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Efficiency Analysis and Comparative Study of Hard

and Soft Switching DC-DC Converters in a Wind


Farm
Aditya Jayam Prabhakar, Joshua David Bollinger, Hong Tao Ma, Mehdi Ferdowsi, and Keith Corzine
Power Electronics and Motor Drives Laboratory
Missouri University of Science and Technology, Rolla, MO 65409
Email: ajkdb@mst.edu, jdbwc6@mst.edu, thmwt6@mst.edu, ferdowsi@mst.edu, corzinek@mst.edu

converters. Converters are regulated to provide a constant


Abstract—This paper focuses on efficiency analysis and output voltage even when the input varies continuously over
comparative study of hard- and soft-switching dc-dc boost a known range. Hard or soft switching techniques are
converters in wind farms. The efficiency of an ac or a dc-based employed in these converters. Large offshore dc wind farms
wind farm is dependent on the efficiency of its key components provide efficient utilization of wind power. The distance from
such as dc-dc converters. The demand for dc-dc converters the wind farm to the PCC is long and hence high voltage DC
depends on how voltage fluctuations are adjusted. This paper (HVDC) transmission is an attractive alternative to ac
analyzes the efficiency of the switching method used in dc-dc transmission systems. There are generally three different
converters. The switching and conduction losses of all the
ways to realize a dc-dc converter, namely full bridge
components of the dc-dc converters are modeled and the
efficiency is calculated accurately. The power rating vs. converter, single active bridge converter and series parallel
efficiency of the dc-dc converters is also considered. The resonant converter. The advantages and disadvantages of
efficiency of the converter in soft switching mode is greater than these three converter topologies are compared in [2]. The use
in hard switching mode. The efficient operation of the converter of soft switching techniques has demonstrated certain
at a given power rating is shown graphically. advantages such as 100% power device utilization, enhanced
Index Terms—Boost converter; Hard switching; Soft robustness, allows for high switching frequencies and gives
switching; Wind farm; Zero voltage switching higher efficiencies [3].
The efficiency of a dc-dc converter is very important
because it is the interface between the grid and the generating
I. INTRODUCTION system and thus has a direct effect on the overall efficiency of
In recent years, more focus has been placed on renewable the system. For larger wind farm connections there are two
energy sources as there is a steady increase in power demand dc-dc conversion steps to increase the dc voltage from the
and the depleting conventional energy sources are not able to wind turbines to the transmission voltage level. The
meet this demand effectively. The ongoing research in the considered wind farm discussed in this paper is a small dc-dc
area of wind power is also focused on improving the layout used in offshore wind farm interconnections. The
efficiency of the generating equipment. Wind turbines are voltage level of offshore wind parks is 60-110 kV and for the
doubly fed induction generators, directly driven synchronous onshore wind parks is 10-60 kV. As the future wind parks
generators, or converter based. In the latter which is the would be of much higher rating, the required dc-dc
focus of this paper, a dc-dc converter connects the dc wind converters should be much larger than the existing dc-dc
farm collector bus to the grid. By modulating the duty cycle converters. The paper will investigate different techniques
of the dc-dc converter, the variable output at the collector bus namely, soft switching and hard switching techniques in
is controlled before being connected to the grid. In a direct order to find the most suitable topology. The paper also
drive wind synchronous generator, the generator is evaluates both techniques with respect to efficiency and
completely decoupled from the grid by the converters. dynamic behavior. Different techniques are simulated and the
Low cost, highly reliable, and efficient converters are now efficiency of the dc-dc converters is evaluated with respect to
available for wind turbine applications with the recent the power ratings of the machine.
advancements in power electronics. The quality of operation The dc-dc converters used in wind power applications are
of wind plants and improved efficiency can be obtained by much different from conventional ones as the input voltage
using advanced power converters. Any wind farm in varies over a wide range with varying wind speed. The total
particular has a number of wind turbines (WTs), a local wind power at the collector bus equals the difference between the
turbine grid, collecting point, transmission system, and total power produced by the wind turbines and the total
finally the wind farm interface to the point of common power losses. The total efficiency of the wind farm connected
connection (PCC). Dc-dc wind farms are considered here and to the grid system is the product of the individual efficiencies
there are three different layouts (vis-à-vis ac-ac, ac-dc, and of the components connected in between the production unit
dc-dc) that are investigated as presented in [1]. and the grid. Hence, the efficiency of each component in the
The application of dc-dc converters in a wind farm is system plays a very important role and this paper focuses on
increasing with the advancements in power electronic the total losses (conduction and switching losses) in a dc-dc

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boost converter. Finally, the point of efficient operation of the TABLE I
BOOST CONVERTER PARAMETERS
boost converter is determined graphically.
Vin=126V~154V dc dc input voltage range

II. BOOST CONVERTER Vdc=360V dc dc output voltage

This paper analyzes two switching techniques, namely Po=1.5kW to 15kW output power range
hard switching and soft switching techniques. Both fs=75kHz switching frequency
techniques are evaluated to determine the power losses and
efficiency of operation of the converter and then propose the On the other hand, soft switching reduces the power lost
best switching technique. An equivalent circuit of the boost during switching interval and also eliminates much of the
converter is shown in Fig. 1. electromagnetic noise. The most common soft switching
L technique employed is the “Zero Voltage Switching” (ZVS).
This method uses the parasitic output capacitance of the
s D power transistors and the leakage inductance of the power
C transformer as a resonant circuit. Switching the transistor ON
Vin Vdc or OFF occurs only when the voltage differential become
zero while the current flows through the switch. This
effectively eliminates the switching power losses in the
Fig. 1. Boost Converter switch due to the smooth resonant transition. The soft
switching achieves greater efficiency and also higher
Boost Converter Component Selection: immunity to the effects of other equipment operating in the
The value of the duty ratio is calculated using (1). near vicinity.
V
V = in (1)
dc 1− D III. HARD SWITCHING BOOST CONVERTER
The values for the capacitance and inductance used for the The Matlab/Simulink diagram of the hard switching boost
simulations are calculated using (2) and (3). converter is as shown in Fig. 2. Duty ratio (D) is assumed to
D(1 − D)2 R be fixed to be 61.11% in this case. This value of D is fixed
Lmin = (2) for a particular value of the input voltage level and the output
2 fs calculations are based on this duty cycle ratio.
D The efficiency of the dc-dc converter is calculated by
C> (3) finding the total losses and hence determining the output
ΔV
Rf s ( o ) power. Conduction losses and switching losses are the losses
Vo considered for loss calculations. These losses are determined
The converter used for calculations must be able to supply using the simulations, for various power ratings. Table II
a dc output voltage Vdc=360 V and the input voltage shows the values of the leakage resistances for the inductor,
Vin=140V±10% (assumed 10% voltage variation with the capacitor and the diode. The internal resistance of the switch
variable outputs produced by the WT’s due to varying wind is considered to be 0.063 Ω. Conduction losses or I2R losses
patterns). In Table I a summary of data specifications for this and the switching losses are calculated to determine the total
boost converter is presented. losses. The switching losses are calculated using (4) [5].
The output voltage is to be maintained within an acceptable 1
range if the output of the boost converter has to be connected Pswitching _ losses = *Vdc * I * f s * (tr * t f ) (4)
to a dc grid or to a dc-ac converter and then to the grid, and
2
hence there has to be some method to control the duty cycle. TABLE II
The boost converter considered in the paper is assumed to be HARD SWITCHING BOOST CONVERTER PARAMETERS
operating in continuous mode. Hard switching and soft Diode Inductor Capacitor
switching are the two basic methods to control the duty cycle L C
Vdc resistance resistance
of any switching component. The hard switching method uses
10µH 105µF 0.7 V 380 µΩ 0.0001 Ω
a fixed duty cycle operation and hence the output is
influenced with the variations in the input.
In the actual switching period in the case of hard The inductor and capacitor are considered to be non-ideal,
switching, there is a finite period during which the switch having small internal resistances. The values of these
conducts as the voltage drops to zero as the current begins to resistances are presented in Table II.
flow. There exists a voltage across the switch and current The switching frequency (fs) considered is 75 kHz and the
flows during the switch turn OFF (or ON) cycle, hence there rise time and fall time are considered to be 0.6µs (much
is a power loss (which is dissipated within the device) during higher than the practical case to allow for a safe margin).
this period, known as the Switching Loss.

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Fig. 2. MATLAB/Simulink model of a hard switching boost converter

Fig. 4. Switching losses versus efficiency for a hard-switched converter

Input voltage versus total losses for a hard switched converter


4500
P1
4000 P2
P3

Total losses in a hard switched converter


P4
3500 P5

3000

2500

2000

1500

1000

500

0
Fig. 3. Output power versus efficiency for a hard-switched converter 126 133 140
Input voltage (Volts)
147 154

Fig. 3 shows the variation between the efficiency and the Fig. 5. Input voltage versus total losses for a hard-switched converter
output power for different input voltages. It is observed that
for a particular level of input voltage, there is a fixed point
corresponding to the maximum efficiency for the dc-dc
converter. This point moves as the value of the input voltage
increases. This shows that if the converter is operated either
below or above the rated voltage and rated output power the
overall efficiency of the converter decreases.
Fig. 4 shows the graph between the switching losses and
efficiency for different input voltages. The wave shapes
obtained for the variation of efficiency with respect to both
the output power and switching losses are similar. The
efficient operation of the dc-dc converter is in the region of
maximum efficiency where the switching losses are found to
be minimal. Fig. 5 is a bar graph showing the total losses
versus input voltages for different loads. The total losses are
less for voltages at and above the rated voltage and the losses Fig. 6. 3-D plot showing the output power, switching losses vs. efficiency
increase two fold for voltages below the rated value. The first
bar corresponding to 120V is for a power level of 21 kW
which increases with the increasing input voltage. The actual The hard switching model is simulated in
ratings of the converter are calculated at 140 V which MATLAB/Simulink as shown. The total conduction losses
correspond to 25 kW, 16 kW, 13 kW, 9 kW and 8 kW are proportional to the switch resistance and inversely
respectively. The converter size varies in order to maintain proportional to the power rating of the system. The total
current constant in the simulations. switching losses are directly proportional to the switch
Fig. 6 shows a 3D plot for the output power, switching capacitance and directly proportional to the power rating of
losses and the efficiency. It is observed that the efficiency of the system.
the converter is the highest at its rated input voltage value.

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IV. SOFT SWITCHING BOOST CONVERTER
There are basically two types of soft switching techniques,
namely, Zero Voltage Switching (ZVS) and Zero Current
Switching (ZCS). Soft switching can mitigate some part of
switching loss and reduce the generation of EMI. In ZVS the
switch turn-on transition occurs at time when the voltage is
equal to zero. Diodes may also operate with zero voltage
switching. ZVS is mostly preferred in modern converters and
the ZVS technique is chosen herein. A circuit diagram of a
boost converter using ZVS topology is shown in Fig. 7.

Fig. 9. Output power versus efficiency for a soft-switched converter

Input voltage versus switching losses for a soft switched converter


250
P1
P2
P3
200 P4
P5

Switching losses (Watts)


150
Fig. 7. Circuit diagram of a boost converter using ZVS topology

100

50

0
133 140 147
Input voltage (Volts)

Fig. 10. Input voltage versus switching losses for a soft switched converter

Fig. 8. MATLAB/Simulink of a soft switching boost converter


Input voltage versus total losses in a soft switched converter
3000
P1
Fig. 8 shows the MATLAB/Simulink diagram of the soft P2

switching boost converter. The same simulation parameters


P3
2500
P4

(as mentioned in Table II) are used for analysis of both hard P5

and soft switching converters. The loss calculations are done 2000
Total losses (Watts)

in the same way as performed in the case of hard switching.


The switching losses, total losses and efficiency calculations 1500

are performed.
Fig. 9 shows a graph between the output power and 1000

efficiency. It can be observed that the efficiency of high


power rated machines are high and that the efficiency has a 500

negative slope. The operation of the dc-dc converter either at


or above the rated voltage gives higher efficiencies than if it 0
133 140
Input voltage (Volts)
147

were operated below its rated voltage level. Fig.10 shows the
bar graph between input voltage and switching losses in a Fig. 11. Input voltage versus total losses in a soft-switched converter
soft switched converter. It is observed from the bar chart that
switching losses are relatively constant for a particular output V. COMPARISON OF TWO TECHNIQUES
power. For low power output machines the switching losses
are relatively low and switching loss in the ZVS mode are The efficiency of the dc-dc boost converter using soft
very low when compared to that in the hard switching mode. switching is higher than the converter using hard switching.
Fig. 11 shows the bar graph between input voltage and Fig. 12 shows the graph between input voltage and efficiency
total losses. The total losses are lower for low rated machines of a converter under hard switching and soft switching
which increase with the power rating. The losses are conditions. The efficiency of the dc-dc converter improves
relatively constant for varied range of voltages for low rated when soft switching technique is employed and this has been
converters but do increase with rating and voltage levels. substantiated by the simulation results. Switching losses are

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drastically reduced in the case of ZVS soft switching as [2] Lena Max, Stefan Lundberg, “System efficiency of a DC/DC converter
based wind turbine grid system,” Nordic Wind Power Conference, May
shown in Fig. 13. Fig. 13 shows the variation of switching
2006, Finland.
losses with respect to input voltage. The switching loss for [3] Jaber Abu-Qahouq, Issa Batarseh, “Generalized analysis of soft-
both hard switching and soft switching mode are shown in switching DC-DC converters,” The 2000 IEEE International
the graph. It is clearly observed that the efficiency of a dc-dc Symposium on Circuits and Systems, vol. 3, pp. 507-510, May 2000.
[4] K. Sheng, S.J. Finney, B.W. Williams, X.N. He, Z.M. Qian, “IGBT
converter is improved in the case of soft switching dc-dc
Switching Losses”, Research, Rugters University, 1997.
converter. [5] Qun Zhao, Fred C. Lee, “High-efficiency, High step-up DC-DC
Converters,” IEEE Transactions on Power Electronics, vol. 18, pp. 65-
73, January 2003.
[6] Rajapandian Ayyanar, Ned Mohan, “A novel soft-switching DC-DC
converter with wide ZVS-range and reduced filter requirement,” 30th
Annual IEEE Power Electronics Specialists Conference, vol.1, pp. 433-
438, June-July 1999.
[7] K. Mark Smith, Keyue Ma Smedley, “A comparison of voltage-mode
soft-switching methods for PWM converters,” IEEE Transactions on
Power Electronics, vol. 12, pp.376-386, March 1997.
[8] F. Blaabjerg, Z. Chen, R. Teodorescu, F. Lov, “Power Electronics in
wind turbine systems,” 5th International Power Electronics and Motion
Control Conference, vol.1, pp. 1-11, Aug 2006.
[9] Nicola Femia, Giovanni Spagnuolo, Massimo Vitelli, “Steady state
analysis of hard and soft switching DC-to-DC regulators,” IEEE
Transactions on Power Electronics, vol. 18,pp. 51-64, January 2003.
[10] Z. Chen, E. Spooner, “Wind turbine power converters: A comparative
study,” Power Electronics and variable speed drives, Conference
Publication no. 456, pp.471-476, September 1998.
[11] “http://www.powerdesigners.com/InfoWeb/design_center/articles/SSI/s
Fig. 12. Input voltage versus efficiency comparisons si.shtm”

Fig. 13. Input voltage versus switching loss comparisons

VI. CONCLUSIONS
With the present dc-dc converter topology for the directly
driven wind turbine, the conduction loss and switching loss
are comparable and hence the efficiency of the system falls.
With the simulation results, it can be concluded that soft
switch application in variable wind turbine, both conduction
loss and switching loss are significantly reduced. The voltage
stress on a switch in the case of soft switching is less when
compared to the stress in case of hard switching. Thus, our
basic objective of showing efficiency improvement in case of
soft switching mode for a dc-dc converter is presented in the
paper.
REFERENCES
[1] Stefan Lundberg, “Evaluation of wind farm layouts”

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