Advanced High Frequency Switched-Mode Power Supply Techniques and Applications
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ADVANCED HIGH FREQUENCY SWITCHED-MODE POWER SUPPLY TECHNIQUES AND APPLICATIONS A thesis submitted to The University of Manchester for the degree of Doctor of Philosophy in the Faculty of Engineering and Physical Sciences 2010 Daniel Robert Nuttall The School of Electronic and Electrical Engineering Abstract This Thesis examines the operation and dynamic performance of a single-stage, single- switch power factor corrector, S 4PFC, with an integrated magnetic device, IM. Also detailed is the development and analysis of a high power light emitting diode, HP LED, power factor correction converter and proposed voltage regulation band control approach. The S 4PFC consists of a cascaded discontinuous current mode, DCM, boost stage and a continuous current mode, CCM, forward converter. The S 4PFC achieves a high power factor, low input current harmonics and a regulated voltage output, utilising a single MOSFET. A steady-state analysis of the S 4PFC with the IM is performed, identifying the operating boundary conditions for the DCM power factor correction stage and the CCM output voltage regulation stage. Integrated magnetic analysis focuses on understanding the performance, operation and generated flux paths within the IM core, ensuring the device does not affect the normal operation of the converter power stage. A design method for the S 4PFC with IM component is developed along with a cost analysis of this approach. Analysis predicts the performance of the S 4PFC and the IM, and the theoretical work is validated by MATLAB and SABER simulations and measurements of a 180 W prototype converter. It is not only the development of new topological approaches that drives the advancement of power electronic techniques. The recent emergence of HP LEDs has led to a flurry of new application areas for these devices. A DCM buck-boost converter performs the power factor correction and energy storage, and a cascaded boundary conduction current mode buck converter regulates the current through the LED arrays. To match the useful operating lifetime of the HP LEDs, electrolytic capacitors are not used in the PFC converter. Analysis examines the operation and dynamic characteristics of a PFC converter with low capacitive energy storage capacity and its implications on the control method. A modified regulation band control approach is proposed to ensure a high power factor, low input current harmonics and output voltage regulation of the PFC stage. Small signal analysis describes the dynamic performance of the PFC converter, Circle Criterion is used to determine the loop stability. Theoretical work is validated by SABER and MATLAB simulations and measurements of a 180 W prototype street luminaire. 1 Dedication For my parents, for your constant drumming into me ‘never to give up’…. its been a long time in the making. And for all those school summers forced to do extra homework…. well…. this is the result!! For Isabel, without you, your unquestionable support, your inspiration and your belief…this would have never been possible. 2 Copyright Statement The author of this thesis (including any appendices and/or schedules to this thesis) owns any copyright in it (the “Copyright”) and he has given The University of Manchester the right to use such Copyright for any administrative, promotional, educational and/or teaching purposes. Copies of this thesis, either in full or in extracts, may be only made in accordance with the regulations of the John Rylands University of Manchester. Details of these regulations may be obtained from the Librarian. This page must form part of any such copies made. The ownership of any patents, designs, trade marks and any and all other intellectual property rights except for the Copyright (the “Intellectual Property Rights”) and any reproductions of copyright works, for example graphs and tables (“Reproductions”), which may be described in this thesis, may not be owned by the author and may be owned by third parties. Such Intellectual Property Rights and Reproductions cannot and must not be made available for use without the prior written permission if the owner(s) of the relevant Intellectual Property Rights and/or Reproductions. Further information on the condition under disclosure, publication and exploitation of this thesis, the Copyright and any Intellectual Property Rights and/or Reproductions described in it may take place is available from the Head of School of Electrical and Electronic Engineering (or the Vice-President). 3 List of Contents Abstract ................................................................................................................... 1 Dedication ............................................................................................................... 2 Copyright Statement................................................................................................ 3 List of Contents ....................................................................................................... 4 List of Figures ......................................................................................................... 9 List of Tables......................................................................................................... 16 List of Tables......................................................................................................... 16 Nomenclature ........................................................................................................ 18 Declaration ............................................................................................................ 23 Acknowledgement................................................................................................. 24 About The Author ................................................................................................. 25 1 Advanced High Frequency Power Supply Techniques................................. 26 1.1 Introduction........................................................................................... 26 1.2 Literature Review.................................................................................. 33 1.2.1 Power Factor Correction Techniques................................................ 33 1.2.2 Passive Power Factor Correction...................................................... 33 1.2.3 Active Power Factor Correction ....................................................... 35 1.2.4 Single-Phase Single-Stage Power Factor Correction........................ 38 1.2.5 Power Factor Correction Regulation Control Strategies................... 45 1.2.6 Magnetic Modelling and Integrated Magnetic Concepts.................. 48 1.2.7 Devices and Components.................................................................. 49 1.2.7.1 Power Diodes ....................................................................................50 1.2.7.2 High Power Light Emitting Diodes...................................................51 1.2.7.3 MOSFET ...........................................................................................54 4 1.2.7.4 Capacitors..........................................................................................55 1.2.8 Street Lighting Considerations and Regulations............................... 58 1.3 Summary of Literature Review............................................................. 58 1.4 Thesis Structure..................................................................................... 59 2 Single-Stage Single-Switch Converter Analysis with Integrated Magnetic . 61 2.1.1 Introduction....................................................................................... 61 2.1.2 Principles of Operation of S 4PFC ..................................................... 61 2.1.3 Integrated Magnetic Principles of Operation.................................... 72 2.2 S4PFC Prototype ................................................................................... 76 2.2.1 Single-Stage Single Switch Power Factor Correction Specification 76 2.2.2 Design Procedure.............................................................................. 77 2.2.3 Design Summary............................................................................... 83 2.2.4 Integrated Magnetic Design.............................................................. 84 2.3 Component Selection and Loss Audit................................................... 91 2.4 Steady-State SABER Simulation.......................................................... 96 2.5 Summary............................................................................................. 103 3 Single-Stage Single-Switch PFC Converter Dynamic Behaviour and Control Design.................................................................................................................. 105 3.1 Introduction......................................................................................... 105 3.2 Line-to-Output..................................................................................... 105 3.3 Control-to-Output................................................................................ 108 3.4 Identification of Suitable Control Approach the S 4PFC ..................... 110 3.5 Design of Control Loop ...................................................................... 114 3.6 SABER and MATLAB Simulation Verification................................ 119 3.7 Summary............................................................................................. 123 4 Experimental Performance