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Design of CLLC Resonant Converters for the Hybrid AC/DC Microgrid

Applications

Conference Paper · November 2018

DOI: 10.1109/PEAC.2018.8590451

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 Design of CLLC Resonant Converters for the
Hybrid AC/DC Microgrid Applications
Bin Zhao
School of Electrical and Electronic
Engineering,
Nanyang Technological University
Singapore
binzhao.iecas@foxmail.com
Abstract— the CLLC resonant converter is widely used in
the hybrid AC/DC microgrid as a DC transformer to interlink
the AC and DC bus, because of its advantages of high power
density and the capacity of bidirectional power transfer. In the
hybrid AC/DC microgrid applications, as the voltages of AC
and DC bus are controlled by the energy management system,
the CLLC resonant converter operates under open-loop
condition as a DC transformer. This paper mainly focuses on
the parameters design of the CLLC resonant converters, with
fully consideration of the parameter variations caused by the
real working conditions, such as the operation power and
ambient temperature. A circuit design method for the CLLC
resonant converter to counteract the side effect caused by the
working conditions is proposed. With the proposed method,
the open-loop CLLC resonant converter can enjoy favourable
power transmission and voltage regulation ability although the
real values of the resonant inductances and capacitances
deviate from the designed values. The proposed method is
validated by the experiments.
Keywords—hybrid AC/DC microgrid, CLLC resonant
converter, parameter variations, real working conditions
I. INTRODUCTION
Nowadays, as the power system is integrated with more
and more renewable energy sources, such as the PV panels,
wind turbines, the hybrid AC/DC microgrid is getting
increasingly popular [1-3]. Due to the integration of the AC
and DC power sources, the bus conversion system (BCS) is
required to interlink between the AC and DC bus. The
typical structure of a hybrid AC/DC microgrid is shown in
Fig. 1, where both AC sub-microgrid and DC sub-microgrid
are included [4].
DC Bus AC Bus
DC
DC
PV
DC
DC
HFT BIC
Battery
DC Load
DC transformer
DC sub-microgrid Bus converter system AC sub-microgrid
Fig. 1 The typical structure of a hybrid AC/DC microgrid
It can be seen that in the bus conversion system, a DC
transformer and bidirectional interlinking converter (BIC)
are included [5]. The BIC operates as an inverter when the
power flows from DC to AC bus while operating as a
rectifier when the power flows from AC to DC bus. As for
the DC transformer, the CLLC resonant converter, as shown
in Fig. 2 or the dual active bridge is always applied [6, 7],
because of their advantages such as high power density,
978-1-5386-6054-6/18/$31.00 ©2018 IEEE
Xin Zhang Jingjing Huang
School of Electrical and Electronic School of Electrical and Electronic
Engineering, Engineering,
Nanyang Technological University Nanyang Technological University
Singapore Singapore
jackzhang@ntu.edu.sg hjj7759@163.com
high efficiency, buck & boost capability and bidirectional
power transfer [8]. However, for the DAB converters, under
light load conditions, the advantage of Zero Voltage
Switching (ZVS) will disappear. In contrast, the
symmetrical CLLC resonant converter can achieve ZVS for
the primary main switches and Zero-Current-Switching
(ZCS) for the secondary rectifiers [8]. As a result, in order
to achieve the ZVS and ZCS over the whole load range, this
paper focuses on the CLLC resonant converter.
+ S1 S3 1:n S7 S5 +
Cr1 Lr1 Lr2 Cr2
A C
VL ip B Lm D is VH
im
- -
S2 S4 S8 S6
Fig. 2 CLLC resonant converter for the hybrid AC/DC microgrid applications
Previous researches on the CLLC resonant converter mainly
focused on the topologies [9, 10, 12], controls [9, 13] and
magnetic design [13, 14, 15, 16, 17]. The working principles
and equations of the circuit parameters are detailed explained in
[9, 10]. In addition, a voltage gain based design methodology
for the CLLC resonant converter is proposed. In [12], the
conventional CLLC resonant converter is integrated with a
buck/boost converter, where high voltage gain can be achieved
by pulse width modulation. As for the control of the CLLC
resonant converter, in [9], intelligent digital control algorithm is
proposed to regulate output voltage and to control bidirectional
power conversions. In [13], a linear state-space model for a
phase-controlled CLLC resonant converter is derived. This
model can be used for fast simulations, prediction of the state
Wind turbine variables with large signal variation. Besides the conventional
AC
AC
way, where two separate inductances are used [8], the leakage
inductances are used as the resonant inductances [14, 15]. In
Utility Grid
[16], a novel 6-layer PCB winding transformer is proposed
Utility grid
for a three phase CLLC resonant converter, where all the
AC Load
resonant inductors are integrated into a transformer. In [17], a
high frequency transformer is designed for modular power
conversion with consideration of insulation, efficiency and
power density.
However, different from other applications, where the
CLLC resonant converter always operates under close-loop
control, in the hybrid AC/DC microgrid applications, since
the voltages of the AC and DC bus are controlled by the
energy management system [7], the CLLC resonant
converter operates under open-loop conditions as a DC
transformer. Furthermore, the performance of the CLLC
resonant converter is heavily dependent on parameters of the
converter. As a result, the circuit parameter design for the
open-loop control is an important issue. Unfortunately,
although the circuit parameters are designed for superior
performance, the actual values will deviate from the
designed values because of the real working conditions,
such as the operation power and ambient temperature.
Nevertheless, the research on the circuit parameter design of
the open-loop CLLC resonant converter is rarely reported.
Therefore, this paper proposes a circuit parameter design
method for the open-loop CLLC resonant converter to
eliminate the side effects caused by the deviations of the
circuit parameters. The rest of this paper is arranged as
follows. In section II, the design criterions based on power
transmission and voltage conversion gain are presented.
Section III mainly focuses on the proposed circuit parameter
design. The proposed circuit parameter design method is
validated by experiments, which are show in Section IV.
Section V summarizes the whole paper.
II. DESIGN CRITERIONS BASED ON POWER
TRANSMISSION AND VOLTAGE CONVERSION GAIN
In this section, the design criterions based on the power
transmission and voltage gain are presented, which will be
used for further parameter design. The design criterions
include power transmission and voltage conversion gain.
A. Circuit parameters of the CLLC resonant converter
As shown in Fig. 2, the parameters in a CLLC resonant
converter include:
The resonant inductances, Lr1 and Lr2; the resonant
Cr 2 1 ZrT n 2 ReqLQ2  (3f)
B. Design requirement of the CLLC resonant converter
1). Design requirement based on the power transmission
The average power of the CLLC resonant converter can
be derived as:
2VL ( H ) I p ( s ) cos M
Zs 2π
(4)
2π ³
pL ( H ) | pAB (CD ) Z v s i
AB ( CD ) p ( s )
0 π
where Ip(s) is the peak value of ip(s).
The relation between pL(H) and φ are shown in Fig. 3.
p s
s
p
(a) (b)
Fig. 3 The relationship between pL(H) and φ: a). pL and φ; b). pH and φ
As a result, it can be seen from Fig. 3 that in order to
achieve the maximum power transmission capacity in both
power conversion directions, φ should be 0.
As a result, it can be obtained that
ZrT 1 Lr1Cr1 1 Lr 2Cr 2 Zs 2πf s (5)
As a result, due to the requirement of the power
transmission, (5) is the design criterion.
2). Design requirement based on the voltage conversion gain
In practice, there are voltage fluctuations of VL and VH. In this
paper, the ranges of the variations of VL and VH are expressed by
capacitances, Cr1 and Cr2; and the turns ratio of the VL  ¬ª1  E %  ˜ VLR , 1  E %  ˜ VLR º¼ (6a)
transformer, n.
Since the parameters in a CLLC resonant converter are
interacted each other, the following intermediate parameters
are defined to analyze the CLLC resonant converter:
The resonant angular frequency between Lr1 and Cr1: ωrT;
The quality factor when the power flows from VL to VH: Q1;
The quality factor when the power flows from VH to VL: Q2;
VH  ª¬1  D %  ˜ VHR , 1  D %  ˜ VHR º¼ (6b)
where VLR is the rated voltage of the VL; VHR is the rated
voltage of the VH. β% and D% are the allowable variation
ranges of VLR and VHR respectively.
The voltage conversion gain of the CLLC resonant
converter from VL to VH are defined as G. Based on (6), the
range of G is
G VH  nVL   >Gmin , Gmax @ (7a)
The ratio of Lm1 and Lr1 (same as Lm2 and Lr2): k.
Gmin (1  D %) ˜ VHR / > n ˜ (1  E %) ˜ VLR @ (7b)
The intermediate parameters, can be calculated by:
Gmax (1  D %) ˜ VHR / > n ˜ (1  E %) ˜ VLR @ (7c)
ZrT 1 Lr1Cr1 1 Lr 2Cr 2 (1a)
From the perspective of the voltage conversion gain, the
2
Q1 n Lr1 Cr1 ReqH (1b) design requirement is: G should satisfy (7) at any operation
Q2 2
Lr 2 Cr 2 (n ReqL ) (1c) conditions in the hybrid microgrid applications.
k Lm1 Lr1 Lm 2 Lr 2 (1d) C. Design criterions of the CLLC resonant converter based
where ReqH is the equivalent load on the VH side while ReqL is the on design requirement
equivalent load on the VL side. ReqH and ReqL can be calculate by During the operation of the CLLC resonant converter,
ReqH 8VH2 S 2 PH  , ReqL 8VL2 S 2 PL  (2) the actual values of the capacitors and the inductors will
deviate from their designed values. In this paper, the
Based on the intermediate parameters, the circuit parameters variation range is defined as:
can be calculated by LxA  ª¬1  ] %  LxD , 1  ] %  LxD º¼ (8a)
Lr1 Q1ReqH n 2ZrT (3a)
CxA  ª¬1  [ %  CxD , 1  [ %  CxD º¼ (8b)
Lr 2 n ReqLQ2 ZrT
2
(3b)
Lm1 kQ1ReqH n ZrT2
(3c) where Lx represents Lr1, Lr2, Lm1 and Lm2; Cx represents Cr1,
and Cr2. LxD and CxD are the designed value of the Lx and Cx.
Lm 2 kn 2 ReqLQ2 ZrT (3d)
LxA and CxA are the actual value of the Lx and Cx. ]% and [%
Cr1 n ZrT Q1ReqH 
2
(3e) are the possible variation ranges of Lx and Cx respectively.
 1). Design criterion based on the power transmission Based on the analysis of (17), the conditions to achieve
At the most of time, the CLLC resonant converter G1(k)t0 and G2(k)d0 can be derived as:
operates at rated power and temperature conditions in the
­
°Q1  ¬ª0, Q1max ¼º
hybrid AC/DC microgrid, this paper suggests to design ZrT 1 d O3 d
1
ˈwhen
2 ® (18)
according to the rated power and temperature conditions, M min °Z*  ª¬Z*min , Z*max º¼
¯
which can be expressed as:澳
ZrTR 1 Lr1RCr1R 1 Lr 2 RCr 2 R 2S f s As a result, the design criterion based on the voltage
(9)
conversion gain has been derived.
where ZrTR, Lr1R, Lr2R, Cr1R, and Cr2R are the values of the ZrT, Lr1, Since the design criterions based on the power
Lr2, Cr1, and Cr2 at the rated power and temperature conditions. transmission and voltage conversion gain have been derived,
Equation (9) is the design criterion based on the power in the following section, the proposed circuit parameter
transmission. design method will be presented.
2). Design criterion based on the voltage conversion gain
G can be derived as III. PROPOSED CIRCUIT PARAMETER DESIGN METHOD FOR
VH vC D k (10) THE CLLC RESONANT CONVERTER IN THE HYBRID AC/DC
G  Q1 , Z* , k  | 1 1
|
nVL vAB O3k 2 +O2 k  O1 MICROGRID APPLICATIONS
O1, O2 and O3 can be calculated by In this section, the circuit parameter design method is
O1 (Z*2  1) 2 [Q12 (Z*2  1) 2  Z*2 ] / Z*6 (11a) proposed. At first, the intermediate parameters are designed.
After that, the circuit parameters are calculated based on the
O2 2(Z*2  1)[2Q12 (Z*2  1) 2  Z*2 ] / Z*4 (11b)
relations between the circuit parameters and intermediate
O3 4Q12 (Z*2  1) 2 / Z*2  1 (11c) parameters.
Z* can be calculated by A. Design of n
Z* Zs ª¬1 Lr1Cr1 º¼ Zs ª¬1 Lr2Cr2 º¼ (12) n is designed based on the rated VL and VH, which can be
It can be seen from (10) that G is affected by Q1, Z* and calculated by
n VHR / VLR (19)
k, and the variation ranges are given as follows:
The variation range of Q1 is
Q1  > 0, Q1max @ (13a) B. Design of ZrTR, Q1R, Q2R and kR
1). Design of ZrTR
Q1max n2
1  ] %  Lr1R ReqH min (13b) ZrTR is designed based on (9).
1  [ %  Cr1R 2). Design of Q1R
where ReqHmin can be calculated by The voltage conversion gain based design criterion can be
8 ª¬1  D %  ˜ VHR º¼ S PHR  expressed as
2
ReqH min 2
(14)
­Q1  >0, Q1max @
°
0  Q1R d Q1RX when ® (20a)
where PHR is the rated power of the VH side.
°̄Z*  >Z*min , Z*max @
The variation range of Z* is Z* 1  M min
2

Z*  >Z* min , Z* max @ (15a) Q1RX

2Gmin | Z*  1|
2
(20b)
Z* min (1  ] %)(1  [ %) (15b) The minimum value of Q1RX can be calculated by
Z* max (1  ] %)(1  [ %) (15c) Q1RX min min ªQ1RX , Q1RX º (21a)
¬ Z* Z* min Z* Z* max ¼
k can be calculated by
1  >(1  D %) (1  E %)@ ˜ (1  ] %)(1  [ %)
2
k Lm1R Lr1R Lm 2 R Lr 2 R (16) Q1RX (21b)
Z* Z* min
2>(1  D %) (1  E %)@ ˜ >1  (1  ] %)(1  [ %)@
where Lm1R and Lm2R are the values of the Lm1 and Lm2 at the
1  >(1  D %) (1  E %)@ ˜ (1  ] %)(1  [ %)
2
rated power and temperature conditions. Q1RX (21c)
It should be noted that the leakage inductances and Z* Z* max
2>(1  D %) (1  E %)@ ˜ >(1  ] %)(1  [ %)  1@
magnetizing inductances share the same magnetic core, As a result, the design criterion based on voltage conversion
which means k will become relatively stable when the gain is
converter operates within its maximum permitted 0  Q1R d Q1RX min when Q1  >0, Q1max @ (22)
temperature. As a result, k is assumed as constant.
According to the design requirement based on the voltage Q1R is suggested to select Q1RXmin, therefore,
conversion gain, with (10), the following equations can be derived: Q1RX min ReqH min 1  [ %  (23)
Q1R
1
G d Gmax Ÿ F1 (k ) (O3  2 )k 2  O2 k  O1 t 0 (17a) ReqHR 1  ] % 
Gmax
1 3). Design of Q2R
G t Gmin Ÿ F2 (k ) (O3  2 )k 2  O2 k  O1 d 0 (17b) Based on the symmetry of the CLLC resonant converter,
Gmin
Q2R can be calculated by
As a result, the design criterion from the voltage
conversion gain is that the valid k should be selected to Q1RX min ReqH min 1  [ %  (24)
Q2 R
satisfy G1(k)t0 and G2(k)d0 during Q1[0, Q1max] and Z*  n 2 ReqLR 1  ] % 
[Z*min, Z*max]. 4). Design of kR
 In order to achieve the design criterion of voltage within the allowable range, which is [Mmin, Mmax], which
conversion gain, F1(k)t0 and F2(k)d0 during Q1[0, Q1max] validates the effectiveness of the design.
and Z*[Z*min, Z*max] should be satisfied. As a result, k
should satisfy: IV. EXPERIMENTAL VALIDATIONS
k ! max(k2 , k4 ) (25) With the design example presented in Section III, the
prototype of the CLLC resonant converter is built in this
where, k2 and k4 can be derived by F1(k)=0 and F2(k)=0 section and tested to further validate the proposed circuit
respectively: design method. The CLLC resonant converter is integrated
1ª 4O º ª 1 º into a hybrid AC/DC microgrid prototype, which is shown
k2 = « O2  O22  4O1O3  21 » «O3  M 2 » (26a)
2¬ M max ¼ ¬ max ¼ in Fig. 5. In the hybrid AC/DC microgrid prototype, the BIC
is controlled by a dSpace while the CLLC resonant
1ª 4O º ª 1 º converter is controlled by a DSP (TMS320F28335). Silicon
k4 = « O2  O22  4O1O3  21 » «O3  M 2 » (26b)
2¬ M min ¼ ¬ min ¼
Carbide (SiC) MOSFETs, C2M0080120D, are used as the
It should be noted that with larger k, the volume of the main switches. The specifications of other components are
CLLC resonant converter will increase as well. As a result, listed in Table I.
this paper would suggest to select the minimum k.
5). Lr1R, Lr2R, Lm1R, Lm2R, Cr1R, Cr2R
With the design of the intermediate parameters finished,
the designed circuit parameters can be calculated with the
relations between the circuit parameters and intermediate
parameters, which are (3) in section II.
C. The design example
In this part, the proposed circuit parameter design method is
Fig. 5 The hybrid AC/DC microgrid prototype with the designed CLLC
utilized to design a CLLC resonant converter with the open loop resonant converter
control for the hybrid AC/DC microgrid applications. The
TABLE I
specifications of the CLLC resonant converters are shown as
follows: SPECIFICATIONS OF THE CLLC RESONANT CONVERTER
x PHR=PLR= 6 kW; fs =100kHz; Item Parameters
x VLR=380 V, VHR=760 V; Magnetic core PC40-T80×50×25
x ]% =[%=4%, D%=E%=2%. Resonant capacitor 940C30SXK-F(X=1/15/22)
With the specifications, the proposed circuit design Switching dead-time 200 ns
method presented above is utilized for the parameter design,
which is shown as follows: Under real working conditions, the parameters Lm1(2),
Step 1: design of turns ratio, n=2; Lr1(2) and Cr1(2) will deviate from the designed values. The
Step 2: design of the resonant angular frequency between values of Lm1(2), Lr1(2) and Cr1(2) under different temperatures
Lr1 and Cr1, ωrTR=628×103rad/s; are measured, which are shown in Fig. 6.
5
Step 3: design of Q1R, Q2R, Q1R=Q2R=1.786; 4
Parameter Deviation Percentage (%)

3
Step 4: design of kR, based on (25), kR>24, as a result, 2 (Cr1(2)െCr1(2)R)/ Cr1(2)R
1
kR=25; 0
(Lm1(2)െLm1(2)R)/ Lm1(2)R
(Lr1(2)െLr1(2)R)/ Lr1(2)R

Step 5: based on (3), the parameters of the CLLC resonant -1

-2

converters are: -3
-4

Lr1R=56 PH; Lr2R=223 PH (27a) -5

10 20 30 40 50
Temperature(oC)
60 70 80 90

Lm1R=1.4 mH; Lm2R=5.6 mH (27b) Fig. 6 Deviation of the parameters under different temperatures
Cr1R=0.045 PF; Cr2R=0.011 PF (27c) It can be seen from Fig. 6 that the actual parameters
D. Design validation of the CLLC resonant converter Lm1(2), Lr1(2) and Cr1(2) vary with temperatures. In addition, it
0
can be concluded from Fig. 6 that the range of the variation
1.05
1.04 0
0.962
is within ±4% of the rated value, which is in accordance
1.03
1.02 0.961 with variation range in Section III.
1.01 0.96
1.04 1.03 1.5

A. Experimental waveforms of the bidirectional power flow

1
1 Z 1.02 1.01 1 0 0.5 Q1

0.99
0.98 Mmax
0.97 M The waveforms of vAB, vCD, iAB, iCD, PH, PL are shown in
0.96
1.05
1 1.2 1.4
1.6 1.8
Mmin
Fig. 7. It can be seen from Fig. 7 that in both power flow
Z 0.6 0.8 1
0.95 0 0.2 0.4 Q1 directions, the voltage and current are in the same phase and
Fig. 4 Gain curve of the CLLC resonant converter the rated power transmission is ensured.
The gain curve of the CLLC resonant converter is shown The waveforms when the power is changed from half
in Fig. 4. In the converter design, ]%=[%=4%, power to full power under various Z* (Z*=1, 0.96, 1.04) and
D%=E%=2% and Mmin=0.96, Mmax=1.04, Q1[0, 1.786], power flows are shown in Fig. 8. It can be seen that, VL and
Z*[0.96, 1.04]. It can be seen from Fig. 4 that M is always VH are stable under different conditions, which means the
proposed circuit design method is effective. parameter design method has been proposed for the hybrid
Power flow: HV՜V, P=6kW Power flow: HV՜V AC/DC microgrid applications. With the proposed method,
vCD :350V/div PH: 6kW/div
vAB :350V/div
the open-loop CLLC resonant converter can enjoy stable
power transmission and voltage conversion gain even
iCD :20A/div PL: 6kW/div
iAB :20A/div though the parameters of the converter are changing due to
Time [5μs/div] Time [10ms/div]
the temperature and working conditions.
(a) (b)
Power flow: LV՜V, P=6kW Power flow: LV՜V
The proposed circuit parameter design method has been
vCD :350V/div
vAB :350V/div PL: 6kW/div validated by a 6 kW open-loop CLLC resonant converter
based hybrid AC/DC microgrid.
iCD :20A/div PH: 6kW/div
Time [5μs/div]
iAB :20A/div
Time [10ms/div]
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0.98
u
u
’ u 0.98 2018.
u
’
Efficiency

’
Efficiency

[8] B. Zhao, Q. Song, W. Liu and Y. Sun, "Overview of Dual-Active-Bridge

’
u
’
u
’
u u u u
’ u
’
u
’
u u
’ ’
u
’
u
’ ’ ’
0.96 0.96
u ’
Isolated Bidirectional DC–DC Converter for High-Frequency-Link
Power-Conversion System," IEEE Trans. on Power Electronics, vol. 29,
’
0.94 0.94
Power flow: LV՜V
’
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’

0.92
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0.92
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P (kW)
4 5 6 0.96 0.98 1
Z
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on Industrial Electronics, vol. 65, no. 5, pp. 3879-3889, May 2018.
1 u u u u u u  
u
M

u 1  u  [13] W. L. Malan, D. M. Vilathgamuwa and G. R. Walker, "Modeling and

M

 u u 
 u u u u 
0.95 Mmin u u Control of a Resonant Dual Active Bridge With a Tuned CLLC Network,"
0.95 Mmin
IEEE Trans. on Power Electronics, vol. 31, no. 10, pp. 7297-7310, Oct.
0.9 0.9
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0 1 2 3 4 5 6 0.96 0.98 1 1.02 1.04
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[15] G. Liu, D. Li, J. Q. Zhang, B. Hu and M. L. Jia, "Bidirectional CLLC
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V. CONCLUSION
In this paper, based on the design requirements of power
transmission and voltage conversion gain, the circuit

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