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Analysis and Implementation of LCC Resonant
DC–DC Converter for Automotive Application
M. Prabhakar and V. Kamaraj
Department of EEE, Sri Venkateswara College of Engg, PO Box No. 3, Pennalur, Sriperumbudur, Tamil Nadu, India
ABSTRACT
In this paper, a non-isolated inductor-capacitor-capacitor (LCC) topology based DC–DC converter for automotive
application is practically implemented. The resonant tank with one inductor and two capacitors provides soft
switching of the inverter switches and a voltage gain of 2. All possible LCC topologies are listed and categorized based
on the order of their voltage gain expression. Based on the source/sink requirement for automotive application,
some topologies are found to be realizable. For all these realizable topologies, voltage gain expressions are obtained
and plotted against normalized frequency. From the voltage gain plots, one candidate topology is chosen and
analyzed further. Expressions for current gain, stress across resonant tank elements, circulating reactive power and
stored energy in the tank are obtained. The optimum value of Q which results in smallest possible resonant tank is
determined and is found to be 0.545. The resonant tank is designed and implemented based on the optimum value
of Q. Experimental results show that soft switching is achieved for a wide load range and is suitable for automotive
application.
Keywords:
DC–DC power conversion, Frequency domain analysis, Power electronics, Resonant power conversion.
third and fourth order circuits were analyzed in [18]. topologies shown in Figure 2 can be categorized based on
However, most of the third order resonant DC–DC the order of the resonant tank transfer function. The order
converters available in literature are isolated and use the is determined based on the following criteria.
transformer leakage parameter as one of their resonant
elements. Though this is advantageous, the behavior The order of the system is determined by the number of
of all available inductor-capacitor-capacitor (LCC) elements that contribute to dynamical change in energy.
topologies, particularly non-isolated topology, has not
been analyzed so far, especially for their suitability in Elements connected in shunt with the source and load do
automotive application. not contribute to the dynamical change in energy. Hence,
the voltage gain (order) of such systems will always be
The objective of this paper is to analyze all possible third unity. Topologies 7 and 18 exhibit this behavior and hence
order LCC resonant converters for their suitability in the order is 1 for both topologies.
automotive loads like wind shield wiper motor, head
lamp, etc. Based on the desired voltage gain characteristic A loop formed by two elements in which there is no
plot, one LCC topology is analyzed in detail. Closed possibility of dynamical change in energy between them,
can be combined as a single element.
form expressions for kVA/kW and energy stored in
the resonant tank are obtained. From these expressions,
When a possibility of dynamical energy change between
the optimum value of Q which gives smallest possible
this resultant element and another element exists, then
resonant tank is determined, designed and implemented
the order of the system will be 2. For instance, in topology
for practical verification.
3, input, C1 and C2 form a loop. Hence, C1 and C2 are
combined as a single element. There is a possibility of
2. SELECTION OF TOPOLOGIES
dynamical change in energy between this combination
2.1 Preference for LCC Topologies and L. Hence, the order is 2.
For a converter to be used in automotive application, Based on the above criteria, 18 possible LCC topologies
the converter must be compact so that least space is are classified as unit gain, first, second and third order
occupied by the converter in an already limited volume. systems as shown in Table 1 [Figures 1 and 2].
In converter technical terms, we know that the size of the
converter is mainly dictated by the size of the reactive 2.3 Choice of Topology Based on Source/Sink
elements, especially inductor. Hence, for a converter to be Combination
as compact as possible, the number of inductive elements
must be minimum. Therefore, all LLC and isolated The resonant tank can be excited from either a voltage
topologies which use transformers are not considered. (v) or current (i) source and can be used to feed either a
Thus, only LCC topologies are considered for analysis voltage or current sink. Thus, two individual source and
and implementation. sink combinations are possible. These two individual
combinations can be suitably arranged to give four
Arrangement of one inductor and two capacitors in possible source/sink combinations: v/v, v/i, i/i and i/v.
various possible combinations results in 18 possible
topologies [18]. The analysis of LCC topologies is well In automotive application, the input power is fed from
documented in literature [19-33]. However, only one
topology has been analyzed in all the references quoted Table 1: Topology categorization based on order
and hence the motivation behind the analysis of remaining Order Unity gain First order Second order Third order
LCC topologies is particularly for their suitability in Topology 7, 18 8, 11, 16 3, 9, 10, 1, 2, 4, 5,
Number 14, 15, 17 6, 12, 13
automotive application.
This is because when the converter is driven or terminated in the literature [19-45]. Some of the methods reported
by a two state square wave voltage source or sink, are (a) fundamental harmonic approximation (FHA)
respectively, when the voltage changes its state instantly, or fundamental frequency approximation or AC
an infinite current spike will occur in the capacitor. analysis [19,25,26,29-32,34,35,39-45], (b) state-plane
Similarly, when the converter is driven or terminated by analysis [20-24,33], (c) discrete time domain analysis
a two state current source or sink, respectively, when the [27,28], (d) cyclic averaging method [36,37] and (e)
source or sink current changes state instantly, an infinite extended fundamental frequency analysis (EFFA) [38].
voltage spike will occur across the inductance. Generally, the preferred attributes of a particular method
are mathematical simplicity, providing insight into
Based on these conditions, only eight topologies which required details, ease of practical implementation, lesser
are shown in Figure 3 are realizable for automotive time consumption or faster to solve and acccuracy. All
application. Voltage gain for all the eight topologies the methods mentioned above possess some attributes
are obtained using AC analysis as explained in the next and lack some other attributes. Based on the application
section. requirement, a choice is made in favor of one particular
method of analysis [46]. Recently, EFFA has been applied
3. ANALYSIS OF TOPOLOGIES to obtain more accurate results compared to FHA.
3.1 Methods of Analysis However, when the converter is operated below the
resonant frequency, both EFFA and conventional FHA
There are several methods to model and analyze the methods produce almost similar results. The difference
performance of resonant converters of all nature and is significant only at resonant frequency and the region
types. All these methods have been successfully applied beyond the resonant frequency [38]. Because of this
to analyze resonant converters and are well documented reason, researchers continue to use conventional FHA
methods to analyze and design resonant converters The voltage and current gain are defined as
[39-45]. Therefore, in this paper also, conventional FHA
method is used to analyze and obtain the necessary V0 I
M= and H = 0 = MQ
performance parameters. Vd Vd (4)
Zn
3.2 Introduction to AC Analysis The voltage and current base values are given by
In AC analysis method, the output rectifier and the
Vd
filter are replaced by their equivalent AC resistance Vb = Vd and I b = I in =
and the square wave input voltage source is replaced Zin (5)
by its fundamental sinusoidal equivalent. The power
Voltage gain for all candidate topologies is computed by
transfer from input to output is assumed to be only via
using Equations (1)–(5). From the voltage gain expression,
the fundamental component and the contribution of all
a characteristic plot of voltage gain vs. normalized
the harmonics is neglected [34].
frequency with x = 1 is obtained for each topology.
The equivalent AC resistance for the rectifier with This is compared with the desired characteristic plot to
capacitive filter and the RMS value of the fundamental decide upon the suitability for automotive application.
component of square wave voltage (input to resonant Table 2 gives the voltage gain expression for all candidate
tank) are given by topologies.
2n
j
8Q
(
1 + x − n2x ) 1
8Q
4 8 1− j
2n
1 − n2 + j
8Q
(
1 + x − n2x ) 2n x
are plotted. Only two topologies, 1 and 2, meet the 4. OPTIMIZATION OF RESONANT TANK SIZE
desired requirement. Figures 5 and 6 show the voltage
gain plots for 1 and 2, respectively. Other topologies The size of the resonant tank depends on the energy
do not possess the desired voltage gain characteristic. stored in the tank elements and the (kVA/kW) ratio.
Figures 7 and 8 show the voltage gain plots for topologies In order to obtain smallest possible resonant tank, the
6 and 8, respectively. For instance, in topology 6, voltage energy stored in resonant tank and (kVA/kW) ratio has
gain converges to zero at a normalized frequency of to be minimum at a particular value of loaded quality
1. This feature is not desirable as the output voltage factor Q. The energy and (kVA/kW) ratio are computed
would not be sufficient enough to meet the load from the stress equations. These parameters are plotted
requirements. In topology 8, voltage gain never remains with respect to Q. From the plot, the value of Q which
a constant when Q is varied. In order to obtain desired gives smallest possible resonant tank is determined.
voltage gain, switching frequency has to be changed in
accordance with load variation. Hence, it cannot be used From Figures 5 and 6, it is observed that the voltage gain
in automotive application without using complicated for both topologies remain constant at ωn= 0.7. Hence,
closed loop control to change the frequency to obtain the energy and (kVA/kW) ratio are computed at this
the required voltage gain. Similar justification can be Table 3: Voltage and current stresses of topology 1
applied to remaining topologies also. L C1 C2
Voltage stress 2 1
3.5 Stresses Across Resonant Elements 2n3x n x
−n2(1 + x ) − j 1+ j
8Q 8Q A
To design a resonant converter, the voltage and current A A
stress of the resonant elements must be known. The Current stress
2n2x 2n2x j n x
voltage and current stresses are derived from circuit j n (1 + x ) −
8Q
j n −
8Q A
theory basics as given in Appendix. Tables 3 and 4 A A
give expressions for normalized voltage and current
stresses experienced by resonant elements L, C1 and C2 2n x 2n3x 2 2
A = 1 + j − n2(1 + x ) − j
for topologies 1 and 2, respectively [Figures 4–8]. 8Q 8Q
Current stress
2 2Q 1 2 2 2Q 1 2 2 2Q 1 2
− 2 − j 1 − 2 − j 1 − 2 − j
B n x 8nQ B n x 8nQ B n x 8nQ
1 8Q 1
B =1− +j − (1 + x )
n2 2n x n2
to be 6.6 micro henry and 0.67 micro farad, respectively. used as inverter switches and four MUR8100E (800
However, Q increases as load increases. Hence, the V, 8 A, 1.8 V) ultrafast recovery diodes were used to
design was done for a worst case of Q = 2. The values of L construct the bridge rectifier. Table 5 gives the summary
and C were calculated by using Equations (2) and (3) and of experimental set-up used.
were found to be 12 micro henry and 0.36 micro farad,
respectively. The resonant frequency for these values Figure 11a shows the simulated waveforms of the
of L and C was calculated by using Equation (2) and resonant converter. Figure 11b shows the hardware
was found to be 76.4 kHz. For a normalized frequency output waveforms of the resonant converter. It is
of 0.7, the switching frequency was calculated by using observed that the load voltage is around 20 V. The
Equation (2) and was found to be 53.5 kHz. Ferrite core voltage drop across rectifier diodes and inductor has
was used to construct the inductor and the measured
contributed to reduction in output voltage. However,
value was 11.5 micro henry. Four capacitors, each with a
the output obtained was sufficient to drive the wiper
value of 0.1 micro farad, were connected in parallel to get
motor which was operating at normal load condition.
the required resonant capacitor value. Measured value of
capacitor was 0.4 micro farad. The switching frequency
In order to study the soft switching characteristics of
for these values of inductor and capacitor was calculated
the converter over a wide load range, a 100 ohm/10 W
by using Equation (2) and was equal to 51.9 kHz.
resistor was connected as load so as to obtain the lightly
Four IRF540N (100 V, 33 A, 0.044 ohm) MOSFETs were loaded characteristics. Figure 12 shows the voltage across
the MOSFET switch S1, current through S1 and the output
voltage under lightly loaded conditions. We observe that
zero voltage turn-on is achieved.
is negligible. However, during turn off, the voltage stress gain reduces. Therefore, we observe a slight reduction
on the device increases rapidly, and consequently, this in output voltage. Inspite of slightly overloading the
causes the switching loss also to shoot up for a very converter, we observe that zero voltage turn-on is
short duration. Overall, the switching loss is very much achieved.
reduced and satisfactory during lightly loaded condition.
Figure 15 shows the switching loss waveforms under
The converter performed satisfactorily under light load full load condition. The waveforms clearly show that
and normal load conditions when it fed the wind shield turn-on loss is completely zero while the conduction loss
wiper motor. The load range was further increased to is slightly increased compared to light load conditions.
verify if soft switching could be achieved over a wider During turn off, the voltage stress on the device is
load range. Figure 14 shows the voltage across S 1, slightly reduced compared to light load condition. This
current through S1 and the output voltage under full is mainly due to reduced gain when compared to light
load condition. The output voltage is slightly reduced load condition. As a result of reduced voltage stress, the
compared to light loaded conditions. This is because of switching loss also reduces during turn off. Overall, the
the increased voltage drop across the resonant inductor. total losses will be slightly increased because of increased
In addition, as loaded quality factor Q increases, the conduction loss.
Ch1: Voltage across S1 (20 V/div), Ch1: Voltage across S1 (20 V/div),
Ch2: Current through S1 (5 A/div), Ch2: Current through S1 (5 A/div),
Ch3: Output voltage (20 V/div), Ch3: Switching loss (100 VA/div),
Time: 5 micro second/div. Time: 2.5 micro second/div.
Figure 12: Waveforms of switch S1 – light load. Figure 13: Switching loss waveforms – light load.
2 x
− n2 − n2 x − j n3
8 Q
VL ,N = ×
2 2 2 x 2 2
2
3 x
1 + j n − n − n x − j n (A9)
8 Q 8 Q
Simplifying, we get
2 x
− n2 (1 + x ) − j n3
8 Q
Figure 16: Circuit to find voltage gain. VL ,N =
A
1 Vd 1 2 2 2 x 2 x
A= (1 + j n − n2 (1 + x ) − j n3 ) (A10)
sC 1 Zin sC 1 8 Q 8 Q
I o = I in =
1 1 1 1 The normalized value of inductor current stress is
+ + Rac + + Rac (A1)
sC 1 sC 2 sC 1 sC 2 given by
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AUTHORS
M. Prabhakar received his B.E. from University of V. Kamaraj obtained his B.Tech. from Calicut university,
Madras in the year 1998 and M.E from Bharathidasan M.E. and Ph.D. form Anna University. He has 20 years
University in the year 2000. He is currently pursuing his of teaching experience. His area of research includes
Ph.D in Anna University, Chennai. His areas of interest networks and power electronics.
include DC – DC converters and power electronics.
E-mail: kamarjv@ssn.edu.in
E-mail: mprabhakar.ped@gmail.com