Soft-Switching Converter With HF Transformer For Grid-Connected Photovoltaic Systems
Soft-Switching Converter With HF Transformer For Grid-Connected Photovoltaic Systems
5, MAY 2010
Abstract—In this paper, the design, realization, and perfor- A prototype has been realized, and a fully digital control
mance evaluation of a single-phase 3-kW dc/ac power converter, algorithm, including power management for grid-connected
using an active-bridge dc/dc converter and a full-bridge dc/ac, are operations and maximum power point tracking (MPPT) algo-
introduced, presenting a novel solution on the industrial scenario
for the considered application. Control algorithms, including the rithm, is implemented on a dedicated control board, equipped
maximum power point tracking, paralleling to the grid, and con- with last-generation 32-b microprocessor.
verter switching signals, are digitally implemented on a standard
microcontroller. II. S TATE OF THE A RT OF C OMMERCIAL PV C ONVERTERS
Index Terms—Distributed generation systems, phase-shift
modulation, photovoltaic (PV) power systems, synchronous
In addition to a PV generator, a typical PV grid-connected
phase-locked loop (PLL). system installation for residential and small commercial ap-
plications includes a dc/ac converter, and a battery pack in
I. I NTRODUCTION the case of stand-alone operation is also required. Off-the-
shelf dc/ac converters, in the power range of 1–5 kW, can be
It has to be considered that proper integration of the converter III. P ROPOSED C ONVERTER
system in the specific environment of the selected application
The scheme of the proposed converter is shown in Fig. 1. It is
can only be ensured by control. Control actions must allow
composed of an input bridge (M 1–M 4) connected to an active
interface and communication of the PV converter with the
bridge through an HF transformer, and an FB inverter used to
power grid and the user. They also must comply with mod-
generate a controlled 230-Vrms 50-Hz sinusoidal voltage.
ularity, reliability, and compatibility demands. Therefore, the
The active bridge, connected to the secondary of the trans-
control scheme of an efficient PV converter has to include an
former, is used to achieve ZVS operation for both input and
MPPT algorithm that is responsible for setting the PV field bias
output devices of the dc/dc converter (Fig. 2). Moreover, the
point in order to extract the maximum energy in all irradiation
current stress on the secondary-side switches is reduced. The
conditions; a grid synchronization control (GSC) algorithm
transformer provides galvanic isolation between the PV array
that is responsible for the initialization of the system, grid
and the ac output voltage, improving the overall safety of the
angle estimation, and anti-islanding monitoring; and a power
system. The leakage inductance of the transformer, which is
management control (PMC) algorithm that is responsible for
typically considered an unintended parasitic component with
the current injection into the grid. While performing all such
a negative impact on the power converter, is used in such
tasks, the converter system proposed in this paper will introduce
a topology as a power transfer element, thus eliminating the
some new aspects that will be detailed in the following. DSP
device overvoltage and the need of snubber circuits. Proper
microcontrollers are widely used to perform all control actions,
phase-shift control between the input bridge legs and the output
owing to their good performance with complex mathematical
bridge legs allows one to shape the transformer current, thus
operations and multiple pulsewidth modulation (PWM) outputs
achieving ZVS for all the power devices and voltage step-up
for drive signal generation.
from a minimum input of 150 V to a regulated 450-V dc. The
Over the last few years, many different inverter topologies
operating principle of the converter is based on the phase shift
have been designed and their performance investigated for grid
between the secondary leg (devices M 6 and M 7) and the first
connection in the power range of 1–5 kW. Among non-isolated
leg of the input bridge (devices M 1 and M 4). The input and
configurations, the cascade connection of a buck, boost, or
rectifier bridges generate two square waveforms, respectively,
buck–boost converter and an FB or half-bridge (HB) inverter
across the primary and secondary windings of the transformer,
seems to be very common, while the cascade connection of a
shifted by the angle δ. The effect of the primary voltage
current source FB dc/dc converter and an FB or HB inverter
V trasfprim and secondary voltage reflected to the primary
is often used when galvanic isolation and high conversion
V trasfsec is to shape the inductance current according to the
ratios are required [5]. In both cases, decoupling capacitors for
ratio (V trasfprim /V trasfsec ) [11]. Due to symmetry during
LF voltage ripple can be placed either on the low- or high-
the two halves of the switching period, the current expression
voltage side.
can be written as
HF link topologies are also suitable for this application [6]
but are not largely employed due to control issues and consid-
1 Vbus
erable component count. Moreover, decoupling capacitors can iLlk (θ) = Vdc + θ
ωs Llk n
only be placed on the low-voltage side. Another class of con-
verters, whose performance evaluation has been recently started
n ·δ+ Vdc − n
2 Vbus Vbus
π
by manufacturers, is represented by zero-voltage-transition − , 0≤θ≤δ (1)
2ωs Llk
phase-shift converters. Among those, the FB phase-shift con-
verter is already used in telecom and server applications, where 1 Vbus
iLlk (θ) = Vdc − (θ − δ)
high power density and high efficiency are mandatory. Active ωs Llk n
bridges, first introduced in [7], also exploit the phase-shift
concept in order to achieve zero-voltage switching (ZVS) for 2Vdc ·δ+ Vbus
n − Vdc π
+ , δ ≤θ≤π (2)
the power devices [8]–[10]. 2ωs Llk
1680 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 57, NO. 5, MAY 2010
and the power transferred to the output is all the power devices of the dc/dc converter, the following
equations must be satisfied:
2
Vdc δ
n · δ + Vdc − n
2 Vbus Vbus
Pav = dδ 1 − (3) π
ωs Llk π iLlk (0) = − <0 (4)
V2ω s Llk
2Vdc · δ + bus n − Vdc π
where Llk is the leakage inductance, Vdc is the input voltage, iLlk (δ) = <0 (5)
2ωs Llk
Vbus is the dc-link voltage, ωs = 2π · fs , δ is the phase-shift
angle, and d = ((Vbus /n)/Vdc ). In order to achieve ZVS for which means that d < 1/(1 − 2(δ/π)) and d > 1 − 2(δ/π).
CACCIATO et al.: SOFT-SWITCHING CONVERTER WITH HF TRANSFORMER FOR GRID-CONNECTED PV SYSTEMS 1681
Then, the dc/ac modulation is disabled, and the interface relays TABLE II
C ONTROL B LOCK T IMING E XECUTION
are disconnected, preventing any power flow from the system
to the grid. After that, the control algorithm performs some
checks on the input and bus dc voltage values and on the
grid voltage and frequency values. If the sensed voltages are
in the allowable range (150–400-V input, 370–450-V bus dc,
230 Vrms +/−10%, and 49.7–50.3-Hz grid voltage), the dc/dc
converter is operated in burst mode in order to charge the bus
dc voltage at the minimum reference voltage level. The dc
bus voltage may never exceed 450 V and must never decrease
below the peak grid voltage plus the drop across the IGBTs and
LCL filter.
The minimum dc-bus voltage is set according to
√ Pdc ∗ Zc
Vbus ref _ min = 2 Vgrid_ max + (8)
Vgrid_ max
where Pdc is the average power on the dc bus, Vgrid_ max is the
maximum rms value of the grid voltage, and Zc is the output
LCL filter impedance.
Once the system is connected to the grid, the MPPT algo-
rithm is started to track the maximum available power.
The LCL filter is designed to reduce high-order harmonics
on the grid side [21]. The inductor value on the converter side
is chosen to obtain 10% current ripple according to
Vgrid_pk 1 ma
Li = − (9)
ΔiL · fsw π 4
Fig. 9. (ch1, ch2) Phase shift and control signals, (ch3) transformer input Fig. 12. Inverter output current with Id sawtooth reference.
current, and (ch4) primary current.
Fig. 13. Inverter output (ch2) voltage and (ch4) current in the stand-alone
Fig. 10. ZVS primary switch operation.
operation.
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1686 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 57, NO. 5, MAY 2010
Mario Cacciato (S’98–M’01) received the M.S. Rosario Attanasio was born in Catania, Italy, in
degree in electrical engineering (cum laude) from 1977. He received the M.S. and Ph.D. degrees
the University of Catania, Catania, Italy, in 1996, in electrical engineering from the University of
and the Ph.D. degree in electronic engineering from Catania, Catania, in 2003 and 2006, respectively.
the University of Reggio Calabria, Reggio Calabria, He is currently a Senior Application Engineer in
Italy, in 2000. the Power Systems Group, Industrial and Multiseg-
In 2000, he joined the Department of Electrical ment Sector, STMicroelectronics, Catania. He is the
Engineering, University of Rome “La Sapienza,” author of more than ten technical papers published
Rome, Italy, as an Assistant Professor. Since 2004, in journals and proceedings of international confer-
he has been with the Department of Electrical, ences. He has also participated in research projects
Electronics and System Engineering, University of funded by Italian and foreign agencies. His major
Catania, where he is currently teaching courses on electrical drives. His research interests include power electronics converters and control, renewable
main scientific interests include power electronics, control of electric drives, energies, and electromagnetic compatibility.
electromagnetic compatibility, renewable energies, and hydrogen applications. Dr. Attanasio is a member of the AEIT, the Italian Electric Association.
He is the author of more than 60 technical papers, published in journals
and proceedings of international conferences. He has also participated in
several research projects funded by Italian and foreign agencies such as the Francesco Gennaro received the M.S. (cum laude)
Ministero dell’Istruzione, dell’Università e della Ricerca, Consiglio Nazionale and Ph.D. degrees in electrical engineering from the
delle Ricerche, Ente per le Nuove Tecnologie, l’Energia e l’Ambiente, and the University of Catania, Catania, Italy, in 1996 and
European Community. 2000, respectively.
Dr. Cacciato is a member of the AEIT, the Italian Electric Association, where In 1999, he was a Visiting Scholar at the Uni-
he is currently a member of the Scientific Board of the Automation Group. versity of Wisconsin, Madison, and a New Product
Development Engineer at Soft Switching Technolo-
gies Corporation, Madison. After one year as an
Alfio Consoli (M’79–SM’88–F’00) was with the Associate Researcher in the Department of Electrical
R&D Unit, FIAT, Turin, Italy in 1973–1974. Since and Electronic Engineering, University of Catania,
1975, he has been a Professor of electrical machines he joined STMicroelectronics, Catania, as a Senior
at the University of Catania, Catania, Italy, teaching Application Engineer for high-voltage smart power ICs, where he is cur-
in the areas of electrical machines, electrical drives, rently the Power Converters Team Manager in the Systems Lab, Application
and power electronics, where he is currently the Laboratory of Industrial and Multisegment Sector, developing system solu-
Head of the Center for Promotion and Transfer of tions in several application fields, e.g., low-power industrial converters, and
Innovation Technology, which he created in 1999. photovoltaic and fuel cell systems. He is also involved in funded project
Since 1980, he has been visiting the U.S. for research technical management and development. He is the author of more than
and teaching assignments. Since 1987, he has been 30 papers on power converters and is the holder of four international patents
responsible for the Ph.D. program in electrical en- on power converters.
gineering and is currently the Coordinator of the Ph.D. program in energy at
the Scuola Superiore of Catania, Catania. His research activities include energy
conversion systems, electrical drives, robotics, and power electronics, having
been performed in the frame of industry cooperation, national, and international
research programs. He has authored or coauthored over 300 technical papers
and is the holder of four international patents. He is the coauthor and the coed-
itor of the book Modern Electric Drives (Kluwer, 2000). He is also the author
of Electrical Motors within the Italian National Encyclopedia “Treccani.”
Dr. Consoli is a Distinguished Lecturer of the IEEE Industry Applications
Society (IAS)/Power Electronics Society (PELS). He is the past President
of Converters, Machines, and Electrical Drives, which is the Association of
Italian Professors of Power Electronics. He is an Associate Editor of the IEEE
T RANSACTIONS ON P OWER E LECTRONICS and a member of the Advisory
Committee of the IEEE PELS as the Chairman of the Motor Drives Committee.
He is also a member of the Italian Electric Association (AEI) and a member
of the Executive Committee and the International Steering Committee of the
European Power Electronics Association. Among his international achieve-
ments are two IEEE awards—the best paper published in the IEEE T RANS -
ACTIONS ON P OWER E LECTRONICS and the best paper presented at the IEEE
IAS Annual Meeting.