages in the coupled inductor topology the amplitude of these variations are not equal. This occurs because the charge interval is performed through L1, while the discharge interval is performed through the total inductance, composed by L1 plus L2. In addition, it can be also observed that the current through L2 is zero during the charge interval (switch is on). Finally, the output capacitor current Ic presents a zero dc component, as expected, and this capacitor supplies all the load current during the charge interval. IV. HIGH-GAIN BOOST CONVERTER MATHEMATIC MODEL The equation of the proposed converter can be easily obtained through the equivalent model shown in Figure 7. In this model it is assumed that an inductive load Lm (Lm = L1) is charged during the initial stage of operation and it is

k=
Where:

N1 + N 2 N = 1+ 2 N1 N1

(1)

k: Relation of transformation of the ideal transformer; N1: Number of turns of the inductor L1; N2: Number of turns of the inductor L2; Indeed, although equation 1 is dependent on number of turns N1 and N2, it is not necessary to know their absolute values, since k contains only information about the relationship N2 / N1. The values of L1 and L2 can be obtained from the parameters k and Lm , used in (2) and (3b). L1 = Lm (2)

L1 ( N1 ) N1 e = = (k 1 ) 2 L2 ( N 2 ) N2
2

(3a) (3b)

L2 = L1(k 1 )2 = Lm(k 1 )2

Returning now the attention to the equivalent model stages of operation shown in Figure 7, it can be noted that the inductor Lm is influenced by input voltage Vin (considered constant) during the charging interval. Thus, it is the differential equation which rules the behavior of an ideal inductor. Through this, it can determined the behavior of ILM in this range, as shown in (4a).

v Lm (t ) = Lm

diLm (t ) di (t ) v (t ) Lm = Lm dt dt Lm

(4a)

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Lm ( t ) =Vi = cte v I Lm =

Vi .t Lm

(4b)

Equation 4 states that the current ILM varies in a linear form over time. Taking into account the linearity of the current ILM variation, equation (5) can determine, which then provides a range of ILM for the discharge range.

I Lm =

(Vo Vi ) .t k Lm

(1 D) k. D + Vo k = K .D + 1 D = Vi (1 D) (1 D) Vo D(k 1) + 1 = Vi (1 D)
Rearranging (12), equation (13) is obtained.

(11)

(12)

(5)

k=

Similarly to the range of load, the equation 5 states that the current ILM also varies in a linear form on time for the range of discharge. However, this range variation of current is negative. From equations (4) and (5), considering the appropriate intervals of time and current variation, the instantaneous coupled inductance current is shown in Figure 8.

(1 D).(Vo Vi ) D.Vi Lm = D.T .Vi I 1

(13)

From (7) and(14), it is determined the value of Lm. (14)

V. BOOST CONVERTER DESIGN The proposed system is designed to supply the loads listed on Table 1.

ILm
I1
t1 = D.T t1

I2
Quantity

TABLE 1 Loads estimated in a rural school.

Load Type Eletronic Lamps 23W TV Set Parabolic aerial Radio set

t 2 = (1-D).T T

06 01 01 01

Power (W) (23x6) 138 55 25 10

Demand (h/ day) 5 3 3 3

Fig. 8. The current wave form from the ILM model equivalent.

From Figure 8, the duty-cycle is given by (6).

t t D= 1 = 1 t1 + t2 T
Where: t1: t2: T: D: Time which the switch is closed; Time which the switch is opened; Switching period; Duty-cycle;

(6)

According to Table 1, in the worst case, when all loads are connected at the same time, the system should be able to supply 228W of power. Considering a safety margin, the rated power of boost converter has been defined as 300W. VI. SIMULATION RESULTS The proposed converter was simulated using the PSPICEbased simulation tool. The diagram of the circuit simulation is shown in Figure 9. The simulations were made for a constant duty-cycle, and presented the results for load output of 300 W and steady state operation.
1 L1 136.8uH D4 2 DMBRF20100CT U3 IRFP3710 C3 100u 3 C2 9.7u R1 322.4 1 26mH 2 1 L2 2 D2 mur2100e/ON

In figure 8, the current variation through Lm during the charging interval should be equal to the current variation through Lm during the discharging interval. Using (4) and (5) together with the definitions set in Figure 8, the current ripple is given by (7).

(Vo Vi ) (1 D).T Vi .D.T k I1 = I 2 = Lm Lm

(7)
24Vdc

The simplification of (7) is illustrated from (8) to (11), thus resulting in (12), which provides the static gain of the proposed converter.

V2 V1 = 0 V2 = 10 TD = 0 V1TR = 10n TF = 10n PW = 15.22u PER = 33.33u

2 1

(V Vi ) Vi .D = o (1 D ) k V (1 D) Vi (1 D ) Vi .D = o k k (1 D ) Vo (1 D) = Vi D + k k

(8) (9) (10)

Fig. 9. Schematic diagram of the simulation circuit.

Figure 10 shows the current waveform through inductor L1, where it can be observed the continuous conduction mode in this inductor.

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Fig. 10. Current in inductor L1.

Fig. 13. Current and voltage in the diode.

Figure 11 shows the current in inductor L2, where there is current only in the second stage of operation (when the switch is open). The value of current that passes through the inductor will depend on the relation of the number of turns of the two inductors in series.

Figure 14 shows the ripple voltage and average output voltage, clearly showing that the output voltage has a small "ripple", which depends on the added capacitance value at the converter output.

Fig. 14. Ripple voltage and average output voltage. Fig. 11. Current in inductor L2.

Figure 12 shows the current and voltage waveforms in the power switch. It is observed that the overvoltages across the switch is much smaller than the output voltage.

Finally, the switching on and the switching off processes are shown in Figures 15 and 16, respectively. It can be seen an excellent switching characteristic, and the relatively low level of voltage surge in the switch.

Fig. 12. Current and voltage in the power switch.

Fig. 15. Switch S1 turn on process.

Figure 13 shows the current and voltage waveforms in the diode. The diode operates in a discontinuous conduction current mode, and the conduction interval occurs when the switch is turned off. It can also be observed that the maximum reverse voltage across the diode is larger than twice the output voltage.

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Fig. 16. Switch S1 turn off process.

Fig. 19. Voltage across the power switch (with load) (10V/div).

VII. EXPERIMENTAL RESULTS A photograph of the implemented laboratory prototype is shown in Figure 17. The results of the preliminary test of the prototype (no-load and with a 150W load) are presented in this topic.

Figure 20 shows the current through L1 and the voltage across the power switch. It can be noticed that the variation of the inductor current is almost linear, as demonstrated in the theoretical analysis previously discussed. Also some oscillations occur in the current IL1 just after the power switch is turned on. Such behavior can be attributed to the parasite inductance and capacitance presented in the printed circuit board layout of the implemented prototype. It can also be seen some oscillations on the current IL1 that occur as soon as the power switch goes into conduction. Here there is also some relation to the parasite inductance and capacitance presented in layout of this prototype.

Fig. 17. Top view of the implemented prototype.

The voltage waveform across the power switch for the converter operating at no-load is shown in Figure 18. It can be observed that there are no voltage overshoots across the power switch. On the other hand, when the converter operates with load, the voltage across the power switch presents some overshoot when it is switched off, as shown in Figure 19. This voltage overshoot is due to the sudden charge of the snubber capacitor, which occurs due to the dispersion inductance of the coupled inductor.

Fig. 20. Current through L1 and voltage across the power switch. (10V/div), (5A/div).

The current across inductor L2 is showed in Figure 21. As expected, it is possible to notice that IL2 is discontinuous. It can also be seen the linear variation of IL2 during the second operation cycle (discharge of the coupled inductor).

.
Fig. 18. Voltage across the switch of power (no load) (10V/div). Fig. 21. Current through inductor L2 (500mA/div).

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Figure 22 shows the input current in the other words, the current on batteries. You can see that the current is practically constant, because the prototype has a large input capacitance, as seen in Figure 17 (on the left of the inductor).

proposed converter performance. With the proposed topology, it has been possible to achieve efficiency of 95%. The proposed system presents high efficiency and low cost when compared with other solar home systems, and it is an eco-friendly electric energy production unit. It is applicable in small power consumption rural loads, which is the case of most houses in remote areas of the northeast of Brazil. IX. REFERENCES [1] M. T. Peraa, Conversores CC-CC Elevadores para Aplicao em Equipamentos de Refrigerao. MSc Dissertation - UFSC, Florianpolis, Brazil, February 2002. [2] Q. Zhao, Performance Improvement of Power Conversion by Utilizing Coupled Inductors. MSc Dissertation - Faculty of the Virginia Polytechnic Institute and State University, Blacksburg, Virginia, February 2003. [3] T. L. Skvarenina, The Power Electronics Handbook, CRC Press LLC, Boca, ISBN 0-8493-7336-0, Raton Florida, 2002. [4] P. Lee, Y. Lee, D. K. W. Cheng, Steady-State Analysis of an Interleaved Boost Converter with Coupled Inductors, in Proc. IEEE Transactions on Industrial Electronics, vol. 47, no. 4, pp. 787-795, August 2000. [5] Q. Zhao, F. Tao, F. C. Lee, A Front-end DC/DC Converter for Network Server Applications, in Proceedings of IEEE, pp. 15351539, 2001,. [6] F. L. M. Antunes, E. M. S. Junior, S. Daher, C. M. T. Cruz, K. M. Silva, A. R. Filgueira Photovoltaic System For Supplying Public Lighting as Peak Demand Shaving, in Eletrnica de Potncia - SOBRAEP. v. 12, no 2. pp. 113-120, July 2007.

Fig. 22. Input current (into the battery) (5A/div).

Finally, Figure 23 shows the output voltage, where it can be seen it is around 311V and its ripple is low.

Fig. 23. High gain boost converter output voltage (100V/div).

Finally, Figure 24 shows the converter efficiency, where the value average of this efficiency is 95%.

Fig. 24. High gain boost converter efficiency.

VIII. CONCLUSION The simulation and the experimental results of a 300W laboratory prototype have been presented to demonstrate the

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