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6, NOVEMBER 1994 60 1
Abstract-A new family of zero-current-transition(ZCT) pulse- frequency operation is also achievable if phase-shift control is
width-modulated (PWM) converters is proposed. The new family employed in full-bridge topologies [lo]. However, these types
of converters implements zero-current turn-off for power tran- of circuits usually are operated with large amount of circulating
sistor(s) without increasing voltagdcurrent stresses and operates
at a fixed frequency. The proposed converters are deemed most energy and thus require the power devices and other circuit
suitable for high-power applications where the minority-carrier components to be rated for significantly higher VA ratings, as
semiconductor devices (such as IGBT’s, BJT’s, and MCT’s) are compared to their PWM counterparts.
predominantly used as the power switches. Theoretical analysis As a compromise between the ZCS resonant and PWM
is verified on a 100 kHz, 1 kW ZCT-PWM boost converter using techniques, the ZCS quasi-resonant (QRC) technique was
an IGBT.
proposed [ 1I]-[ 131. While the underlying power conversion
principle of ZCS-QRC’s is similar to that of the PWM
I. INTRODUCTION converters, a resonant network is employed to shape the switch
current waveform so that the power transistor is operated with
R ECENTLY, a number of soft-switching PWM techniques
were proposed aimed at combining desirable features of
both the conventional PWM and resonant techniques [ 11-[5].
ZCS and the rectifier diode with ZVS. Compared with the
conventional resonant converters, the ZCS-QRC’s operate with
Among them, the zero-voltage-transition (ZVT) PWM tech- less circulating energy. However, these converters operate with
nique is deemed desirable since it implements zero-voltage sinusoidal current through the power switch(es) which results
switching (ZVS) for all semiconductor devices without in- in high peak and rms currents for the power transistors and
creasing voltagekurrent stresses [4], [5 ]. This technique min- high voltage stresses on the rectifier diodes. Furthermore, when
imizes both the switching losses and conduction losses and the line voltage or load current varies over a wide range, ZCS-
is particularly attractive for high-frequency operation where QRC’s are modulated with a wide switching frequency range,
power MOSFET’s are used as power switches. making the circuit design difficult to optimize.
Due to continuous improvement of switching characteristics, This paper presents a new family of zero-current-transition
lower conduction losses, and lower cost, IGBT’s are gaining (ZCT) PWM converters. The proposed ZCT-PWM convert-
wide acceptance in switched-mode power converters/inverters. ers implement zero-current turn-off for the transistors with-
Since IGBT is a minority-carrier devices, it exhibits a current out substantially increasing voltage/current stresses of the
tail at turn-off which causes considerably high turn-off switch- switches. They are particularly suited for high-powerhgh-
ing losses. To operate IGBT’s at relatively high switching voltage applications where the minority-carrier semiconductor
frequencies, either the ZVS or the zero-current switching devices (such as IGBT’s, BJT’s, and MCT’s) are used as the
(ZCS) technique can be employed to reduce switching losses. power switches. In the following section, the ZCT-PWM boost
Basically, ZVS eliminates the capacitive turn-on loss, and converter is used as an example to illustrate the principle of
reduces the turn-off switching loss by slowing down the operation.
voltage rise and reducing the overlap between the switch
voltage and switch current. This technique can be effective 11. PRINCIPLES OF OPERATION
when applied to a fast IGBT with a relatively small current tail.
The circuit diagram and key waveforms of the ZCT-PWM
However, employing ZCS technique eliminates the voltage and
boost converter are shown in Fig. 1. The converter differs
current overlap by forcing the switch current to zero before
from a conventional PWM boost converter by the introduction
the switch voltage rises. ZCS is deemed more effective than
of a resonant branch, which consists of a resonant inductor,
ZVS in reducing IGBT switching losses, particularly for slow
L,, a resonant capacitor, C,, an auxiliary switch, SI,and an
devices [6], [7].
auxiliary diode, D1. This resonant branch is active only during
Several ZCS techniques were reported [7]-[13]. It is well-
a short switching-transition time to create the ZCS condition
known that the conventional resonant converters, such as
for the main switch. In the analysis, the boost inductor, L f ,
the parallel-resonant converter, series-resonant converter, and
is assumed to be large enough to be considered as a current
LCC-type converters, can achieve ZCS for power transis-
source, Ii. In steady-state, five operating stages exist within
tors when operated below the resonant frequency. Constant-
one switching cycle (refer to Fig. 2):
Manuscript received October 25, 1993; revised June 10, 1994.
The authors are with the Virginia Power Electronics Center, The Bradley a) To-Tl: Prior to 7’0,the main switch, S , is conducting,
Department of Electrical Engineering, Virginia Polytechnic Institute and State and C, is charged with certain negative voltage, -Vgzak.
University, Blacksburg, VA 24061 USA. At TO,the auxiliary switch, S1, is turned on, starting a
Eric X. Yang is currently with Harris Power Research and Development,
Latham, NY 12110 USA. resonance between C, and L,. This resonance forces
IEEE Log Number 9405302. the transistor current to decrease in a sinusoidal fashion.
0885-8993/94$04.00 0 1994 IEEE
602 IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 9, NO. 6, NOVEMBER 1994
(3)
if
(5)
Combining (2)-(5) yields
IF,= = -1%
cos cy
2 17, (6)
which means that as long as inequality (4) is satisfied,
ZCS operation will be guaranteed regardless of the input
voltage and load current. In a practical design, T d 2 can
be selected at around 0.07 Tr,so that is about 10%
(d) (e)
higher than Iz,and ZCS is ensured. When S1 is turned
off at T1, both D and D1 will start to conduct, and L, Fig. 2. Equivalent circuits for five topological stages. (a) To-Tl. (b) Tl-Tz.
(c) T2 -T?.(d) T3 -T4. (d) T4 -To.
and C, continue to resonate until the I,, current decays
to zero at T2.
c) T2-T3: At T2, L , and C, complete the half-cycle res- It is interesting to note that in steady-state operation, the
onance, and D1 is reverse-biased. This operating stage energy stored in the resonant tank remains constant over the
is identical to the transistor-off stage of the PWM boost entire switching cycle. This can be clearly seen from the above
converter. description. During each topological stage (shown in Fig. 2),
d) T3-T4:At T3, S is turned on, and the boost inductor is either the voltage across the resonant tank ( L , plus C r )is zero
charged by the input voltage. Meanwhile, C, and Lr or the current through it is zero, so there is no energy transfer
form a half-cycle resonance through S and the anti- between the resonant elements and other parts of the circuit.
parallel diode of S1, which reverses the polarity of the Fig. 3 shows the state-plane trajectory of the resonant tank.
C, voltage. The energy stored in the resonant tank, which is self-adjusted
e) TA-T,: Operation of the circuit is identical to that of in accordance with line and load conditions, can be given by
the transistor-on period of the PWM boost converter. At
TO,S1 is turned on again, and the switching cycle is
(7)
repeated.
HUA er al.: NOVEL ZERO-CURRENT-TRANSITION PWM CONVERTERS 603
(a) (b)
Fig. 4. An additional topological stage occurs when the circuit offsets the 111. EXTENSION
OF THE ZCT CONCEPT TO OTHER TOPOLOGIES
balance operating point: (a) IL,. > I ! and (h) IL,,. < 17 at 2'1.
From the circuit topological point of view, every resonant-
type converter (including the conventional resonant, quasi-
This circulating energy increases as input current increases resonant, and multi-resonant converters) can be viewed as a
(when line voltage decreases or load current increases). In variation of its PWM counterpart. By incorporating certain
a practical circuit, since the resonant transition time is very type of resonant network, it creates a resonance to achieve
short with respect to the switching cycle, the resonant induc- ZVS or ZCS. For different resonant converters, of course, the
tance is very small compared to boost inductance. Therefore, type of resonant network employed is different.
the circulating energy of the ZCT-PWM converter is quite One common characteristic of resonant-type topologies is
small compared to a conventional ZCS resonant converter, as that they all employ a resonant inductor (sometimes a res-
illustrated in the design example given in Section IV. onant inductor plus a resonant capacitor) in series with the
It was mentioned that in steady-state operation, the resonant power switch or the rectifier diode to shape switch volt-
inductor current at TI is always equal to I,, regardless of line agelcurrent waveforms. Soft-switching is achieved by utilizing
or load condition change. Assuming that for some reason 1~~ the resonance between this resonant inductor and certain
at TI is larger than I,. In this case, there will be an additional resonant capacitors, which are usually in parallel with the
topological stage inserted between mode (b) and mode (c) in semiconductor devices. Due to the fact that these resonant
Fig. 2, as shown in Fig. 4(a). During this operating stage, the elements are placed in the main power path, the resultant
resonant branch transports energy to the load. Therefore the resonant converters are always subjected to inherent problems.
energy stored in the resonant branch decreases. In contrast, if First, since the resonant inductor is subjected to bidirectional
1~~at TI is lower than I,, there will be another topological voltage, it inevitably generates additional voltage stress on
stage inserted between mode (b) and mode (c) in Fig. 2 , as the semiconductor devices. Second, since all the power flows
shown in Fig. 4(b). It can be seen that the boost inductor through the resonant inductor, substantial circulating energy
will pump some energy into the resonant branch during this is always created, which significantly increases conduction
operating stage. Therefore, the energy stored in the resonant losses. In addition, the energy stored in the resonant inductor
branch will increase until it reaches the balance point given strongly depends on the line voltage and load current. There-
by (7). fore, soft-switching condition is sensitive to line voltage and
From steady-state operation, it can be seen the ZCT-PWM load current changes. This is why most resonant converters
technique implements zero-current turn-off for the power are unable to maintain soft-switching for a wide line and load
transistor without penalizing the voltage stresses of both range.
the power transistor and the rectifier diode. Although the To alleviate the above-mentioned limitations, it is necessary
main switch current waveform exhibits a resonant peaking, to remove the resonant element(s) from the main power path.
it does not increase the conduction loss, since the average Instead of using a series resonant element, an altemative way
current through the power switch (IGBT) is essentially the is to use a shunt resonant network across the power switch.
same compared with its PWM counterpart. Another unique During the switching transition, the shunt resonant network
advantage of the proposed technique is that it has minimum is activated to create a partial resonance to achieve ZVS or
1 OK+ .
...
...
...
...
t..
...
...
.. . .......+.......+....... +
0 8Kt t
0 6Kt t
0 4Ki
.-
Time
24u5 26us 28u5
1 OK+ ........................................*.............+.............,
I
I1
(e) (0
0 8Kt II I i Fig. 6. Six basic ZCT-PWM topologies. (a) Buck. (b) Boost. (c) Buck-boost.
(d) Cuk. ( e ) Sepic. (0Zeta.
T,me
24U5 26U5 28U5
factor with simple fixed-frequency and fixed-duty-cycle con-
(b)
trol. The use of the shunt resonant network enables the circuit
to operate at much higher switching frequencies. The features
Fig. 5. Typical transistor I-/lwaveforms of boost convert using an additional
inductor for damping reverse-recovery of the diode: (a) with the ZCT-PWM of the ZCT-PWM converters are summarized in the following:
technique, and (b) with the PWM technique. zero-current turn-off for the power switch,
low voltage/current stresses of the power switch and
rectifier diode,
ZCS. When switching transition is over, the circuit simply
reverts back to the familiar PWM operating mode. In this way, minimal circulating energy,
wide line and load ranges for ZCS,
the converter can achieve soft-switching while preserving the
constant-frequency operation.
advantages of the PWM converter. In fact, the above-suggested
concept of using a shunt resonant network has been adopted
in the ZVT-PWM converters [4]. Apparently it can also be VERIFICATION
IV. EXPERIMENTAL
applied to implement ZCT, as illustrated above. A 100 kHz, 1 kW ZCT-PWM boost converter was imple-
It should be mentioned that ZVT or ZCT can be imple- mented to illustrate the operation of the new converters. The
mented in perhaps a number of different ways. One should circuit is regulated at 400 V output with a 200-300 V input
keep it in mind that it is desirable to minimize the circulating range. The circuit diagram of the experimental converter is
energy and circuit complexity. Furthermore, it also is desirable shown in Fig. 8. In the breadboarded converter, the main power
to implement some form of soft-switching for the auxiliary switch is implemented by an IR fast-series IGBT, IRGPF40
switch as well. (V& = 600 V, IC = 40A, t, = 37 ns, and T f = 420ns, rated for
The ZCT concept can be extended to any switched-mode up to 8 kHz switching frequency operation). Since the auxiliary
power converters or inverters. Fig. 6 shows six basic ZCT- switch only handles a little resonant transition energy, a small
PWM topologies. Fig. 7 shows a single-switch three-phase MOSFET, IRF830, is employed. The small diode in series with
ZCT-PWM boost converter. By running this circuit in discon- 5'1 is used to block its slow body-diode from conduction. L,
tinuous conduction mode, it can provide fairly good power and C, are selected at 10 pH and 8.2 nF, respectively. With
HUA er al.: NOVEL ZERO-CURRENT-TRANSITION PWM CONVERTERS 605
D
Lf HEXFRED-10
+
1 1
Vi 400 V
200--300 UHVP206
IRGPCSOF
IRF830
Fig. 8. Power stage circuit diagram of the 100 kHz, 1 kW ZCT boost
converter.
output. For the PWM converter, it can be seen that the major IGBT tum-on switching 3.0 W 3.0 W
power dissipation comes from the tum-off switching loss of IGBT tum-off switching 37.0 W 5.2 w
the IGBT, which is about 37 W. The estimation of IGBT
auxiliarv switch NIA 1.0 w
switching losses is based on the actual switch voltage/current
waveforms, roughly in agreement with the data given in the I auxiliarydiodes I/ NIA I 0.6 W I
IGBT designer’s manual [14]. For the ZCT circuit, power I resonanttank(L,andC,) 1) N/A 1 0.2W 1
losses involved in the operation of the auxiliary resonant shunt I diodeconduction 1) 1.7 W 1 1.7 w 1
are only about 1.8 W, which is less than 0.3% of the output diode switching 29W 29W
power. boost inductor 20w 19w
>i‘\ ;.....................
......... .i ...... %A--.. ............... [ I l l K. H. Liu and F. C. Lee, “Resonant switch-A unified approach to im-
i ,PWMbwst prove performance of switching converters,’’ in IEEE In?. Telecommun.
94 - .. ~.... I
......--i.........
1 i \
................ .;......................
~
Energy Con$ Proc., 1984, pp. 334-341.
L ............ .i................ :...... *..-..\ .... j . . . .
[I21 K. H. Liu, R. Oruganti, and F. C. Lee, “Quasi-resonant convert-
i \ I ers-Topologies and characteristics,” IEEE Trans. Power Electron., vol.
1 .........
92 -. ........... :
.............. , ; - . \ { ...... . 2, pp. 62-74, 1987.
[I31 M. M. Jovanovic, F. C. Lee, and D. Y. Chen, “A zero-current-switched
off-line quasi-resonant converter with reduced frequency range: Anal-
90 I ysis, design, and experimental results,” IEEE Trans. Power Electron.,
200 400 600 800 1000 vol. 4, no. 2, pp. 215-224, 1989.
[I41 International Rectifier Corp., IGBT Designer’s Manual, IRC, 1991.
Output Power (W)