Achieving efficiencies exceeding 99% in a super-junction 5kW DC-DC converter power stage through the use of an energy recovery snubber and dead time optimization

Andrew N. Hopkins, Plamen Proynov, Neville McNeill, Bernard H. Stark, Philip H. Mellor

Research output: Contribution to journalArticle

Abstract

A highly efficient 5-kW bidirectional DC-DC converter power stage operating from a 400-V supply implementing Super-Junction (SJ) MOSFETs is presented. SJ MOSFETs have low on-state resistances and low switching losses. However, their application in voltage-source converters can be compromised by the reverse recovery behavior of their intrinsic diodes and their highly non-linear output capacitances. A series switching-aid circuit is used to control the output capacitance charging current. The dead times between switching transitions are assessed and optimized in order to deactivate the intrinsic diodes. The combination of these techniques enables very high efficiencies to be attained. Calorimetric measurements indicate a full-load efficiency of 99.1% for the prototype 5-kW DC-DC converter power stage. A loss reduction of approximately 50% is achieved with the prototype converter power stage when compared to an equivalent IGBT based power stage. Lastly, a loss vs. duty cycle function is experimentally determined which can be used to inform the design of a maximum efficiency point tracking system.

LanguageEnglish
Pages7510-7520
Number of pages11
JournalIEEE Transactions on Power Electronics
Volume33
Issue number9
Early online date20 Nov 2017
DOIs
StatePublished - 30 Sep 2018

Fingerprint

DC-DC converters
Recovery
Diodes
Capacitance
Insulated gate bipolar transistors (IGBT)
Power converters
Networks (circuits)
Electric potential

Keywords

  • dead time control
  • intrinsic diode deactivation
  • metal-oxide-semiconductor field-effect transistor (MOSFET)
  • output capacitance
  • super-junction

Cite this

@article{68a239c149e242679c8ebca9bb63d867,
title = "Achieving efficiencies exceeding 99{\%} in a super-junction 5kW DC-DC converter power stage through the use of an energy recovery snubber and dead time optimization",
abstract = "A highly efficient 5-kW bidirectional DC-DC converter power stage operating from a 400-V supply implementing Super-Junction (SJ) MOSFETs is presented. SJ MOSFETs have low on-state resistances and low switching losses. However, their application in voltage-source converters can be compromised by the reverse recovery behavior of their intrinsic diodes and their highly non-linear output capacitances. A series switching-aid circuit is used to control the output capacitance charging current. The dead times between switching transitions are assessed and optimized in order to deactivate the intrinsic diodes. The combination of these techniques enables very high efficiencies to be attained. Calorimetric measurements indicate a full-load efficiency of 99.1{\%} for the prototype 5-kW DC-DC converter power stage. A loss reduction of approximately 50{\%} is achieved with the prototype converter power stage when compared to an equivalent IGBT based power stage. Lastly, a loss vs. duty cycle function is experimentally determined which can be used to inform the design of a maximum efficiency point tracking system.",
keywords = "dead time control, intrinsic diode deactivation, metal-oxide-semiconductor field-effect transistor (MOSFET), output capacitance, super-junction",
author = "Hopkins, {Andrew N.} and Plamen Proynov and Neville McNeill and Stark, {Bernard H.} and Mellor, {Philip H.}",
year = "2018",
month = "9",
day = "30",
doi = "10.1109/TPEL.2017.2773459",
language = "English",
volume = "33",
pages = "7510--7520",
journal = "IEEE Transactions on Power Electronics",
issn = "0885-8993",
number = "9",

}

TY - JOUR

T1 - Achieving efficiencies exceeding 99% in a super-junction 5kW DC-DC converter power stage through the use of an energy recovery snubber and dead time optimization

AU - Hopkins,Andrew N.

AU - Proynov,Plamen

AU - McNeill,Neville

AU - Stark,Bernard H.

AU - Mellor,Philip H.

PY - 2018/9/30

Y1 - 2018/9/30

N2 - A highly efficient 5-kW bidirectional DC-DC converter power stage operating from a 400-V supply implementing Super-Junction (SJ) MOSFETs is presented. SJ MOSFETs have low on-state resistances and low switching losses. However, their application in voltage-source converters can be compromised by the reverse recovery behavior of their intrinsic diodes and their highly non-linear output capacitances. A series switching-aid circuit is used to control the output capacitance charging current. The dead times between switching transitions are assessed and optimized in order to deactivate the intrinsic diodes. The combination of these techniques enables very high efficiencies to be attained. Calorimetric measurements indicate a full-load efficiency of 99.1% for the prototype 5-kW DC-DC converter power stage. A loss reduction of approximately 50% is achieved with the prototype converter power stage when compared to an equivalent IGBT based power stage. Lastly, a loss vs. duty cycle function is experimentally determined which can be used to inform the design of a maximum efficiency point tracking system.

AB - A highly efficient 5-kW bidirectional DC-DC converter power stage operating from a 400-V supply implementing Super-Junction (SJ) MOSFETs is presented. SJ MOSFETs have low on-state resistances and low switching losses. However, their application in voltage-source converters can be compromised by the reverse recovery behavior of their intrinsic diodes and their highly non-linear output capacitances. A series switching-aid circuit is used to control the output capacitance charging current. The dead times between switching transitions are assessed and optimized in order to deactivate the intrinsic diodes. The combination of these techniques enables very high efficiencies to be attained. Calorimetric measurements indicate a full-load efficiency of 99.1% for the prototype 5-kW DC-DC converter power stage. A loss reduction of approximately 50% is achieved with the prototype converter power stage when compared to an equivalent IGBT based power stage. Lastly, a loss vs. duty cycle function is experimentally determined which can be used to inform the design of a maximum efficiency point tracking system.

KW - dead time control

KW - intrinsic diode deactivation

KW - metal-oxide-semiconductor field-effect transistor (MOSFET)

KW - output capacitance

KW - super-junction

UR - http://www.scopus.com/inward/record.url?scp=85035755797&partnerID=8YFLogxK

U2 - 10.1109/TPEL.2017.2773459

DO - 10.1109/TPEL.2017.2773459

M3 - Article

VL - 33

SP - 7510

EP - 7520

JO - IEEE Transactions on Power Electronics

T2 - IEEE Transactions on Power Electronics

JF - IEEE Transactions on Power Electronics

SN - 0885-8993

IS - 9

ER -