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This article has been accepted for publication in a future issue of this journal, but has not been

fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TIE.2021.3097597, IEEE
Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS

H5-Bridge Based Single-Input-Dual-Output LLC


Converter with Wide Output Voltage Range
Liang Wang, Student Member, IEEE, Haoyu Wang, Senior Member, IEEE, Bo Xue, Student Member, IEEE, and
Mingde Zhou, Student Member, IEEE

Abstract—In this manuscript, a novel single-input-dual- Among various SIDO converters, LLC based SIDO convert-
output (SIDO) LLC converter is proposed for wide output ers draw wide research attention due to its attractive features
voltage applications. An H5-bridge is utilized on the pri- such as galvanic zero-voltage-switching (ZVS) for primary
mary side and linked with two separate resonant tanks.
By morphing the H5 bridge, the input of each resonant side MOSFETs, zero-current-switching (ZCS) for secondary
tank can be configured as either full-bridge, half-bridge, side diodes, and simple structure [8], [9]. For traditional
or idle. On the secondary side, two semi-active rectifiers LLC converter, pulse frequency modulation (PFM) is used
provide two control degrees-of-freedoms. The circuit oper- to regulate the output voltage. However, PFM based LLC
ation is always tuned at the optimal resonant frequency and converter is unable to generate two decoupled outputs due
the output voltages are modulated by the secondary side
pulsewidth. It exhibits good voltage regulation performance to cross regulation issues. Alternative modulation methods
with two fully decoupled output ports. Both output ports for LLC converter with fixed frequency are proposed such
can achieve wide voltage ranges. All MOSFETs can achieve as primary-side pulsewidth modulation (PWM) [10], primary-
ZVS turning-ON and all the diodes can achieve ZCS turning- side phase shift modulation (PSM) [11], secondary-side PWM
OFF over a wide output voltage and load ranges. To verify [12], secondary-side PSM [13]–[15], and resonant frequency
this concept, a 1.6-kW rated prototype is designed to con-
vert 390 V input into two decoupled 100 - 400 V outputs. The modulation [16], [17]. Those modulation methods provide ad-
designed prototype exhibits 97.72% peak efficiency and ditional control degree-of-freedom (DoF) for SIDO converters.
good decoupled voltage regulation performances. The ex- Generally, the modulation strategies for LLC based SIDO
perimental results agree well with the theoretical analysis. converter can be classified into three categories. The first
category is based on synchronous control with one control DoF
Index Terms—dual-output converter, H5 bridge, LLC, [3], [18]. In [3], a multi-channel constant-current LLC resonant
pulsewidth modulation, wide voltage range. LED driver is proposed. In [18], a dual-output LLC converter
with wide input voltage range is proposed. Only PFM is
I. I NTRODUCTION utilized and both output ports are regulated simultaneously.
Consequently, both ports are fully coupled and the issue of
I N applications such as multi-output programmable dc
power supplies, integrated battery chargers, and multi-
channel LED drivers [1]–[3], multiple dc outputs are required
cross regulation occurs. This type of multiple-output control is
not suitable for the applications that require decoupled control
of each channel.
with a wide output voltage range. A straightforward way
The second category is based on master and slave control
to generate multiple outputs is to utilize multiple single-
[19], [20]. To ensure each channel independently regulated, the
input-single-output (SISO) converters. Compared with mul-
required control DoFs should be no less than the number of
tiple SISO converters [4], integrated single-input-multiple-
the outputs. In [19], a novel complementary PWM and PFM
output (SIMO) converter exhibits superior advantages such
strategy is proposed. The master output is regulated by the
as fewer components, reduced cost, and higher power den-
duty cycle of the primary-side switches while the slave output
sity [5]–[7]. Single-input-dual-output (SIDO) converter is the
is regulated by frequency. In [20], by regulating the phase-
simplest SIMO converter with wide applications. To generate
shift angle and the switching frequency, each channel can be
two independent outputs, the two output modules need to be
regulated separately. However, these control variables are still
regulated in a decoupled manner.
coupled. When the master port voltage is being modulated, the
Manuscript received February 5, 2021; revised March 18, 2021 and slave port voltage is also affected. Cross regulation problem
May 30, 2021; accpeted July 3, 2021. This work was supported in still exists with complicated control.
part by the National Natural Science Foundation of China under Grant
52077140, and in part by the Shanghai Rising Star Program under Grant The third category is based on independent control [21],
20QA1406700. (Corresponding author: Haoyu Wang.) [22]. In [21], a dual-output LLC resonant converter with
L. Wang is with Power Electronics and Renewable Energies Labo- magnetic control is proposed. Variable resonant inductance
ratory, School of Information Science and Technology, ShanghaiTech
University, Shanghai 201210, China, also with the Shanghai Institute is enforced to adjust the resonant frequency of LLC tank to
of Microsystem and Information Technology, Chinese Academy of regulate the output voltages. Two outputs can be regulated by
Sciences, Shanghai 200050, China, and also with the University of two independent resonant frequencies. However, the output
Chinese Academy of Sciences, Beijing 100049, China (e-mail: wan-
gliang1@shanghaitech.edu.cn). voltage range is limited. In [22], LLC resonant converter
H. Wang, B. Xue and M. Zhou are with the Power Electron- and phase-shift-full-bridge (PSFB) converter are hybridized
ics and Renewable Energies Laboratory, School of Information Sci- to achieve a SIDO converter. The output voltage of the LLC
ence & Technology, Shanghaiech University, Shanghai 201210, China
(e-mail: wanghy@shanghaitech.edu.cn; xuebo@shanghaitech.edu.cn; resonant converter is modulated by the switching frequency,
zhoumd@shanghaitech.edu.cn). while the output voltage of the PSFB converter is modulated

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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TIE.2021.3097597, IEEE
Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS

iin S1 S2 S1 S2 S1 S2
S1 S2
Cr1 Lr1 D1 D2
TX1 I1 a a a
a
+ vC - iL1 i +isec1 + RT1 RT1 RT1
1
Lm1 vsec1 C1 R1
Lm1 V1 Vin S5 b Vin S5 b Vin S5 b
-
-
n1:1 RT2 RT2 RT2
S6 S7
c c c
Vin S5 b S3 S4 S3 S4 S3 S4

D3 D4
TX2 I2 FBFB FBHB HBFB
iLm2 +isec2 +
vsec2 C2 R2
vC 2 iL2 Lm2 V2 S1 S2 S1 S2 S1 S2
+ - -
c - a
n2:1 S a a
S3 S4 Cr2 Lr2 8 S9
RT1 RT1 RT1
Vin S5 b Vin S5 b Vin S5 b

RT2 RT2 RT2


Fig. 1. Schematic of the proposed SIDO LLC topology.
c c c
S3 S4 S3 S4 S3 S4

HBHB HBID IDHB

by the phase angle. Therefore, the two output voltages are


Fig. 2. Configurations of the H5 bridge.
regulated independently and free from cross regulation.
The literature survey indicates that although different LLC TABLE I
based SIDO topologies and modulation schemes have been O PERATING M ODES OF H5 B RIDGE
investigated, there is still a lack of systematic solution to RT Mode Voltage vrms Switches
produce two decoupled outputs with ultra-wide output voltage RT1 FB vab : ±Vin Vin
ranges. In [23], [24], a five switches inverter bridge structure is FBFB S5 ON
RT2 FB vcb : ±Vin Vin
proposed to extend the output voltage range of LLC converter. RT1 FB vab : ±Vin Vin
FBHB S3 ON
By reconfiguring the inverter bridge, a much wider output RT2 HB vcb : −Vin ∼ 0 Vin /2
range can be achieved. However, PFM is used to regulate the HBFB
RT1 HB vab : 0 ∼ Vin Vin /2
S1 ON
output voltage, which makes it unsuitable to generate dual RT2 FB vcb : ±Vin Vin
outputs with decoupled control. RT1 HB vab : 0 ∼ Vin Vin /2 S1,3 ON
HBHB
RT2 HB vcb : −Vin ∼ 0 Vin /2 S5 OFF
The main novelties and contributions of this study are RT1 HB vab : 0 ∼ Vin Vin /2 S1 ON
HBID
summarized as follows. First, a novel H5-bridge based SIDO RT2 ID N/A N/A S3,5 OFF
LLC converter is proposed. An ultra-wide output voltage IDHB
RT1 ID N/A N/A S3 ON
range can be achieved by configuring the primary-side H5 RT2 HB vcb : −Vin ∼ 0 Vin /2 S1,5 OFF
bridge and modulating the secondary-side pulsewidth. Second,
the operation principles in different modes are analyzed in
time domain and by trajectory tool. Third, elaborate design II. TOPOLOGY AND B ASIC O PERATION P RINCIPLES
guidelines are provided to ensure wide ZVS range and im- A. Topology Description
prove efficiency. Fourth, based on various operation modes, Fig. 1 shows the schematic of the proposed SIDO LLC
corresponding control strategy is proposed to regulate dual topology. The primary side is a reconfigurable H5 bridge with
independent outputs. five MOSFETs. The H5 bridge generates two high frequency
The benefits of the proposed topology include: wide output square waves, vab and vcb . There are two sets of LLC resonant
voltage ranges; wide ZVS range for all MOSFETs and ZCS tank and rectifier. Those two resonant tanks are fully decou-
for all diodes; fewer components with reduced hardware cost pled. The resonant tank parameters include resonant induc-
compared with dual traditional SISO LLC converters with wide tance (Lr ), resonant capacitance (Cr ), magnetizing inductance
output voltage range [10], [23], [24]; two fully decoupled (Lm ), and transformer turns ratio (n). The parameters of each
outputs; easy design of magnetic components. Moreover, large resonant tank can be designed independently based on the
magnetizing inductance can be selected, which effectively characteristics of the desired output. The resonant frequencies
suppresses the circulating current. between Cr and Lr in two resonant tanks are identical. The
frequencies of vab and vcb are tuned to be equal to the resonant
This manuscript is organized as follows: Section II describes frequency. On the secondary side, there are two independent
the proposed converter and its operation principles. Section III semi-active rectifiers. The output voltage can be regulated by
shows the theoretical analysis of the proposed converter. The modulating the pulsewidth of secondary-side MOSFETs.
key design considerations are presented in Section IV. The loss
analysis and performance comparison are presented in Section
V. The control strategy is shown in Section VI. Section VII B. Operation Principles
demonstrates the experimental results. Finally, this manuscript According to the configuration of the H5 bridge, there are
concludes in Section VIII. six operating modes as shown in Fig. 2. The inputs of two

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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TIE.2021.3097597, IEEE
Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS

I II III IV V VI VIIVIII IX X XI XII III. T HEORETICAL A NALYSIS


vgs vgs1,vgs4 vgs2,vgs3 A. Steady-State Analysis
t
There are six operation modes and two outputs are mutually
vgs vgs7 d1 vgs6 d1 independent. To simplify the theoretical analysis, only the first
t port of FBFB Mode is analyzed in detail. The other port
vgs vgs9 d2 vgs8 d2 and the other operation modes can be analyzed similarly. The
t switching frequency is always tuned at the resonant frequency
between Lr and Cr .
vab t The key waveforms of FBFB mode are plotted in Fig. 3.
For each secondary-side output, the secondary-side MOSFETs
(S6 and S7 , S8 and S9 ) are regulated by duty cycles as shown
iL1 in Fig. 3. The duty cycles d for each branch are identical
t
iLm1 and are always equal to or greater than 0.5. They are driven
in an interleaving manner with 180◦ phase difference. vgs7,9
isec1 t (vgs6,8 ) are in phase with vgs1,4 (vgs2,3 ). The duty cycles of
secondary-side MOSFETs are utilized to regulate the output
voltages. It should be noted that when d = 0.5, secondary-side
MOSFETs function as synchronous rectifier switches. This
iD1
branch operates like a traditional LLC converter. The critical
iD2 t
steady-state waveforms with duty cycle d1 and d2 are shown
in Fig. 3. As shown in Fig. 3, the steady-state circuit operation
vC1 t can be divided into twelve operation stages. Fig. 4 shows the
equivalent circuits of the six stages over a half switching cycle
iL2 and the next six stages are symmetrical. The input current
t of the converter is equal to the sum of iL1 and iL2 in the
iLm2
positive half cycle. The input current of negative half cycle is
equal to that of positive half cycle. When only considering the
isec2 t operation of the first output, four main parts can be divided
and they are analyzed detailed in the following. The operation
principles of the second output are similar and can be derived
easily.
iin Stage I: (t0 -t1 ][see Fig. 4(a)], before t0 , S2,3 are ON, S1,4
t are OFF and the secondary side is an open circuit. On the
primary side, Lm1 resonates with Lr1 and Cr1 . At t0 , S2,3 are
t0t1 t2 t3 t4 t5 t6t7 t8 t9 t10 t11 t12 turned OFF. At this moment, iLr1 is negative, which charges
Coss of S2,3 and discharges Coss of S1,4 . The freewheeling
Fig. 3. Critical steady-state waveforms.
current discharges the parasitic output capacitance (Coss ) of
S7 . These negative currents create a ZVS condition for the
turning-ON of S1,4 and S7 .
resonant tanks (RT1 and RT2) can be configured as full- Stage II: (t1 -t2 ][see Fig. 4(b)], Coss of S1,4 , S7 is dis-
bridge (FB) mode, half-bridge (HB) mode, and idle (ID) mode. charged to 0V since iLr1 is negative before t1 . Coss can only
Therefore, six possible operating modes can be named as be discharged completely if enough dead-time is employed.
FBFB, FBHB, HBFB, HBHB, HBID, and IDHB based on the At t1 , S1,4 and S7 are turned ON with ZVS. In this stage,
combination of two resonant tanks. The specific configuration Lr1 resonates with Cr1 . The secondary side of transformer
and characteristics are summarized in Table I. vrms means T X1 is shorted. Secondary side voltage vsec1 is clamped to
the RMS value of the resonant tank’s input voltage. In the FB 0V . Due to the deadband is small, the impact of deadband can
mode, vrms is twice as much as that in HB mode. Therefore, be ignored. According to the KVL and KCL of RT1:
the voltage gain in FB mode is doubled compared with that in dvC1
Cr1 = iL1 (1)
HB mode. When one output port works in no-load condition, dt
the corresponding resonant tank can operate in idle mode. diL1
Therefore, the appropriate operation mode can be selected Lr1
+ vC1 = Vin (2)
dt
based on the desired output voltages. It should be noted
that HBID Mode and IDHB Mode are only suitable for the the time domain expressions of inductor current and capacitor
condition when only one output delivers power in half-bridge voltage can be derived in Stages I and II:
mode. The other output stays in idle mode. Compared with iL1 (t) =iL1 (t0 )cos[ω1 (t − t0 )]
HBHB Mode, one more MOSFET is kept OFF. If only one Vin − vC1 (t0 ) (3)
full-bridge input is needed, FBFB Mode can be selected. + sin[ω1 (t − t0 )]
Z1

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Authorized licensed use limited to: ShanghaiTech University. Downloaded on July 22,2021 at 01:55:30 UTC from IEEE Xplore. Restrictions apply.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TIE.2021.3097597, IEEE
Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS

S1 S2 S1 S2 S1 S2
Cr1 Lr1 D1 D2 Cr1 Lr1 D1 D2 Cr1 Lr1 D1 D2
a TX1 I1 a TX1 I1 a TX1 I1
+ vC - iL1 i +isec1 + + vC1- iL1 i +isec1 + +v - iL1 i +isec1 +
C1
1
Lm1 vsec1 C1 R1 Lm1 vsec1 C1 R1 V1 Lm1 vsec1 C1 R1 V1
Lm1 V1 Lm1 - Lm1 -
- -
- -
n1:1 n1:1 n1:1
S6 S7 S6 S7 S6 S7

Vin S5 b Vin S5 b Vin S5 b


D3 D4 D3 D4 D3 D4
TX2 I2 TX2 I2 TX2 I2
+isec2 + +isec2 + +isec2 +
iLm2 vsec2 iLm2 vsec2 iLm2 vsec2
C2 R2 V2 vC 2 iL 2 Lm2 C2 R2 V2 Lm2 C2 R2 V2
vC 2 iL 2 - - vC 2 iL2 -
c + - - c + - - c + - -
n2:1 S S9 n2:1S S9 n2:1 S S9
S3 S4 Cr2 Lr2 8 S3 S4 Cr2 Lr2 8 S3 S4 Cr2 Lr2 8

(a) (b) (c)

S1 S2 S1 S2 S1 S2
Cr1 Lr1 D1 D2 I1 Cr1 Lr1 D1 D2 I1 Cr1 Lr1 D1 D2 I1
a TX1 a TX1 a TX1
+ vC - + +v - + +v - +
iL1 i +isec1 iL1 i +isec1 C1 iL1 i +isec1
1
Lm1 vsec1 C1 R1 V1
C1
Lm1 vsec1 C1 R1 V1 Lm1 vsec1 C1 R1 V1
Lm1 - Lm1 - Lm1 -
- - n1:1 -
n1:1 n1:1 S S6 S7
S6 S7 6 S7

Vin S5 b Vin S5 b Vin S5 b


D3 D4 I2 D3 D4 I2 D3 D4 I2
TX2 TX2 TX2
+ + +
iLm2 +isec2 iLm2 +isec2 iLm2 +isec2
vsec2 C2 R2 V2 vsec2 C2 R2 V2 vsec2 C2 R2 V2
vC 2 iL2 Lm2 vC 2 iL2 Lm2 vC 2 iL2 Lm2
+ - - + - - + - -
c - c - c -
n2:1 n2:1 n2:1
S3 S4 Cr2 Lr2 S8 S9 S3 S4 Cr2 Lr2 S8 S9 S3 S4 Cr2 Lr2 S8 S9

(d) (e) (f)

Fig. 4. Equivalent circuits over half switching cycle: (a) Stage I, t0 < t ≤ t1 ; (b) Stage II, t1 < t ≤ t2 ; (c) Stage III, t2 < t ≤ t3 ; (d) Stage IV,
t3 < t ≤ t4 ; (e) Stage V, t4 < t ≤ t5 ; (f) Stage VI, t5 < t ≤ t6 .

vC1 (t) =iL1 (t0 )Z1 sin[ω1 (t − t0 )] where


(4) p p
+ (vC1 (t0 ) − Vin )cos[ω1 (t − t0 )] + Vin ω2 = 1/ (Lr1 + Lm1 )Cr1 , Z2 = (Lr1 + Lm1 )/Cr1
It should be noted that compared with traditional secondary-
where √ p side phase shift modulation method [13], the adopted
ω1 = 1/ Lr1 Cr1 , Z1 = Lr1 /Cr1
secondary-side PWM control demonstrates reduced body
Stage III-IV: (t2 -t4 ][see Fig. 4(c)-(d)], S7 remains ON while
diode conduction time. Therefore, conduction loss is reduced
S6 is turned OFF. Rectification diode D1 freewheels the
and efficiency can be improved.
current isec1 . vsec1 is clamped at V1 . At the end of this stage,
the current of S7 and D1 drops to zero. S7 and D1 stops
conduction. ZCS turning-OFF is realized for the secondary- B. Trajectory Analysis
side diode D1 . Therefore, the resonant current and voltage of The trajectory tool is employed to describe different opera-
0
RT1 during stages III-IV can be derived as follows, tions to simplify the analysis. Define vC 1N
(t) and i0L1 N (t) as
follows,
0
iL1 (t) =iL1 (t2 )cos[ω1 (t − t2 )] vC (t) i0 (t)Z1
1 0
vC , i0L1 N (t) = L1
1N
(t) = (10)
Vin − n1 V1 − vC1 (t2 ) (5) Vin Vin
+ sin[ω1 (t − t2 )]
Z1 Based on (3)-(10), the trajectories of RT1 in different
vC1 (t) =iL1 (t2 )Z1 sin[ω1 (t − t2 )] + Vin − n1 V1 operation stages are plotted in Fig. 5. Fig. 5(a) and (c) show
(6) the trajectory waveforms in FB mode and HB mode with
+ (vC1 (t2 ) − Vin + n1 V1 )cos[ω1 (t − t2 )]
50% secondary-side duty cycle respectively. They are same to
The magnetizing current of T X1 (iLm1 ) increases linearly the traditional LLC converter operating in resonant frequency
in stages III-IV. It can be expressed as, point. Fig. 5(b) and (d) illustrate the trajectory with more
n1 V 1 than 50% secondary-side duty cycle in FB and HB mode
iLm1 (t) = iL1 (t2 ) + (t − t2 ) (7) respectively. In stages I-II of FB mode, the trajectory is a
Lm1
circle centered at (1, 0). The trajectory of RT1 is a circle
Stage V-VI: (t4 -t6 ][see Fig. 4(e)-(f)], there is no rectification centered at (1-G, 0) in stages III-IV, where G is the normalized
current on the secondary side of T X1 . Cr1 resonates with Lr1 voltage gain. The normalized voltage gain G is defined as
and Lm1 until the end of this half cycle. The resonant current G = n1 V1 /Vin .
and voltage of RT1 can be expressed as, In stages V-VI, Lm1 resonates with Lr1 and Cr1 and the
iL1 (t) = iLm1 (t) =iL1 (t4 )cos[ω2 (t − t4 )] input voltage of the resonant tank is Vin . Hence, the trajectory
Vin − vC1 (t4 ) (8) is an ellipse centered at (1, 0). Since stages VII-XII are
+ sin[ω2 (t − t4 )] symmetric to stages I-VI, the trajectory of other stages is
Z2
similar to that of stages I-VI. Similarly, the trajectory in HB
vC1 (t) =iL1 (t4 )Z2 sin[ω2 (t − t4 )] mode can be derived as shown in Fig. 5(d). Compared with FB
(9) mode, there exists a dc bias for the resonant capacitor voltage.
+ (vC1 (t4 ) − Vin )cos[ω2 (t − t4 )] + Vin

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Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS

Stages I-II 2.5


Stages VII-VIII
Stages III-IV Stages IX-X
Stages V-VI Stages XI-XII 2

Voltage Gain [n1V1/Vin]


iL1N iL1N
1.5

Q=0.03
O vC1N O1 O2 O3 O4 vC1N 0.5 Q=0.06
Q=0.09
Q=0.12
Q=0.15
0
0.5 0.52 0.54 0.56 0.58 0.6 0.62 0.64 0.66 0.68 0.70 0.72 0.74
Duty cycle [d1]
O (0,0) O1 (-1,0) O2 (1-G,0) O3 (G-1,0) O4 (1,0)
(a) (b)
Fig. 6. Voltage gain curves versus d1 under different Q.
iL1N iL1N

The magnetizing current is equal to resonant current at t4 .

O vC1N O1 O2O3 O4 vC1N iL1 (t4 ) = iLm1 (t4 ) (16)

The duty cycle of the S7 and S9 , d1 can be expressed as,


O (0.5,0) O1 (0,0) O2 (1-G,0) O3 (G,0) O4 (1,0)
t2 − t1
(c) (d) d1 = 0.5 + (17)
Ts
Fig. 5. Trajectory of RT1. (a) FB mode with 50% secondary-side duty
cycle. (b) FB mode with more than 50% secondary-side duty cycle. (c) where Ts is the switching period.
HB mode with 50% secondary-side duty cycle. (d) HB mode with more During the first half cycle, based on the power conservation
than 50% secondary-side duty cycle.
law, we can obtain,
Z t6
V2
C. Voltage Gain Analysis 2f Vin iL1 (t) dt = 1 (18)
t0 R1
Although there are two independent outputs, the operating
principles for each output port are identical. Consequently,
Combining (3)-(9), (11)-(18), the normalized voltage gain
only the voltage gain of one port in FB mode is analyzed. To
can be solved numerically by Matlab for a given d1 with Q
simplify the analysis, the impact of deadband on voltage gain
and Ln . Similarly, the voltage gain in half-bridge mode can
G is neglected.
also be derived, which is half of that in full-bridge mode.
The voltage gain can be increased by regulating the
For the proposed LLC converter, Lm should be designed as
secondary-side duty cycle. In this situation, the converter
large as possible to suppress the circulating current. Fig. 6
operates like an isolated boost converter in discontinuous
demonstrates the calculated results of voltage gain versus duty
mode. The resonant inductor is charged when the secondary
cycle. As shown, the normalized voltage gain is designed to be
side of the transformer is shorted. Then, the current of the
in the range of [0.5, 2]. The whole normalized voltage gain
resonant inductor can be released to the output port through
can be divided into two segments. In half-bridge mode, the
rectifier. The output voltage is raised like traditional boost
normalized voltage gain range is [0.5, 1]. Whereas, in full-
converter.
bridge mode, the normalized voltage gain range is [1, 2]. In
The resonant frequency of fr can be derived as,
each mode, the normalized voltage gain is regulated by d1 . A
1 larger duty cycle results in higher voltage gain in the same
fr = √ (11)
2π Lr1 Cr1 load condition. When d1 = 0.5, the proposed converter is
Q is the normalized quality factor and Ln is the inductance similar to a conventional LLC converter. Therefore, we can
ratio. They can be defined as, get the continuous output voltage gain in the range of [0.5, 2]
p for all load conditions by adjusting d1 . According to Fig. 6, to
Lr1 /Cr1 achieve the same voltage gain, higher duty cycle is needed for
Q= (12)
n 1 2 R1 heavier load condition. As a result, maximum voltage gain and
Ln = Lm1 /Lr1 (13) full load condition should be taken into consideration when
designing the resonant tanks.
Moreover, there are more restrictions on time domain anal- The analytical expression of voltage gain in FB mode can be
ysis. Since stages VII-XII are symmetric to stages I-VI, we derived by ignoring the magnetizing inductance with similar
can get the following equations, modulation methods [13]. However, the analytical expression
iL1 (t0 ) = −iL1 (t6 ) (14) is complex and is lack of accuracy. Therefore, the numerical
solution is calculated in this manuscript. It is more accurate
vC1 (t0 ) = −vC1 (t6 ) (15) than the traditional approximate expression.

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10
Q=0.05, R1=100W 1
8 Q=0.1, R1=100W
Q=0.2, R1=100W
6 0.8
iL1_ pk
Current [A]

Amplitude of iLm1 [A]


4
0.6
2 ZVS Region
Lose ZVS 0.4
0 Non-ZVS region iLm1(t0)
ZVS region R1=50W Lm1=467mH
-2 R1=50W Lm1=560mH
0.2
100 120 140 160 180 200 R1=200W Lm1=700mH
R1=100W Lm1=700mH
Output Voltage [V1] R1=50W Lm1=700mH
0
Fig. 7. Profiles of peak current and iLm1 (t0 ) versus output voltage 0.5 0.52 0.54 0.56 0.58 0.6 0.62 0.64 0.66
under different Q. Duty cycle [d1]

Fig. 8. Profiles of iLm1 versus duty cycle with different R1 and Lm1
IV. K EY D ESIGN C ONSIDERATIONS when Lr1 = 46.9µH and Cr1 = 54nF.

The specifications of the designed converter are summarized


as follows: input voltage Vin : 390 V; output voltage Vo1 , (t4 , t6 ]. Moreover, the magnetizing inductance is much larger
Vo2 : 100-400 V; output current Io1 , Io2 : 0.5-2 A; switching than resonant inductance for same load condition. Therefore,
frequency fs : 100 kHz. the magnetizing current can be assumed to increase linearly
The main design considerations are as follows. First, the as,
resonant inductance and resonant capacitance are designed to Vin − vC1 (t4 )
suppress the current stress and meanwhile to satisfy the ZVS iLm1 (t) = iL1 (t) ≈ (t − t4 ) (20)
Lm1 + Lr1
condition. Second, the magnetizing inductance is designed to
Large Q corresponds to small capacitance, which induces
fulfill the ZVS requirement of the primary-side MOSFETs.
a large vC1 (t4 ). It leads to a low magnetizing current at
t6 , which may break the ZVS condition for primary-side
A. Transformer Turns Ratio MOSFETs. Therefore, the parameters of the resonant tank
In HF mode, the designed output voltage is 100-200 V. In should be designed based on the tradeoff between secure ZVS
FB mode, the designed output voltage is 200-400 V. The unity range and low peak current. In our design, Lr1 = 46.9µH and
gain operating point is designed when output voltage equals Cr1 = 54nF are selected.
200 V in FB mode. Hence, the transformer turns ratio can be
calculated as, C. Magnetizing Inductance
390V 39
n= = (19) The main design consideration of Lm is to satisfy the ZVS
200V 20
condition of primary-side MOSFETs. On the primary side, the
B. Resonant Inductance and Capacitance H5 bridge is shared by two resonant tanks. Hence, the ZVS of
primary-side MOSFETs is determined by both resonant tanks.
The design consideration of Lr and Cr is to suppress the As shown in Fig. 3, both iLm1 and iLm2 contribute to the
peak current with a secure ZVS. According to (11), large ZVS realization of primary-side MOSFETs. As shown in Fig.
resonant inductance corresponds to small resonant capacitance 6, the normalized voltage gain for full-bridge mode is double
when the resonant frequency is fixed. For different parameters compared with half-bridge mode for the same load condition
of resonant tank, the peak resonant current is different. Since and duty cycle. The amplitude of magnetizing current in half-
Lm is much larger than Lr , the peak current is insensitive bridge mode is only half of that in full-bridge mode. Therefore,
to the Lm . The profiles of peak current versus output voltage the most vulnerable condition for ZVS is that one port operates
under different Q are plotted in Fig. 7 when the load resistance in half-bridge mode while the other port is in idle mode.
is 100Ω, Lm1 = 700µH. As shown in Fig. 7, the peak current Consequently, the magnetizing current should be large enough
increases with the output voltage for same Q. Moreover, higher to fully charge/discharge Coss of MOSFETs to ensure the
Q corresponds to higher resonant inductance. The peak current ZVS of primary-side MOSFETs in all operating modes. In
is reduced and the loss can be decreased. However, too large Q this mode, the ZVS condition can be described as,
can induce ZVS loss in high voltage gain condition as shown
in Fig. 7. The magnetizing current in t0 is positive to leave the 2Vin Coss
iLm1 pk , iLm2 pk ≥ (21)
ZVS region. Take RT1 as an example, the inductor current iL1 td
is very small during (t4 , t6 ]. Therefore, the voltage of Cr1 is where td is the deadband between two MOSFETs in one
charged slowly and it can be assumed as constant as vC1 (t4 ) in bridge, and Coss is the MOSFET parasitic output capacitance.

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+
R1 V1
H5 dual output -
Vin
converter +
R2 V2
-
S1-S5 S6,S7 S8,S9
Primary-side Secondary-side
PWM Unit PWM Unit
D1 D2
Mode
PI controller PI controller
selection
V1_ref V2_ref
V1_ref V2_ref ∑ + ∑ +
Fig. 9. Loss breakdown in different output voltages at heavy load - - V2
condition. V1

Fig. 10. Diagram of the digital control scheme.


The peak magnetizing current can also be calculated nu-
merically by Matlab in time domain. Fig. 8 discloses the
profile of iLm ’s peak current versus duty cycle with different LLC topologies is summarized in Table II. In [18], PFM is
load conditions and different Lm when the converter operates adopted to regulate both outputs. Therefore, two outputs are
in single half-bridge mode. As we can see in Fig. 8, the coupled with one control variable. In [19], [20], the number
amplitude of iLm decreases with the increase of duty cycle of control degree-of-freedoms is equal to that of outputs.
for the same load condition. For the same resonant tank However, there exists cross regulation issue due to the coupling
and duty cycle, heavy load condition corresponds to low of control variables. In [21], [22], the numbers of control
peak current. Meanwhile, large magnetizing inductance also variables and outputs are identical and the control variables
results in low peak current. The circulating current is reduced are decoupled with each other. Therefore, two outputs are
with narrowed ZVS range. As shown in (21), short deadband regulated independently and free from cross regulation. The
corresponds to high peak magnetizing current. While long proposed topology also has the advantage of independent con-
deadband induces high duty cycle loss. Therefore, there is trol. Compared with the state-of-the-art SIDO LLC topologies,
a tradeoff between magnetizing inductance and deadband. the output voltage range of the proposed converter is much
Moreover, short deadband may lead to the shoot-through of wider. The numbers of MOSFETS and diodes are sacrificed to
the bridge arm. Proper time margin is nacessary. Based on all some extent to achieve wider output voltage ranges. However,
these considerations, 100 ns deadband is adopted to ensure compared with dual traditional SISO LLC converters with
secure ZVS and to avoid shoot-through. The corresponding wide output voltage range [10], [23], [24], the number of
magnetizing current condition with 100ns deadtime is plotted components is reduced.
in Fig. 8. Certain margin is reserved to ensure secure ZVS.
Thus, magnetizing inductance can be designed to ensure the VI. C ONTROL S TRATEGY
ZVS of primary-side MOSFETs. We choose Lm = 700µH to The digital control scheme is plotted in Fig. 10. On the
achieve wide ZVS range and low circulating current. primary side, the configuration of the H5 bridge in Fig. 2
is selected based on the desired two output voltage ranges.
V. L OSS A NALYSIS AND P ERFORMANCE C OMPARISON
The desired output voltages (V1 ref , V2 ref ) are input to the
A. Loss Analysis DSP controller, each resonant tank can be classified into FB
The main losses can be divided into four parts: conduc- mode, HB mode or ID mode. When the desired normalized
tion loss, transformer copper loss, transformer core loss, and voltage gain range is in [1, 2], the resonant tank operates in FB
switching loss. The conduction losses include MOSFET con- mode. The resonant tank operates in HB mode if the desired
duction loss, diode conduction loss, and capacitor conduction voltage is in [0.5, 1]. The output voltage can also operate in
loss. The proposed converter can achieve ZVS turn-ON and idle mode without load. Based on two operating modes of two
diodes can achieve ZCS turn-OFF. Thus, the turn-ON loss resonant tanks, the configuration of H5 can be chosen based
of MOSFET and turn-OFF loss of diode are negligible. The on Table I. The operation of primary-side switches in different
switching loss mainly attributes to the MOSFET turn-OFF modes is also summarized in Table I. On the secondary sides,
loss. The magnetic core loss can be estimated by Steinmetz’s two duty cycles are regulated dynamically by two close-loop
equation. According to the above analysis, the power losses in PI controllers. Two duty cycles are decoupled and two PI
different voltages at heavy load condition are calculated and controllers are independent. The PWM unit generates the
plotted in Fig. 9. The core loss is higher in FB mode than in corresponding gate driving signals for the MOSFETs. Then,
HB mode. Some switching losses are induced by secondary- the output voltage is tightly regulated. This control strategy is
side extended duty cycle. simple and easy to be implemented.

B. Performance Comparison VII. E XPERIMENTAL R ESULTS


As reviewed in Section I, many SIDO LLC converters have To verify the effectiveness of the proposed converter, a
been proposed. The comparison with state-of-the-art SIDO 1.6kW/100kHz prototype with 390V input and dual 100-

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TABLE II
C OMPARISON WITH E XISTING D UAL -O UTPUT LLC C ONVERTERS

Topologies Quasi Two-stage LLC [18] LLC with extended PWM [19] LLC with SAR [20] LLC with variable inductance [21] Hybrid modulation of LLC and FSFB [22] Proposed

Modulation PFM PWM + PFM PFM + PSM Magnetic control PSM + PFM PWM

Number of MOSFETs 8 4 6 2 4 9

Number of diodes 0 8 4 8 6 4

Number of transformer 1(center-tapped) 2 2 2 3 2

Input Voltage 48V-85V 300V-330V 95V-105V 300V-380V 400V 390V

Output Voltage 12V-17V; 6V-8.5V 24V; 48V 28V; 42V 24V; 48V 200V-400V; 48V 100V-400V; 100V-400V

Number of control freedom 1 2 2 2 2 2

Control coupling Yes Yes Yes No No No

Power level 100W 480W 420W 200W 1200W 1600W

Peak efficiency (%) 95.1 94 96.6 N/A 95.3 97.72

TABLE III
iL1(5A/div)
PARAMETER OF C OMPONENTS iL1(5A/div)

vab(500V/div) vab(500V/div)
Symbol Quantity Values
iL2(5A/div)
Vin Input voltage 390V iL2(5A/div)

V1 , V2 Output voltages 100-400V


I1 , I 2 Output currents 0-2A vcb (500V/div) vcb(500V/div)

S1−9 MOSFETs SCT3120 2 ms/div 2 ms/div


D1−4 Rectification diodes C3D10060
(a) (b)
Lr1,2 Resonant inductance 46.9µH
Cr1,2 Resonant capacitance 54nF vgs1(10V/div)
iL1(5A/div)
Lm1,2 Magnetizing inductance 700µH
vgs7(10V/div)
C1,2 Output capacitance 220µF d1 vab(500V/div)
n1,2 Transformer turns ratio 39 : 20
fs Switching frequency 100kHz iL1(5A/div) iL2(5A/div)

T X1,2 Magnetic core PC95 EC4950


vC1(100V/div)
vcb(500V/div)
2 ms/div 2 ms/div

(c) (d)
Oscilloscope
iL1(5A/div)
iL1(5A/div)

Auxiliary vab(500V/div) vab(500V/div)

supply iL2(5A/div)
iL2(5A/div)
Power analyer vcb(500V/div)
vcb (500V/div)
2 ms/div 2 ms/div
PC prototype
(e) (f)

Fig. 13. Experimental steady state waveforms in different modes: (a)


FBFB mode V1 = V2 = 200 V, P1 = P2 = 400 W; (b) FBFB mode
Power source load V1 = V2 = 400 V, P1 = P2 = 800 W; (c) FBFB mode V1 = 400 V,
DSP controller P1 = 800 W; (d) HBFB mode V1 = 100 V, P1 = 100 W, V2 = 200 V,
P2 = 400 W; (e) HBFB mode V1 = 150 V, P1 = 300W, V2 = 250 V,
Fig. 11. Photograph of the laboratory test bench. P2 = 500 W; (f) HBHB mode V1 = V2 = 100 V, P1 = P2 = 100 W.

iD1(5A/div)
iD1(2A/div) vD1(250V/div) vD1(250V/div)

iD2(5A/div)
vD2(250V/div) iD2(2A/div) vD2(250V/div)

2 ms/div 2 ms/div

(a) (b)

Fig. 14. Waveforms of diode voltages and currents when RT1 operates
Fig. 12. Photograph of the designed SIDO LLC converter. in FB mode with I1 = 2 A: (a) V1 = 200 V; (b)V1 = 250 V.

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V1(100V/div)
ZVS ZVS
V2(100V/div)
vds4(250V/div) vgs4(10V/div) vds4(250V/div) vgs4(10V/div)

ids4(500mA/div) iL1(5A/div)
ids4(2A/div)

iO1(1A/div)
2 ms/div 2 ms/div 10 ms/div

(a) (b)

Fig. 18. Dynamic waveforms of load step down from 250 W to 150 W.
Fig. 15. Soft-switching waveforms of the primary-side MOSFET in HBID
mode. (a) V1 = 100 V, P1 = 50 W; (b) V1 = 200 V, P1 = 400 W.
100

98

96
ZVS ZVS
94
vds7(100V/div) vgs7(10V/div) vds7(100V/div) vgs7(10V/div)

Efficiency [%]
92

90
ids7(5A/div) ids7(5A/div)
88
V2=100V
86 V2=150V
V2=200V
2 ms/div 2 ms/div 84 V2=250V
V2=300V
(a) (b) 82 V2=400V

80
0 0.5 1 1.5 2 2.5
Fig. 16. Soft-switching waveforms of the secondary-side MOSFET with Output Current [A]
RT1 operating in FB mode. (a) V1 = 200 V, I1 = 2 A; (b) V1 = 250 V,
I1 = 2 A.
Fig. 19. Measured efficiency versus I2 with different V2 (V1 = 200 V,
I1 = 2 A).
iL2(5A/div) V1 (100V/div)
V2 (100V/div)

operation condition of V1 = V2 = 100 V are captured in


vgs3(10V/div) FBHB Mode FBFB Mode
vcb(500V/div) Fig. 13(f). Both resonant tanks operate in HB mode. The
vcb(500V/div)
vgs8(10V/div)
waveforms of diode voltages and currents are presented in Fig.
V2(100V/div) 14. Fig. 14(a) shows the waveforms when the secondary-side
FBHB Mode FBFB Mode 20 ms/div 20 ms/div duty cycle equals to 50%. The diodes operate like traditional
(a) (b) LLC converter. Fig. 14(b) shows the waveforms of V1 = 250
V. The secondary-side duty cycle is larger than 50%. ZCS
Fig. 17. Dynamic transition from FBHB Mode to FBFB Mode with V1 =
V2 = 200 V, P1 = P2 = 200 W. turning-OFF of diodes can always be realized in all operation
conditions.
The critical soft-switching waveforms are captured in Figs.
400V outputs is designed. The key design parameters are 15 and 16. Fig. 15(a) exhibits the ZVS waveforms of primary
summarized in Table III. Although two identical resonant tanks side MOSFETs in light load with V1 = 100 V, P1 = 50 W. As
and transformers are designed to simplify the analysis, they shown in Fig. 8, the worst ZVS condition is in heavy load con-
can be designed independently based on the requirement of dition of half-bridge mode with maximum secondary-side duty
each output. The picture of the test bench is given in Fig. cycle. The ZVS waveforms in this worst ZVS condition are
11. The photograph of the power stage is shown in Fig. 12. shown in Fig. 15(b). As shown in Fig. 15, there is no overlap
TMS320F28379 from Texas Instrument is used to implement between the rising edge of vgs and the falling edge of vds in
the digital control algorithms. half-bridge mode, which validates the ZVS turning-ON of the
The steady-state experimental waveforms with different primary side MOSFETs in the strictest situation. The negative
output voltages in full load condition are captured in Fig. current contributes to the ZVS turning-ON of the MOSFET.
13. Fig. 13(a) shows the waveforms with two identical out- As a result, ZVS of primary-side MOSFETs in other operating
put profiles in FBFB Mode with 50% secondary-side duty modes can also be realized. Similarly, Fig. 16 proofs that
cycles. The experimental waveforms of the extreme condition ZVS is realized for the secondary-side MOSFETs when RT1
V1 = V2 = 400 V are captured in Fig. 13(b)-(c). S1 and S7 operates in FB Mode. Fig. 16(a) shows the condition of 50%
are turned on simultaneously. There is an extended conduction secondary-side duty cycles. The MOSFETs act as synchronous
time for S7 compared with S1 as shown in Fig. 13(c). Fig. rectifier switches. Fig. 16(b) demonstrates the ZVS waveforms
13(d) demonstrates the steady-state waveforms in HBFB Mode of 250 V output voltage. The negative current contributes to
with 50% duty cycles. The first port operates in HB mode and the ZVS realization of secondary-side MOSFETs. Coss of
the second port operates in FB mode. The effective voltage MOSFETs resonates with the parasitic inductor when there
of vab is half of that of vcb . Fig. 13(e) shows the steady-state is no freewheeling current on the secondary side.
waveforms with V1 = 150 V and V2 = 250 V. The converter Fig. 17 exhibits the dynamic transition of the second port
operates in HBFB Mode with two independent secondary- from FBHB Mode to FBFB Mode. V2 is kept as 200 V. S5
side duty cycles. The critical waveforms of another extreme starts to conduct constantly and S3 starts being switched at

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0278-0046 (c) 2021 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
Authorized licensed use limited to: ShanghaiTech University. Downloaded on July 22,2021 at 01:55:30 UTC from IEEE Xplore. Restrictions apply.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TIE.2021.3097597, IEEE
Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS

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Liang Wang (S’19) received the B.S. degree


in Electrical Engineering and Automation from
Harbin Engineering University, Harbin, China, in
2019. He is currently working toward the Ph.D.
degree in the School of Information Science and
Technology, ShanghaiTech University, Shang-
hai, China.
His research includes renewable energy sys-
tems, multi-port converters and energy harvest-
ing systems.

Haoyu Wang (S’12-M’14-SM’18) received his


bachelor degree with distinguished honor in
electrical engineering from Zhejiang University
in Hangzhou, China. He received his master
and Ph.D. degrees both in electrical engineering
from the University of Maryland, College Park,
MD, USA.
In September 2014, he joined the School of
Information Science and Technology, where he
is currently an associate professor with tenure.
His research interests include power electronics,
plug-in electric and hybrid electric vehicles, the applications of wide
bandgap semiconductors, renewable energy harvesting, and power
management integrated circuits.
Dr. Wang is an Associate Editor of IEEE Transactions on Industrial
Electronics, IEEE Transactions on Transportation Electrification, and
CPSS Transactions on Power Electronics and Applications.

Bo Xue (S’19) received the B.S. degree in Elec-


trical Engineering and Automation from Hefei
University of Technology, Xuancheng, China, in
2017. He is currently working toward the Ph.D.
degree in the School of Information Science and
Technology, ShanghaiTech University, Shang-
hai, China.
His research includes dc-dc converters, the
inductive power transfer system and resonant
converters.

Mingde Zhou (S’19) received the B.S degree


in automation from Shandong University, Jinan,
China, in 2019. He is currently working toward
the Ph.D. degree in electrical engineering with
the School of Information Science and Technol-
ogy, ShanghaiTech University, Shanghai, China.
His research interests include wide gain range
resonant converters and dc-dc converters.

0278-0046 (c) 2021 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
Authorized licensed use limited to: ShanghaiTech University. Downloaded on July 22,2021 at 01:55:30 UTC from IEEE Xplore. Restrictions apply.

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