UDK 621.3:(53+54+621+66), ISSN 0352-9045 Informacije MIDEM 22(1992)1 , Ljubljana UNITY POWER FACTOR CORRECTION CIRCUIT BASED ON BOOST-BUCK DC-TO-DC CONVERTER WITH COUPLED INDUCTANCE Miro Milanovic, Franc Mihalič, Karel Jezernik, Danilo Zadravec, Alenka Planinc, Uroš Milutinovic KEYWORDS: power electronics, power factor correction, DC-TO-DC converters, coupled inductance, single phase circuits ABSTRACT: The Unity power factor correction circuits are nowadays becoming one of the most important requirements for all power electronic rectifiers (equipment). The idea of using coupled inductance in a single phase diode rectifier power factor correction circuits and the influence of the coupling factor on the current rip ple will be discussed in this paper. VEZJE ZA KOREKCIJO FAKTORJA MOČI ZASNOVANO NA BOOST-BUCK ENOSMERNEM PRESMERNIKU SSKLOPLJENO INDUKTIVNOST JO KLJUčNE BESEDE: močnos!na elektronika, korekcija faktorja moči, enosmerniki presmerniki, sklopljena induktivnost, enofazna vezja POVZETEK: Vezja za korekcijo faktorja moči postajajo vse pomembnejši sestavni del vseh naprav močnostne elektronike. V članku bo obdelano vezje za Korekcijo faktorja moči z uporabo sklopljenih induktivnosti, prav tako bo raziskan vpliv faktorja skJopljenosti na valovitost toka. INTRODUCTION Switch-mode power supplies, DC-AC converters for motor drive, (5, 8) require an AC-DC bridge rectifier, with a large filter capacitor. The capacitor is needed to give the specified output voltage ripple and to provide energy storage. Since the capacitor draws line current only when the output voltage is below the line voltage, the line current pulsates. This pulsating current causes a low power factor. Power supplies with such rectifica- tion have less than 0.65 power factor (Fig. 1). •. or.aoot / / / /' ,/ '''OC~t::-:-, --------------:,.oc::+-~-' Fig. 1,' Input current waveform 15 Using the Fourier analYSiS, the line current can be expressed in terms of its fundamental frequency compo- nent iS1 (shown by the dashed line in Fig.1) plus the other harmonic components. If Vs is assumed to be purely sinusoidal, only iS1 contributes to the ave rage power flow (2). In terms of the rms voltage Vs and the rms current IS1 of the fundamental frequency component of is, the ave rage power P, flowing through the rectifier, is: P = Vs Is1 COS c!l1 (1 ) where c!l1 is the phase shift between iS1 and Vs. The magnitude of the apparent power S is: S = Vs Is and the power factor is defined as: P IS1 PF = -S = - cos c!l1 Is (2) (3) From eq. (3), it can be noted that a large distortion in the line current will result in a small value of the current ratio IS1/1s, and hence, a small value of PF, even if cos c!l1 is close to unity. The unity power factor, ie. the current ratio IS1/1s and cos c!l1 are close to unity, can be achieved by the introduction of a high power factor correction circuits (HPFCC) (7). Informacije MIDEM 22(1992)1, str. 15-20 The choice of power electronic converters is bas ed on the following considerations: - ln general, for HPFC circuits, electrical isolation be- tween the utility input and the output of the circuit is not strictly required ln most applications, it is acceptable and in many case s desirable to stabilize the DC voltage Vd slightly higher than the maximum peak of the AC input voltage. Cost, power loss and size of the current shaping circuits should be as small as possible. From the set of diHerent available HPFC circuits for power factor correction, the boost-buck converter is chosen to be discussed. THE PROPOSED CIRCUIT The proposed circuit for current shaping shown in Fig. 2 consists of a boost converter connected to the line, and a buck converter connected to the output capacitor. The boost part of the circuit, appropriately controlIed, forces the input current to be sinusoidal and in phase with the input voltage (5). Relatively high amount of input current ripple is caused by the switching frequency and depends on the value of the used inductance. It will be shown that the current ripple can be significantly redu- ced using the effect of inductance coupling. Filtering of the input current ripple is accomplished by the buck part BOOST CONVERTER: IVd 220 V N SWl Fig. 2: Boost-buck with coupled inductance Gate Drive 16 M. Milanovič, F. Mihalič, K. Jezernik, et al.: Vezje za korekcijo faktorja moči zasnovano na ... of the circuit. The coupled inductance for zero current ripple in DC-DC converters was introduce by Cuk and Middlebrook (3,4). Before describing how the current ripple can be reduced by inductance coupling, the state space equations of cascade boost-buck converter will be reviewed. For the two switch states (ON, OFF), the circuit opera- tion shown in Fig.11 can be described by a set of linear time-invariant differential equations: during dTs (4) and x = A2X + b2Vg during (1-d)Ts (5) where: T X = (iu iL2 uc, UC2); Vg = Vin o O Lm L1 L2 - L~, L1L2 - L~ O O L1 L1 A1= 1 1 L1L2 - L~ L1L2 - L~ - C2 1 O C1 RLC 1 1 O C2 O O BUCK CONVERTER: RL: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ J + Vel,rel M. Milanovič, F. Mihalič, K. Jezernik, et al.: Vezje za korekcijo faktorja moči zasnovano na ... o o O O L2 Lm - L1L2 - L~ L1L2 - L~ O O Lm L1 A2= 1 O L1L2- L~ L1L2 - L~ 1 O C, RLC, O 1 O O C2 The operation of the boost-buck converter with coupled inductance is based on a very simple principle. During the ON time input current flow only through the induc- tance L 1 (Fig. 3a). The slope of the inductance current diL1/dt depends on the input line voltage. By introducing the opposite volt- age source VOPP (Fig. 3b), this slope can be reduced (Fig. 4). Voltage VOPP is due to the introduction of a buck converter and a coupled inductance between L1 and L2 (Fig. 5). The slope of the inductance current can be determined from equation (4). (6) After making the following substitutions: Lm = k-/L1L2 Fig. 5 17 Informacije MIDEM 22(1992)1, str. 15-20 1 L r-- I V. ln I I -1 __ 1 L LI r-- I + Vopp I V. ln I -1 __ Fig.3a,b i L di L 1 = V. dl LI ln -- diu 1 = (VIII-VoPP) dl LI l Fig. 4 Informacije MIDEM 22(1992)1, str. 15-20 Vo = Ve1 Ve2 = d Vo 1 Vo =-- Vin 1 - d Fig. 6 (buck-converter) (boost-converter) and rearranging, the final equation is obtained: dil1 I _ 1 Vin - k Vin dt ON - L1 1 - k2 (7) Generally. it is desired that the slope dil1/dt decreases as the coupled factor k increases. By the well-known theorems of mathematical analysis, it will hold true when k satisfies the following inequality: JL(dil1 I J = - --.L k2Vin - 2kVin 2 + Vin s:; O (8) dk dt ON L 1 (1 _ k2) Since the denominator of inequality (8) is always greater than O, the inequality is equivalent to: (9) The discriminant of the quadratic inequality (9) is equal to 4(vrn - Vrn). Therefore, all val~s of k sat~fy (9) if - - . 2 . Vin s:; Vin, If Vin> Vin, the equallty k Vin - 2kvin + Vin = O has two real solutions k 1 ,2 = ~n ± -Vr-(~-in-J2-_-1- (10) Vin Vin Inequality (9) is satisfied by all k in the range [ O, ~n _ ~(~n)2 _ 1 ] Vin Vin 18 M. Milanovič, F. Mihalič, K. Jezernik, et al.: Vezje za korekcijo faktorja moči zasnovano na ... and is not satisfied by k in the range Using notation (12): Vin .~ 'A = =-, kmax = 'A - 'lA? _ 1 Vin (12) the range of solutions of (9) (0,1) is further restricted to lo, krnax I. If k Il lo, krnax 1, the theorem as well as the experiment show that the slope of the current increases uncontrollably. SMALL SIGNAL ANALYSIS ln order to shape the input current of the boost-buck converter,it must operate under the current-mode control (Fig. 7). PI Error \, Contl'oller Fig. 7 Current Il10cie control S.ri teh control signal Once iL1ref and il are available, there are various me- thods to implement the current mode control of the boost-buck converter. In this section, the constant fre- quency control is described in details. The transfer function iold can be obtained by the follo- wing procedure (1,2), The description of the ave rage state-space model is given below: ~I L2 Lm ( ) dl = 2 Vin + 2VinVC2-VC1 (13) ON L1L2 Lm L1L2 - Lm ~I dt (14) The average state-space model is obtained as the sum of equations (13) and (14), after they are multiplied by d and (1-d) respectively, diLl I l2 Lm) (1 5) dON-OFF = -- (v," - VCI + Vcld)+ --2 (Vc,d + VC2 t l,l2- L;;, L,L2- L;;, By introducing small signal perturbations in (15): iL1 = 1L1 + k. 1 Vin = Vin +Vln Ve1 = Ve1 + Ve1 Vc2 + VC2 + Vc2 d=D+d (16) M. Milanovič, F. Mihalič, K. Jezernik, et al.: Vezje za korekcijo faktorja moči zasnovano na ... and considering that Vin= 0, Vc1= ° andvc2= 0, AC and DC components of (15) can be separated as follows: (17) (18) The transfer function il1/ d can be obtained by applying Laplace Transformations on eq. (18) and considering Vc1 = Vo. After substituting Lm = k--JL1 L2 and n = --JL1/L2 upper equation, the transfer function becomes: '" Gid = iu (s) = Vo 1 - kn .1 d(S) L1 1 - k2 S (19) in the (20) Fig. 8 shows the Bode plots of the transfer function expressed by (20). ln order to obtain the voltage transfer function, the following procedure can be used: the inductance current flows through the 'rest' of the filter (Fig.9) For the circuit shown in Fig.9 system of equations (21) can be obtained: ~.~~---------------------c.~ Fig.10a,b,c,d Informacije MIDEM 22(1992)1, str. 15-20 .11 ~ ______ l.-_______ -.L._----''--' lO • ItO -",tk. Fig.B C 2 J:;jo Q Fig. 9 I 1.«-::' ±:\"'::--__ +-_______________ .;-;;.-:=_ k=O.S ... ...: AA. tJ." J. kcO.7 v Y v 'V"V o .• _ ......... 19 Informacije MIDEM 22(1992)1, str. 15-20 T. , Fig. 11 (21 ) The transfer function can be determined by using (21). (22) The transfer function vo(s)/iref(s) is needed for the volt- age control design. G _ '0'o(S) _ GVi Gid v - lrel(S) - 1 + Gid (23) By dividing the control problem into two parts, it is possible to shape the inductance current (line current) and control the output voltage. SIMULATION RESULTS Fig.10 a,b,c and d show the simulation results for half a line period (10ms) and a part of the line current. The current ripple is reduced by factor 7.S. It is very important to note that the sampling frequency is the same in all cases. 20 M. Milanovič, F. Mihalič, K. Jezernik, et al.: Vezje za korekcijo faktorja moči zasnovano na ... The same ripple can be achieved if the sampling fre- quency is increased by a factor equal to the reduction factor of the line current ripple (Fig.11). With coupled inductance, the power loss increases by 2 folds while with the increase of sampling frequency, it increases by factor 7.S. The sensitivity of the system to the compo- nent value variations was checked by simulation. If the component value varies for 10%, the performance is quite satisfactory. CONCLUSION The goal of current ripple reduction with the coupled inductance lie s behind reduction of power loss. In comparison with current ripple reduction by increasing the switching frequency (Fig.2), the proposed circuit proves to be far superior. By using the Cuk and Middle- brook optimal topology of DC-DC converter circuit for active waveshaping interface Š3C, even a better result can be achieved since only one switching element would be needed. REFERENCES (1) N. Mohan et al. Sinusoidalline Current Rectilication with a 100 kHz B-sit Step up Converter. PESC 1984. (2) N. Mohan. T. Undeland W. Robins. Power Electronics Conver- ters, Applications and Design; John Wiley & Sons, New York 1989. (3) S. CUk. Switching DC to DC Converter with zero input or output Current Ripple. Proceedings of IEEE Industry Applications Society Annual Meeting, October 1978. Toronto. (4) S. CUk. R.D. Middlebrook. Coupled Inductor and Other Exten- sions of a New Optimum Topology Switching DC to DC Converter. IEEE Industry Applications Society Annual Meeting 1977. (5.) C. Zhou. R.B. Ridley, F.C. Lee, Design and Analysis of an Ac- tive Unity Power Factor Correction Circuit. Proceedings VPEC, Bla- cksburg VA.1988. (6) M. Kazerani et al, Programable input power factor correction me- thods for single phase diode rectifier circuits APEC. LA 1990. (7) R. White. M. Sayani, High Power Factor AC-DC converters. Pro- fessional Education Seminars Workbook, APEC '90, L. A., CA, March 11-16, 1990, pp. 1-52. (8) F. Mihalič. M. Milanovic and K. Jezernik, Unity Power Factor Rectification for an AC Motor Drive, IEEE Melecon '91, Ljubljana 1991. SLO. Proceedings Volu me II. pp. 1421-1424. Miro Milanovi6, Franc Mihalič, Karel Jezernik, Oanilo Zadravec, Alenka Planinc, Uroš Milutinovi6* University of Maribor Faculty of Technical Sciences Smetanova 17 62000 Maribor, Slovenia *Faculty of Education Koroška cesta 160 62000 Maribor, Slovenia