Design of a High Efficiency 30 kW

Boost Composite Converter

Hyeokjin Kim, Hua Chen, Dragan MaksimoviC and Robert Erickson
Department of Electrical, Computer and Energy Engineering
University of Colorado Boulder
Boulder, Colorado, 80309
AbstractAn experimental 30 kW boost composite converter
is described in this paper. The composite converter architecture,
which consists of a buck module, a boost module, and a
dual active bridge module that operates as a DC transformer
(DCX), leads to substantial reductions in losses at partial power
points, and to significant improvements in weighted efficiency in
applications that require wide variations in power and conversion
ratio. A comprehensive loss model is developed, accounting for
semiconductor conduction and switching losses, capacitor losses,
as well as dc and ac losses in magnetic components. Based
on the developed loss model, the module and system designs
are optimized to maximize efficiency at a 50% power point.
Experimental results for the 30 kW prototype demonstrate 98.5%
peak efficiency, very high efficiency over wide ranges of power
and voltage conversion ratios, as well as excellent agreements
between model predictions and measured efficiency curves.

I. Introduction
Dc-dc converters in applications such as maximum power
point tracking in photovoltaic power systems, or drive trains in
electric or hybrid vehicles (EV, HEV), are required to operate
efficiently over wide ranges of power and voltage conver
sion ratios. System performance depends on improvements
in weighted converter efficiency. In EV or HEV applications,
such system efficiency improvements translate directly into
increased equivalent miles-per-gallon (MPGe) performance
[1] . Even more importantly, loss reductions translate into
reduced size and cost of the cooling system.
The traditional boost converter employed in EVs or HEVs
[2] has low efficiency at light load power. Also, power density
is low due to the low switching frequency and high power
losses. To increase average efficiency and power density, a
modified dual active bridge has been proposed [3], [4], with
the number of switching devices reduced by half compared
to the conventional dual active bridge(DAB). However, the
switch voltage stresses are equal to the output voltage or the
input voltage. For the case when the voltage rating is higher
than 600 V, silicon IGBTs are commonly employed, as high
voltage silicon MOSFETs are not competitive, while emerging
wide bandgap devices are more expensive. The switching
frequency with silicon IGBTs is limited to around 10 kHz.
Also, switching loss with conventional DAB control (phase
shift between primary and secondary) increases under light
load conditions. Several previous studies have been focused
on reducing voltage stresses over switching devices while
978-1-4673-7151-3/15/$31.00 2015 IEEE

Boost
Mboost(D)

Fig. 1. Composite converter architecture consisting of buck, boost, and DCX

(DC transformer) modules [8]

maintaining high peak efficiency. In [5], a soft-switched con

tinuous current mode(CCM) boost converter was introduced
to achieve a higher voltage conversion ratio and to extend
zero-voltage switching(ZVS) range by auxiliary circuits. Also,
voltage stresses and current stresses imposed on the discrete
components are reduced. However, low efficiency is observed
under light load conditions and accurate control is necessary
to regulate the output voltage. In [6], a multiphase bidirec
tional flyback converter was introduced to reduce number of
discrete components and capacitor RMS current. However,
this flyback topology has large voltage stress over switching
devices and is not suitable for wide voltage conversion range.
In [7], a four level flying-capacitor dc-dc converter (3X dcdc converter) was described. This topology greatly improves
efficiency over wide power range and also reduces voltage
stresses over switching devices. However, the flying capacitors
of this topology have not only large RMS current but also large
energy rating (0.5CV2aring) due to the required capacitance and
voltage ratings. Also the output voltage regulation is restricted
to discrete values,
, 2VIN, and 3V1N.
To reduce the voltage stresses over switching devices,
maintain high efficiency over wide operating range and re
duce the energy rating of capacitors, a composite converter
architecture has been proposed [8], as shown in Fig. 1 with

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tii [Link] .r.h rvr* Hie hiviie-, r liiien-.v.

lid then .[Link] of rhe DV7X nodule ia expla nut.

liy. Ill li'iz .In- DC IX .i:rk ir:.n<:lmr .:m*t:nl iv::Vi:lm-iiis
ii". .Ii Ti i.:-il. Inii.l xiiiiiI lions. I In [Link] .-.ipxviu.I.'l v.-::vi fnrn

Ill: loo ill IIk: .hiii |x>\i r tv'iivr i:r i\ [Link]

ii .

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u
/

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lli: .ys'rin iriplrim rliilio'i.

divei! A'-x.t = 2. I ho [Link] pnX\[Link].I by lliC I'.[Link] [Link]

si .eh Jut V;),.y = X'xViTin- iuilp.r. u ia*;i is liiylivi

iVail Ayn f V.p [Link] .i_i.lt i>[Link] n.t 1'iwxi llniii

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:k I v.V Vie I |iv* y ! *vv -i.j V * V .V"

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uv'.tfocim'; vurv.t. ^vjv^;rm. [Link]

in l*<

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vi/Ulgr Vsir be

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[Link]-i

irwi

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i. v*: v * >irvf pj V'1oI I'j il*v
my:lnl;*

riiiiwl nl lr;irix :**hicsr is [Link]:*.

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*ik vJtdl nf u

hsMvv tout with ;,ut7s,spuDilioi$ vuuenl yjivrkrou ;itv sfavwo

ii*
sind iv>. T^p<xlivelv.

.tX =

AS dv;**.vi: i i jl.V. ;i slni|ilifi*l .nurbl

CHlullI;jIC lie

ftC-UldIC lvVwi I-L\*IVL*IV *.llli- ly s:

I hi* xmipli ic*il sldiiilx* Nhily DC !X riNXie* is hii^e:* oil [Link]'x

li!-riri :,nrr?**ii w;ivHoirr .>hir*ri ir l*ijs. * * :irnl [Link] .\

= i

ni.i iip. ii iris:

IX:skI li:iiL* I *.:l.v.*i\:i i kjv/ ^ iili* ;:ikI liix.l. sic*: M< >S h KI y;aU:
s yaii;il is /i ii.
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I ^ U. MftwiKd Ji'X [Link].v^[Link].'cr<ir.n :eM v*. * ttplirrt r<v-*i irtr*.l

j:i:i

v input

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V-.I.V i H

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;<>i

To '.[Link] iba. .be limisi'emer aneol wiivylbiiL is [Link] i. i. is rot aired l.v.l

k- h =

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,r.

Ly:?. [Link]. .lic/f/ Jl/pA

It

I hr sivcr%"e lr:r liirn-- <(ir?iii should ys nyiU

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[Link] i. rln:kil .0 I lii" [;1iri::Tv Ur
O. = Til 'll - Tl

lu die <".i.[;vi

+ t l \-r - .'i -1

* %MwaiVuV* [Link].l. ' *

(ID
Soluiior. .71" ;[Link] i7: to
allows A/ cn b: [Link]. ond
(he DCX vnltec; coir/cis'.mi ratio Is dun nbtalnrd tion ffn.
Fig. 12 shews -.lie sfllrulatcd voltaic conversion [Link] cmi:pared to :hc c*i|>:[Link] ic:ul:s. Notice thru -.lie [Link] dcv:a:c rror.i tic :no;lrl more signitic-inily [Link] at very
Iijli: loads. This is because iT.i is a simplifier. model. whicli is
do Jougoi valid <il liafcl loads. All iitit'[Link] solution valid across
all louts oau be found lx |13|. Keverlhclcss, l':vr.i t ig. 12. ii
tsCL x tibt-n>rd ib. Ifce [Link] model is very mtuMle
lot
> 2K5'i'... Oner W.. r... t.. rr.t l, me wived. ihe
;ii:lil<ll ,"<in>l"uririf*T tureril yvavriymi is k i\av ii . anil various
It's' toinpiiriri.s tin hr ;::K:i.l,ikd
H<iwd vii ilk vriplilird -'.e<uly tune nodel >?' OCXs Hie
uplimvrv Uink [Link]:l,|ntr. fan
[Link] ii I lie ipven oyer.i
[mill AI he U> V mpi.l : hlH Vl-.i.- iniljii.l ,vi h IS k\V
sysleir [ar*ei, 1)1 "X [llsveNse* *S.7 IW 11 syslnr [mwei The
I MIX rilrhil.' ihe :el ellii'ieirv
when .hr [Link] [Link]
z
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vlu. xii:^ a. 2JO X' im-ul a>.16JC V v. c vL^v.

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l i;:

17 .* n;v.- I

ip

lOnp etifllirlVif loss mu,lpl < liiipnvv inil

ll'p mp::s,upil pllivip'iey Milder "ixpfl 15 k\V syslprv piivpr in

liv imljii.l vollii'p vvrsns

tijii.I

vs'liayp jilanr, ilrmimslia.m^.

I*ijl rlli':ierirv jwriorii'.irii'n iv ilillvravl [Link] i.; irimlrs.

I In- measured I'lli:: i"u:v sl'.nivs an exevllrii. .iy.n>:fii."il xvilli
ill Man-aI e'lieieni'y [Link]'iy I Ik: less mm Ivl.

VI. ( iiNii... iixs

la ill is |X1|iv', ili'siy a i>| >1 i 'iii /':I mi i of :> oil k W lx\i'. i:i ii 11| >i is
ile ee-ilc emivLiie: is ivesvesed l>j-e<l mi a n: npi elei is! vc less
iV.'K. Tie kiss .ill del is vei lied I is [Link] I Ii ivi: Is. Bii-eil ml
rl:e opijv.i. dcxip.i. the kiboiavoiy inoiniyise of rl.e ?>.) [Link] [Link] [Link] 9R.59": peck eefieiency at 50A
powe.- jiii". [Link]:[Link] high erticicney mcr a wide iterating
[Link].

AsKSWISKtEMEMT
The :[Link]:i. data, e: xvx:/k presentee, herein wr.s funded
ir. purl 'ey .lie Oilier ui liifflgy leliieirncy aod Rruoivable
Lu.'iyj, fL'LRLi. V.S. De>[Link] oi lencr^y. uuds1: Awmi
Nuinbrr m>LL0006i>21.
R T KVNVI*1
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rn?

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r l!lo:rt:nic<
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hip il Vul ly V

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[Link] :ha*.
swirih'np I1, aefcievvd. re,su!ri.i i.i very
higl: .[Link] and i>vcra".l cam .wire convener cftisjencics.
Based on the coiH|>rihcn:ivj less model. ;ns=cs ere'. ef
ficiency of die composite [Link] are caLUiarcd (i"i a
vide opciKlh? /xijc. Fie. 14 tk:xvs a corr-parison oi the
[Link]-piedieted crticicncy and .liccisi'.rcd efficiency for the
boost rvxlulc <il 150 V Lopil, 2uu V [Link], and
200 V
[Link]. 400 V oulpul. repceiively. Ab-e. -i eaupaiion of the
nwie'.-picdLard 1X"X rJIidfiu-y [Link] [Link] DC.X eiiicLiy
uodr: -UU v [Link] <iod lX) v inp.i. me s*.i ir. 11'. 15.
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[Link] v\>l.::yp is liivlipi ....... U p i-ipiu nj l;igp by Vtvrv One
ri"iv rnil<* rxiv IvrM [Link]; Mwrrn niixlnl jin'll'v -iiiw .mil
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hi

tip :irii[iiisilr.

ip.'

ills liir .tip niixl Up'. I tip leys rmr/p

[Link] i*orr:irir> I in rvivmln li'ss nkxlrl'.

Ill' [Link]. iiiiiiIvl piixliili::.:;in: iii,:isiiii,il rl h:i:,,ii,h:sii,iiIi:i

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