Power electronics Slobodan Cuk

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1 Power electronics Slobodan Cuk came to Caltech in 1974 and obtained his PhD degree in Power Electronics in From 1977 until December, 1999 he was at the California Institute of Technology where he conducted research and taught courses in Power Electronics and Fundamentals of Energy Processing. During his 23 years at Caltech, more than 35 students obtained Ph.D. degree in Power Electronics under his guidance. From 2000 until present, Dr. Cuk continued his research contributions through TESLAco, the company he founded. Dr. Cuk is Fellow of IEEE and is the inventor of numerous switching converter circuits such as the Cuk converter, the TESLAconverter and many others. Dr. Cuk is also the originator of the State-Space Averaging Method and more recently new switching methods: Hybrid Switching and Storageless Switching methods, which resulted in a number of ultra efficient, very compact and low cost switching converters for solar inverters, AC-DC battery chargers, data center power supplies and many other Power Electronics applications.

2 USC Power Research Workshop: Power Electronics Dr. Slobodan Ćuk November 18,

3 PCSC 70 and PCSC 71 Power Conditioning Specialists PPESC 72 What is in the name: Power Processing and Electronics PESC 73 Power Electronics Specialists 2

4 Electrical Engineering at Caltech Sept. 2010: celebration of 100 years of Electrical Engineering at at Caltech : High Voltage Laboratory of Prof. Sorensen Power Electronics Laboratory (Profs. Middlebrook and Cuk) 3

5 Power Electronics at Caltech : Started in 1970 by Prof. Middlebrook as second in nation after Duke 1968 Both academic courses and research program on a PhD level PCSC 71 at Jet Propulsion Laboratory PESC 73 at Caltech 4

6 Power Electronics Group ( PEG) From PhD students 1998: 11 PhD in in Electrical Engineering out of which 5 in in Power Electronics Prof. Middlebrook retired in in 1998 Prof. Cuk semi-retired in in

7 First Sponsors 1974 and on NASA ( subcontract from TRW) NOSC ( Naval Ocean System Center (San Diego ) ONR- Office of Naval Research IBM Other companies 6

8 Boost Converter L CR V g /(1-D) + V S g C - R S T ON T S T OFF t 1973: Prof. Middlebrook sent me an article with boost converter 7

9 Power Electronics-Emerging from Limbo 1973 keynote by by W.E. Newell, Westinghouse 8

10 35 Years Anniversary State-space Averaging *Slobodan Ćuk; MODELING, ANALYSIS, AND DESIGN OF SWITCHING CONVERTERS Ph.D. Thesis, Caltech, November 1976 *R.D.Middlebrook and Slobodan Ćuk; A general Unified Approach to Modeling Switching- Converter Power Stages, IEEE PESC,

11 35 Years Anniversary State-space Averaging *Slobodan Ćuk; MODELING, ANALYSIS, AND DESIGN OF SWITCHING CONVERTERS Ph.D. Thesis, Caltech, November 1976 *R.D.Middlebrook and Slobodan Ćuk; A general Unified Approach to Modeling Switching- Converter Power Stages, IEEE PESC,

12 The State-space Averaging Uses Different Criteria 1. Flux Balance on All Inductors 2. Charge Balance on All Capacitors i C (t) C: Charge Balance v L1 (t) L 1 : Flux Balance + v L2 (t) L 2 : Flux Balance 0 + t 0 t 0 + t DT S (1-D)T S DT S (1-D)T S DT S (1-D)T S L 1 C L 2 + V/V g =D/(1-D) V g D S 1-D CR + R Ćuk Converter* *US *US Patents: 4,184,197; 4,257,087; 4,274,133 11

13 v L1 (t) V g 0 + t Flux Balance on on L 1 v L1 = L1 DV g + (1-D)(V g -V -V C ) ) V g -V C DT S (1-D)T S i C (t) I 1 + Charge Balance on on C rr 0 t i C i = D(-I 2 )) + (1-D)(I 1 )) I 2 DT S (1-D)T S v L2 (t) V C -V 0 + t Flux Balance on on L 2 v L2 L2 = D(V C -V) + (1-D)(-V) DT S V (1-D)T S DC DC Solution: V L1 = L1 0; 0; I C I = C 0; 0; V L2 = L2 0 12

14 State-space Formulation of Flux and Charge Balances ON-time Interval: OFF-time Interval: V g L 1 C L C R V g L 1 C L C R D { (1-D) { v L1 = V g i = -I C 2 v L2 = V C -V v L1 = V g -V C i C = I 1 v L2 = -V State-space Averaging DC Model: Multiply equations for for ON-time by by D Multiply equations for for OFF-time by by (1-D) Add Add together and and set set V L1 =0, L1 =0, I C I =0, C =0, V L2 =0 L2 =0 13

15 Dynamic (Small Signal AC) Response v = V + v$ ; x= X+ x$ g g g Steady-State AX+ bv g = 0 A= DA + D' A d= D+ d$ ; d' = D' d$ 1 2 b= Db + D' b 1 2 x$& = Ax$ + bv$ + A A X b b V d$ g g 14

16 S C A M P Switching Converter Analysis and Measurement Program 15

17 Coupled-Inductor Isolated Ćuk Converter 16

18 Manu Driven Graphics on First IBM-PC From Paper at APEC Conference 17

19 Frequency Response Loop Gain 18

20 Power Electronics Group exhibit at at 1983 conference in in San Diego 19

21 Question asked: Can your SCAMP program do this: Enter desired frequency plot then Draw the converter topology? 20

22 Related question: Can you enter desired DC voltage gain such as V/Vg = D x D and: DRAW ALL SUCH CONVERTERS: Both known converters and NEW (!!!) converter topologies? 21

23 Computer Generated Converters* CONFIDENTIAL CONFIDENTIAL V g S 1 S 2 S' 1 S' 2 C 2 R L 1 L 2 C 1 If Solution to: AX + bvg = 0 exists, than: Valid DC-DC Converters: 2 Inductors 1 Capacitor 2 States: ON&OFF } 1 million possibilities Only Working (Ćuk converter was there too!)!) *Dragan Maksimovic, Synthesis of of PWM PWM and and Quasi-resonant DC-to-DC Power Power Converters, Ph.D. Ph.D. Thesis, January 12, 12, 1989, 1989, Caltech, Pasadena 22

24 Enumeration via Incidence Matrices AN EXAMPLE: (243, 146.2) L C 2 L 2 1 L L 1 C V g 0 C 1 R V C C L L g V C C L L g T1 E H V g 0 C 1 R T2 E H 23

25 NEW CONVERTER One Transistor, Three Diodes T L 2 D 1 D 3 C 1 D 2 C 2 L 1 M (D) = D 2 ( 243, ) 24

26 Dr. Ćuk s Power Technics 1988 cover 1988 f s =500kHz P loss =20.5W η=83% β=20.5% 25

27 Power Electronics 117 class of of 1998: TESLA temple prank 26

28 TESLAco years: present TESLAconverter NCT converter Hybrid Switching Method Storageless Switching Method Bridgeless PFC converters Single-stage converters Solar inverters 27

29 Isolated Full-bridge Buck Converter Two magnetic components L DV g S 1 S 2 D 1 D 2 1:1 V g + C R S 3 S 4 T D 3 D 4 Total of 8 Switches 28

30 Square-wave Switching: No 3 switches allowed Eight needed for isolation No capacitors Hybrid-Switching Method: 3 switches only Resonant capacitor Resonant inductor 29

31 What about converters with 3 switches 1. Three Switches S 1 S 2 CR 2. A Resonant Capacitor C r 3. A Resonant Inductor L r 30

32 Birth of Hybrid-Switching Method and Related Converter Topologies #1 #2 #4 #3 #5 #6 #7 #8 #9 31

33 AC-DC Converter Comparison 32

34 Conventional Three Power Processing Stage Approach L B D B 400V L 48V D B1 D B2 S 1 S 2 D 1 D 2 L f n:1 v ac C f S B + C B C + R S 3 S 4 D B3 D B4 D 3 D 4 33

35 Polarity Inverting DC-DC Converter 34

36 Boost Converter L CR V g /(1-D) + V S g C - R S T ON T S T OFF t Problem How to make a polarity inverting boost converter 35

37 V g L Polarity Inverting 3 Switch Boost Converter* C r I L I C CR 1 I V + - V r - S CR 2 C R + L r V=V g /(1-D) C r L I L I C + - V r Boost Converter V g S CR2 V r =V g /(1-D) C r + - V r I C L r CR 1 S Resonant C - + Discharge I R V=V r OFF-time Interval (1-D)T S *US Patent No. 7,778,046 36

38 Positive and Negative Half-cycle of of Input Voltage V g + - L C r I L I L CR A r 2 r I V + - i + S V Cr D' + D S D CR 1 C R - - V Cr =0 V g - + L G C r I L I L CR A r r 2 I V - + i - S V Cr D + D S D' CR 1 C R - + G V=V g /(1-D) V Cr =V Source Polarity Controls Conduction Interval of of Two Two Diodes: Full-Bridge Eliminated 37

39 True Bridgeless PFC Converter 38

40 True Bridgeless PFC Converter* v AC C r i AC L I L CR r r 2 I V - + i - S V Cr + D S CR 1 C R - + Input Voltage 110V THD=1.7% PF=0.999 *US *US and and foreign patents pending 39

41 One Implementation of of the Controlling Switch I ON I V OFF D S 1 III S 2 v AC L D C r I L A I r L CR r 2 I V + - V Cr S 1 + CR 1 C R - S 2 40

42 Input Current Modulation for Each Phase at at High Switching Frequency S T ON T S T OFF t v i, i i i i v i Index "i" =1, 2, 3 t 41

43 Voltage and Current Waveforms in in Ćuk-rectifier with Integrated Magnetics Implemented Input Voltage 110V THD=1.7% PF=0.999 Input Voltage 220V THD=2.0% PF=

44 Efficiency and Power Loss of of Ćuk-rectifier 99% 98% 97% 96% Efficiency 95% 94% 93% 92% 91% 90% Input Voltage [V] Power Loss Input Voltage [V] 43

45 Demo #1: 400W Bridgeless PFC converter 44

46 45

47 46

48 True Isolated Bridgeless PFC Converter 47

49 True Bridgeless PFC Converter with Isolation* i AC L IM C r2 L r CR 2 V v AC S C r1 N P N S CR 1 C + R PFC IC Controler S T ON T S T OFF t v AC, i AC v AC i AC t *US *US and and foreign patents pending 48

50 True AC Transformer +B S B S 2B S H -B S No Air-gap No Energy Storage Automatic Reset Scalable to High Power 49

51 Comparison Power Processing Single-stage Three-stage Type of Converter Isolated Bridgeless PFC Bridge-Boost PFC-Fullbridge Switching Method HYBRID Square-wave Number of switches 3 14 Switch-voltage Stress Low High Lossless-switching YES NO Control Simple Complex Magnetics pieces 1 4 Power Losses 3% 10% Efficiency >97% 88% to 90% Size Small Big Weight Light Heavy Cost Low High 50

52 Three-Phase AC-DC Converter Comparison 51

53 Present Approach: Two Stages First Stage: Rectification and PFC Efficiency = 98% i 0 +V H L 1 Q 1 Q 2 Q 3 v 0 L 2 C v 240 L 3 Q 4 Q 5 Q 6 Three-phase properties prematurely lost after rectification and PFC control 52

54 Second Stage: Isolated DC-to-DC converter +V H Second Stage: DC Isolation Efficiency = 95% L V S 1 S 2 n:1 D 1 D 2 C C + R S 3 S 4 D 3 D 4 Power processed sequentially in Two stages so Low Total Efficiency of 92% 53

55 New Single-stage Three-phase Rectifier 54

56 55

57 56

58 New Direct Three-Phase to to DC Conversion with PFC and Isolation in in a Single Stage i 1 98% Isolated Bridgeless PFC Phase 1 i 01 i 0 +V v 1 v 3 n v 2 i 2 98% Isolated Bridgeless PFC Phase 2 i 02 C R i 3 98% Isolated Bridgeless PFC Phase 3 i 03 Power processed in parallel and not in series Each Phase Efficiency 98%; TOTAL Efficiency 98% 57

59 AC-DC Converter for Each Phase with PFC and Isolation* i i L C r2 L r CR 2 V v i S C r1 N P N S CR 1 C + R Islolated Bridgeless PFC IC Three Switches Only *US *US Patent Patent No. No. 7,778,046 58

60 Three-Phase Ćuk-rectifier with PFC IC Control i 1 v 1 v n 2 v 3 i 2 Bridgeless 3-phase Isolated PFC Converter C R i 3 3-phase Isolated Bridgeless PFC IC 59

61 Sum of of Instantaneous Output Powers of of Three Phases is is Constant p o1, p o2, p o3, P P 1 p o1 p o2 p o

62 Sum of of Instantaneous Output Currents of of Each Phase is is Constant i o1,i o2,i o3,i I 1 i o1 i o2 i o

63 Constant Output Power and Constant Output Voltage Lead to to Constant Output Current v(t) V i 0 (t) I i 01 + i 02 + i 03 0 t 0 t P = constant V = constant I = constant 62

64 Birth of Storageless Switching Method and Related Converter Topologies #1 #2 #4 #3 #5 #6 #7 #8 #9 63

65 Demo #2: 200W DC-DC converter 48V to 24V 64

66 Power Stage of of 200W Storageless Converter CONFIDENTIAL CONFIDENTIAL 65

67 Bi-directional Specifications CONFIDENTIAL CONFIDENTIAL Switching Frequency: Input Voltage: Output Voltage: Output Current: Power: 50kHz 48V 24V 4A 200W Volume : 0.2in 3 Power Density: 1kW/in 3 No Heat Sink No Forced Air Cooling 66

68 200W, 48V/24V Storageless Ćuk-buck Converter CONFIDENTIAL CONFIDENTIAL 67

69 100.0% 99.5% Efficiency of of 200W Storageless Converter Efficiency vs Output Power CONFIDENTIAL CONFIDENTIAL Efficiency 99.0% 98.5% 98.0% 97.5% 97.0% Output Power (W) 68

70 Power Stage of 750W, 48V Prototype ** Storageless Buck Converter Efficiency over 99% * US * US and and foreign patents pending 69

71 Efficiency of 750W, 100V to 48V Converter 100.0% 99.5% Efficiency 99.0% 98.5% 98.0% Iout (A) 70

72 Isolated Storageless Converter ** * US * US and and foreign patents pending 71

73 Efficiency of Isolated Storageless Converter 98.2% efficiency 360V to 24V Efficiency % 95.00% 90.00% Eff 85.00% 80.00% 75.00% Output Power (W) 360V to 24V Efficiency 72

74 Green Dream Power Technology Efficiency 98% 99% 97% i 1 48V 12V 1V v 1 v n 2 v 3 i 2 3-phase Isolated Bridgeless PFC C 3 switchbuck non-isolated 3 switch POL R i 3 3-phase Isolated Bridgeless PFC IC Switching method Hybrid Storageless POL 73

75 Applications Summary - Computer servers Battery chargers for electric cars and bycycles - Desktop computers - AC Adapters, projectors, etc. -Solar photovoltaic conversion -LED lighting VRM (12V to 1V regulators) 74

76 Applications Summary -Wide range of power -From cell hones and under a one 1 Watt to 100kW for electric drive for motors, etc. 75

77 July 10, 2010 :: Memorial for Professor Middlebrook 76

78 July 10, 2010 :: Power Electronics Group Members and their relatives 77

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