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3037
NONDISSIPATIVE DC TO Dc
IIEGULATOR-CONVERTEt STUDY
F I R S T QUARTERLY REPCBlT
GREENBELT, KARPLAND
A p p r o v e d by:
Section Page
I. ABSTRACT ii
I1
I11
.. PURPOGE
INTRODUCTION
1
2
Iv. TECHNICAL DISCUSSION 3
A‘. L i t e r a t u r e Search 3
R. C l a s s i f i c a t i o n of Power Stages 12
C. C r i t e r i a f o r S e l e c t i o n of C i r c u i t r y 14
D. Comparison of Power Stages 15
E. Duty R a t i o Requiremnts 18
F. Power Stage Drive Considerations 21
G. M a t e r i a l s I n v e s t i g a t i o n 23
a . Available Power Sem5cmduct o r s 23
3. Usable Frequency Range of Semiconductors 23
c . Available Magnetic Materials 32
H. Ppder Source and Load Considerations 34
V. CONCLUSIONS A N D EiFCO&ENDATIONS 38
VI
VI1
.. PROGRAK FOR NMT INTERVAL
BIBLIOGRAPHY
39
40
VI11 . C0”CES 43
nr. NEW TECHNOUXY 43
LIST OF‘ ILLUSTRATIONS
Table Pa R e
Figure Page
1. Bedford Step-up 3
2. S e l f - S t a b 5 l i z i n g Chopper 4
3. Pulse-width Nodulated Power Supply 4
4. S i m p l i f i e d Two-St a t e Plodula t o r 5
5. Blocking O s c i l l a t o r Regulator 6
6. Low F r e qucncy Pulse Generat o r 6
7. Monost a b l e Regulator 7
8. Capa c i t i v e Doubler 8
9. Capa c l t ive Divi der 8
0 10. Hybrid Booster-Converter 9
(Continmd)
HSER 3037
Figure Page
b
e\
L
1.
ABSTRACT
7. A preliminary i n v e s t i g a t i o n of a p p l i c a b l e magnetic m a t e r i a l s .
ii
HSER 3037
11. PURPOSE
I% j c r program g o a l s a r e t h e maximization of e f f i c i e n c y , s i m p l i c i t y ,
and r e l i a b i l i t y , along with minimization of s i z e , weight, and
response times of t h e converters,
0 1
~ ~~
RSER 3037
a 111. INTRODUCTION
2
N. TECHNICAL DISCUSSION
During tk f i r s t q u a r t e r l y period, t h e a r e a s o f e f f o r t included:
A. L i t e r a t u r e Search
B. C l a s s i f i c a t i o n of Power Stages
C. C r i t e r i a f o r S e l e c t i o n o f C-hcuitry
E. Duty R a t i o Requireroents
G. Materials I n v e s t i g a t i o n
A. L i t e r a t u r e Search
3
3037
Developed by SeEer5l Eleztr-ic Conpany f o r use i n DC b o o s t
a p p l i c a t i o n s , t'nis c i r c E i t is commonly r e f e r r e d t o a s t h e
ITlyback .
If t h e trmsistor i s t u r n e d o f f , DC c u r r e n t flows d i r e c t l y
t o the l o a d . If the t r a n s i s t o r i s a l t e r n a t e l y t u r n e d on and
o f f , t h e choke s t o l e s eriergy dilring t h e Iron1' time and dis-
cnarges i n t o t h e l o a d d w i n g rroff'r t i m e . The choke's discharge
v o l t a g e i s added t o the source v o l t a g e s o t h a t a boosting a c t i o n
occurs.
(18)
S e l f - s t a b i l i z i n g Chopper
r,,
T
I L-
Figure 2.
1 I
S e l f - s t a b i l i z i n g Chopper
I
w 0
I N I- ' I
(Reprinted w5th I ; e m i s s i o n f r o m ELECTRONICS, Feb. 23,1962
Copyri&t MsGraw-Hill, Inc. 1962)
Xgwe 3. Pulse-Width Modulated Power Supply
%
4
This u n i t , designed by Lockheed I"lissi1es and Space Co., u s e s
e s s e n t i a l l y t h e same mechanism a s the S e l f - S t a b i l i z i n g Chopper,
except t h a t an output transformer and r e c t i f i e r s convert i t t o an
t n v e r t e r - r e c t i f i e r c i r c u l t . The constant v o l t -second t r a n s f ormr
i s used as a d r i v e transformer, and a "turnoff winding" i s added.
This winding s e r v e s t o s h u n t the d r i v e t r a n s i s t o r ' s base s i g n a l s .
t o ground when the t r a n s f o m r s a t u r a t e s , t h u s preventing the
drive t r a n s i s t c r s f r o m d e l i v e r i n g c u r r e n t i n t o a s h o r t c i r c u i t .
The c i r c u i t a l s o u s e s l o a d current feedback i n t h e power s t a g e .
(498 1
Two-State Modulation System
(4) (8)
This concept, described by Bose o f MIT. and Rosenthal of
the U n i v e r s i t y o f C a l i f c m i a , i s a s e l f - o s c i l l a t i n g system which
i s q u i t e i n t e r e s t i n g because of i t s s i m p l i c i t y . A simple mech-
a n i z a t i o n uses a r e l a y with m e c o n t a c t grounded and t h e o t h e r
c o n t a c t connected t o B+. The swinger i s connected t o an RC network
such t h a t t h e c a p a c l t o r v o i t a g e i s an e x p o n e n t i a l charge-discharge
waveform w i t h r e s p e c t t o ground. This waveform i s AC coupled t o
t h e base of a t r a n s i s t o r , the c o l l e c t o r l o a d of which i s t h e relay
c o i le
E IN
31
--
e\
4b 0
€04 7
-
A -
e
Figure 7. Monostable Regulator
T h i s c i r c u i t u s e s t w o t r a n s i s t o r s connected i n a monostable
c i r c u i t . One i s a chopper t r a n s i s t o r . A t h i r d t r a n s i s t o r i s
used as a v a r i a b l e irpedznce t o c o n t r o l t h e chopper t r a n s i s t o r ' s
OFF time by modulating tne charging of the commutating c a p a c i t o r .
(14)
Unregulated Low Voltage Converter
(a)
T h i s c i r c u i t , described by Driebach i s an unregulated b o o s t e r
c i r c u i t . Regeneration i s provided by a s a t u r a t i n g transformer,
and the unique f e a t u r e i s t h a t t h e output c u r r e n t i s t h e base
c u r r e n t 3f t h e switching t r a n s i s t o r s . The output v o l t a g e i s
approximately e q u a l t o the inpcit v o l t a g e p l u s half of t h e emitter-
base reverse voltage.
(15)
U n s p i i e t r i c a l Low Voltage Converter
9
1 Qz.
8
HSER 3037
9
3037
ftf
6. ZERO CLr9MP
ffl
a) Chopper Regulator
b) Capacitive Divider
c) Bedford Step-up
d) Capacitive Doubler
e1 I n v e r t e r -rectifier
Of t h e s e f i v e b a s i c types, a number of v a r i a t i o n s e x i s t .
The most obvious v a r i a t i o n i s t h e push-pull connection. I n
general, t h e other v a r i a t i o n s d i f f e r only i n drive c i r c u i t r y
and t h e means o f c o n t r o l l i n g t h e output duty cycle. The only
known exception t o t h i s statement i s t h e use of t h e " p o s i t i v e
clamp" which changes the i n v e r t e r - r e c t i f i e r t o t h e b o o s t e r and
hence modifies t h e c i r c u i t s function.
12
HSER 3037
TABLE 1
13
HSER 3037
2. C r i t e r i a f o r S e l e c t i o n of C i r c u i t r y
1. Degree of commonability o f c i r c u i t r y f o r Ifbuck" or lrboost"
a p p l i c a t i o n . This i s a r a t h e r s u b j e c t i v e i t e m t o e v a l u a t e ,
however, t h e following d e f i n i t i o n s w i l l be used:
The weighttng f a c t o r i s 4.
5;. Input r i p p l e c u r r e n t . This i s r a t e d on t h e r e l a t i v e
degree of f i l t e r i n g r e q u i r e d t o smooth t h e i n p u t . The
maximum i s 5 , minimum i s 0 . The weighting f a c t o r i s 2.
6. Output r i p p l e voltage. C i r c u i t s w i t h LC f i l t e r s a r e
r a t e d 2.5, and c a p a c i t i v e f i l t e r s a t 5. The weighting
f a c t o r i s 5.
The weighting f a c t o r is 5.
Ilr
8. Ienimurr! s i z e and weight. Each magnetic component i s
r a t e d a t 1: and each r e s i s t o r , c a p a c i t o r , o r semiconductor
a t G.5. The weighfirg f a c t o r i s 3.
A. Single-ended Chopper
B . Pllsh - p u l l Ch o p p r
7 -
Bedford Step-up
AJrn
Single
Inverter
- Ended
- Rectifier
- +
Capacitive Doubler Push- Pull Inve r te r Rectifier
3
--
C I
- a
Capacitive Divider
FIGURE 14
E. Push-pull I n v e r t e r - r e c t i f i e r
F. Push-pull Booster
G. Capacitive Doubler
H. Capacitive Divider
E. Duty R a t i o Requirements
(.1 -3 .)
Sorenson p r e s e n t s a very d e s c r i p t i v e d i s c u s s i o n of the
v a r i o u s m a n s of modxlation, using switching techniques, i n which
he discusses the c h a r a c t e r i s t i c s of Pulse-width, Pulse R a t i o , and
t w o t y p e s of Pulse-frequency modulation.
18
HSER 3037
- .
2-
r,
p:
P
3
19
HSER 3037
S e v e r a l important points can be taken f r o m h i s discussion:
Reviewing t h e Sin@-ended I n v e r t e r - r e c t i f i e r i n t h i s l i g h t ,
there are ssveral limitations t o t h i s circuit. F i r s t , since
the %ettf and "reset" volt-second products must be e q u a l , i t
i s obvious t h a t ; a ) i f t h e attempt i s made t o operate n e a r 100%
ON time, t h e ftresetE1 voltage must be q u i t e h i g h and t h e r e f o r e
s c b j e c t compor,ents t c severe usage, b ) transformer losses i n c r e a s e
r a p i d l y with decreasing "reset" t i m e , and c ) s c a l i n g the trans-
20
former s o a s t o s h i f t t h e duty c y c l e range means t h a t the f r e e -
wheeling diode w i l l conduct for a l o n g e r time, hence lowering
e f f i c i e n c y , a d t h e output choke must be s i z e d t o supply contin-
uous current for a longer period. Therefore the push-pull
systems, which have no limitations, offer a distinct
advantage over the single-ended design, and the study will be
l i m i t e d t o the push-pull chopper a n d t h e push-pull I n v e r t e r -
.
re c t if i e r
-f
.._
41 V6E
0
I
!
- J'
.- .- __
. &
r; Vk€
I
22
schme does supply high amplitude turn-& and turn-off edges
but does not supply r e v e r s e b i a s during t h e majority of t h e
dwell time.
G. Materials I n v e s t i g a t i o n
e
!x
33
24
HSER 3037
r
0
A -
% )
\ R
25
HSER 3037
b 10 1w
e
1ov 10.'LTi
-
7
Figure 1 7 . Switching Model
Table 4. a 2 8 8 0 Parameters
B
Zond. Time Freq.
-~
45.2% 1KC
45.4% lOKC
117.0% 1GOKC
49.6% 2SOKC
54.1% SOOKC
91.1% 1KC
91.2% lOKC
92.9% iOOKC
95.5% 252KC
99 9$ SOOKC
1 .
26
~
~
HSER 3037
1
Table 5. 2N1908X (assumed) Parameters
Cond. T i m e
45.2%
540
46.01
67.6
90.5
91.4
99.5
1 !iz i!z
tr+tf
1 . 8 ~ ~
1
.112
IB
,112
,113
.n6
,
IC
1.12
1.12
1.13
1.16
'CS
.08v
'BS Freq.
13OKC
lOKC
2 COKC
lOKC
iOOKC
XC
lKC
as
.546
7
94 84 SOOKC 10
27
HSER 3037
2'
0
OD
29
wk-ich agrees -FPsx:cbly well with the c u r v e
l a b e l l e d B2 of F l ? u r e I?,.
Secmaly, -k:e f r e q u x c p e t --** pi- i A the curves (31 and B2) cross
n.7
summary
T r a n s i s t o r s with v e r y low s a t u r a t i o n v o l t a g e s a r e more e f f i c i e n t a t low
frequencies. Most high frequency t r a n s i s t o r s possess higher s a t u r a t i o n
v o l t a g e s , but a t higher frequencies t h e i r i n c r e a s e d switching speeds render
them more e f f i c i e n t .
If "OFF" l o s s e s and delay and storage times a r e neglected, equations 8
a n d 9 allow t h e p x d i c t i o n of the e f f i c i e n c y r o l l - o f f frequency of any
t r a n s i s t o r a s a f u n c t i o n of known c i r c u i t requirements and t r a n s i s t o r
parameters. Operation above the r o l l - o f f frequency will r e s u l t i n a r a p i d
d e c l i n e of t r a n s i s t o r e f f i c i e n c y . Calculations i n d i c a t e t h a t operation
a t any'frequency below r o l l - o f f will not i n c r e a s e e f f i c i e n c y by more than
1 o r 2%.
If "OFF" losses and delay and s t o r a g e times a r e neglected, equations / O
and / I allow t h e p r e d i c t i o n of t h e crossover frequency. The crossover
frequency i s a composite r o l l - o f f frequency which s e t s the upper frequency
l i m i t f o r a t r a n s i s t o r which must operate over an i n p u t v o l t a g e range w i t h
duty cycle c o n t r o l . Operation above crossover frequency r e s u l t s i n r a p i d
d e c l i n e of e f f i c i e n c y f o r t h e high i n p u t , low duty cycle condition. Oper-
a t i o n below crossover w i l l r e s u l t i n an e f f i c i e n c y i n c r e a s e ranging f r o m
almost 0 upward t o about 1 o r 2%, depending upon i n p u t v o l t a g e and duty
cycle.
32
I n surveying t h e a v a i l a b l e nagne t i c m a t e r i a l s , both
stamped l a n i n a t i m s and c-cores were eliminated
im9ediately became t h e y have b u i l t - i n air-gaps and
because t h e i r windings cannot be uniformly d i s t r i b u t e d
o r tightly-coupled t o t h e core. The hermetically-sealed, o i l -
f i l l e d , tape-wound v a r i e t y of t o r o i d s was considered, b u t
t h e s e cores a r e available with a minimum tape t h i c k n e s s o f
1m i l , which ailows f o r operation up t o about lOKCPS, beyond
which t h e core l o s s e s become p r o h i b i t i v e .
Freq.,
CPS
Core
Material
Hyst e r e s i s
Ll ;s I
Ed$. C u r .
Loss
I
I Permeability
I I
0 ,S-lSX Moly- Perm. Powder Low LOW H i g h , Decreasing
Iron Powder Moderate LOW High, Decreasing
Ferrite High LOW Low, Constant
15-4OK Moly-Perm. Powder LOW High Moderate, Decreasing
I r o n Powder Lmr Moderate Moderate, Decreasing
Ferrite Mode r a t e Low Moderate, Constant
35
HSER 3037
b , Load Considerat i o m
A s d i s c u s s e d abose, t h e s u p p r e s s i o n o f t h e c y c l i c
input v a r i a t i o n w i l l be a f u n c t i o n o f t.he response
of t h e moduiatlng c i r c u i t r y . There will be an
excursion of output v o l t a g e due t o t h e s t e p l o a d
changes, since t h e change occurs i n t h e o r e t i c a l l y
z e r o t i m e and the c o n t r o l l e r cannot be i n f i n i t e l y
fast.
36
HSER 3037
I I
37
HSER 3037
V. CONCLUSIONS AND RE C O I ~ ~ N D A T I O N S
The t y p e of c i r c u i t r y s e l e c t e d f o r f u r t h e r study i s t h e
push-pull chopper and t h e push-pull i n v e r t e r - r e c t i f i e r .
The m o s t promising mode of operation i s a combination of
p u l s e and frequency modulation.
A reasonably l a r g e s e l e c t i o n o f t r a n s i s t o r s i s a v a i l a b l e ,
with frequency c a p a b i l i t i e s a p p l i c a b l e t o t h i s study. The
s e l e c t i o n of high-speed r e c t i f i e r s i s much m o r e l i m i t e d
but should prove adequate. The a v a i l a b l e magnetic m a t e r i a l s
appear t o be l i m i t e d t o t o r o i d s using molybdenum-permalloy
powder, i r o n powder, o r f e r r i t e s , and tape-wound bobbin cores.
I n a pulse-width modulated system w i t h i n p u t v o l t a g e and duty
cycle v a r i a t i o n s equivalent t o t h o s e of t h e l c r W chopper, t h e
maximum operating frequency appears t o be about 20 t o 30KCPS,
based only on semiconductor e f f i c i e n c y considerations.
HSER 3037
39
. VII. BIBLIOGRAPHY
1.
2.
I1A Report on Contract Programs a t General E l e c t r i c Co."
C. Christianson, S Nielsen
Proceedings -
.
BuFieps Symposium on Power Transformation
and Voltage Regulation, J u l y 18, 1963.
a. B.llLcmDriesbach
Voltage DC t o DC Conversion"
43