NOWADAYS, it is not enough to increase the power
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1 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 44, NO. 5, OCTOBER An Integrated Battery Charger/Discharger with Power-Factor Correction Carlos Aguilar, Student Member, IEEE, Francisco Canales, Member, IEEE, Jaime Arau, Senior Member, IEEE, Javier Sebastián, Member, IEEE, and Javier Uceda, Senior Member, IEEE Abstract Distributed power-supply systems are an attractive solution to meeting the requirements (redundancy, modularity, battery backup, etc.) for the next generation of power-supply systems. In addition, the normalization regarding power factor and total harmonic distortion (THD) makes it necessary to include the power-factor correction in the input stage in those architectures. This paper presents a novel approach of an integrated battery charger/discharger which offers power-factor correction and battery galvanic isolation in a simple structure. Placing the battery in the primary side overcomes the need of galvanic isolation integration in each one of the dc/dc on-board converters when this topology is used as part of a distributed power-supply system. Index Terms AC DC power conversion, batteries, communication system power supplies, dc power systems, reactive power correction, switched-mode power supplies, pulsewidth-modulated power converters. I. INTRODUCTION NOWADAYS, it is not enough to increase the power density, which implies use of high-frequency conversion strategies, elaborate mounting techniques, etc., to meet the requirements of modularity, redundancy, and battery backing, all of which appear to be necessary for the next generation of power supplies. Distributed architecture in power-supply systems solves part of the problem, introduces new challenges and opens very attractive research areas. The most interesting challenge in the primary stage of a power supply is probably power-factor correction (PFC) [1]. However, an important disadvantage of distributed power systems (DPS s) is that they need to incorporate galvanic isolation in each one of the dc/dc on-board converters. One possible solution to this problem is to incorporate the battery into the primary side at the front-end converter [2], [3]. One drawback, however, is that PFC is not incorporated. This paper presents a new approach in order to incorporate battery galvanic isolation by placing the battery into the primary side and the PFC features in a single-stage topology, to be used as a front-end converter in a DPS. Manuscript received March 16, 1996; revised January 29, C. Aguilar, F. Canales, and J. Arau are with the Centro Nacional de Investigación y Desarrollo Tecnológico (CENIDET), Cuernavaca, Morelos, México. J. Sebastián is with the Universidad de Oviedo, Campus Universidad de Viesques, E Gijón, Spain. J. Uceda is with the Universidad Politécnica de Madrid, Madrid, Spain. Publisher Item Identifier S (97) II. PROPOSED CIRCUIT The circuit of the proposed topology is shown in Fig. 1 [4]. The topology operates as a preregulator with PFC capacity, with the battery integrated into the primary side. The converter in its normal operation is capable of carrying out the battery charging. The function of the energy backup is carried out by means of a winding and an extra switch. The switch selects the operation mode and protects the battery from higher charging current levels than those specified by the battery manufacturer. The converter has normal, backup, and charging operation modes, which will be described in the following sections. A. Normal Mode of Operation When the main power input is functioning properly, the MOSFET is turned off and the transistor is turned on. The equivalent circuit of the proposed converter for this operation mode is shown in Fig. 1. In this condition, the equivalent circuit is a discontinuous-conduction-mode (DCM) flyback converter; the power flow from to the load is controlled by the duty cycle of MOSFET with a pulsewidth modulated (PWM) pattern. The current in the secondary side is given by the following equation [5]: where duty cycle of ; switching period of ; magnetizing inductance referred to the secondary; secondary voltage. If the secondary voltage is then The average input current of the converter is (1) (2) (3) (4) (5) /97$ IEEE
2 598 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 44, NO. 5, OCTOBER 1997 Fig. 1. (c) (d) Operation modes of the proposed converter. Basic circuit. Normal mode. (c) Backup mode. (d) Charging mode. Using (3) into (5), we have where Now, if the input voltage is then the low-frequency component of the input current is (6) (7) (8) (9) (10) Therefore, the average input current, or the low-frequency component, of the converter is directly proportional to the input voltage. B. Backup Mode of Operation If a failure of the main input power is detected, the MOSFET is turned off and the MOSFET now governs the backup energy transference with a PWM pattern, while the transistor continues ON. The equivalent circuit is shown in Fig. 1(c), which corresponds to a dc/dc flyback converter. In this case, the MOSFET current will be much higher than the MOSFET current, because the voltage is much lower than the main input voltage. Therefore, the selection of MOSFET is more critical than the MOSFET concerning its internal resistance. C. Charging Mode of Operation When the main power input is functioning properly and the battery is discharged, the converter could be operated as a battery charger. During this operation mode, the PFC capacity is preserved. In this mode of operation, the transistor is turned off, and the equivalent circuit is shown in Fig. 1(d). Due to the position and polarity of the battery, the effective voltage seen by the primary is (11) Since the polarities of and are opposite, then the magnetizing inductance in this mode of operation is (12)
3 AGUILAR et al.: INTEGRATED BATTERY CHARGER/DISCHARGER 599 On the other hand, in some applications it is desirable that the battery connections are accessible to the user, basically for maintenance purposes. In the proposed topology, the battery is placed in the primary input side of the circuit (utility line side). This placement could present a safety hazard, therefore, we must avoid user access to the battery. However, if we take into account that, currently, there are many applications which use maintenance-free batteries and that the output of the converter is isolated from the batteries and the utility line, there should be no possibility that the user will have contact with the battery when some load is connected or disconnected to the proposed converter. Thus, the proposed topology would work as a power supply with integrated backup. Besides, considering the advantages of having the batteries in the primary side (we can control both the charge and the discharge of the battery), the proposed solution could be an interesting alternative. III. CONTROL OF THE BATTERY CHARGING/DISCHARGING The primary current of this converter depends on the load; however, the battery-charging current can be controlled through the duty cycle of MOSFET. Depending on the converter load and the charging time of the battery, the duty cycle of the transistor would be regulated. Taking into account the operation frequency of the switch, it could be a power bipolar junction transistor (BJT). The primary and battery-charging currents for different load conditions are shown in Fig. 3. In these conditions, the batterycharging current needs to be kept at an adequate level, so that it does not exceed the peak current established by the battery manufacturer. In the case where the converter is operating in backup mode, the battery discharge can be controlled through the duty cycle. (c) Fig. 2. Versions of integrated battery charger/discharger using Sepic converter, Cuk converter, and (c) zeta converter as the main power stage. where number of turns in the main primary; number of turns in the backup primary; magnetizing inductance in the main primary. The primary current, which is the battery-charging current, flows through the body diode of the MOSFET. Therefore, it is not necessary to turn on in this mode of operation. This principle of operation could be easily extended to other buck boost-derived topologies, such as the Sepic, Cuk, and zeta converters, operating in DCM. Versions of Sepic, Cuk, and zeta converters operating as integrated battery chargers/dischargers can be seen in Fig. 2 (c). IV. CRITICAL DESIGN CONSIDERATIONS Since the transformer has two primary windings, we must take into account some special considerations in its construction. During the converter operation, it requires that, when a primary winding is functioning, the other must be idle and vice versa. If a magnetic field crosses over an idle winding, then an extra leakage inductance will appear, which will cause an increase in switching loss. Therefore, we must select windings sequences upon which the magnetic field does not cross. These sequences could be or. As explained in Section II, the body diode of MOSFET is used to carry on the current in charging mode. However, it must not carry the current when the converter is functioning in normal mode, so that the backup converter and can disappear from the equivalent circuit. In order to achieve that, it is necessary to fulfill the following condition [4]: (13) Such selection prevents diode conduction when is turned on, so that the backup converter is idle.
4 600 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 44, NO. 5, OCTOBER 1997 Fig. 3. Theoretical waveforms of the input and battery currents for half-load and full-load conditions. Fig. 4. Experimental input waveforms (1: line voltage; 2: line current) in normal mode under full-load conditions, PF = 98.26%. Regarding the input filter, the first purpose of is to limit the amount of ripple current seen by the power utility. Its selection depends on the switching frequency, the source impedance, and conduced EMI specifications. The presence of the capacitive filter introduces a reactive component on the input current. Because the diode bridge carries power flow in the first quadrant only, the diode bridge will stop conducting when the reactive load tries to send energy back to the source. At this time, the input current goes to zero, remaining in this condition until the magnitude of the source voltage becomes greater than the capacitor voltage. That means that the value of has influence on the input current distortion. A relatively large value of will not appreciably affect the total harmonic distortion (THD) at higher power levels, but, if we want to maintain a low THD over a wide output power range, the value of must be kept small. On the other hand, when the proposed converter is working in the charging mode, it has different battery polarities concerning the main source input [see (11)]. Therefore, it is necessary to have a sufficiently large capacitor value to avoid the effective voltage being zero in the proximity of the zero crossing of the input voltage, which introduces a higher distortion on the input current in normal mode. It is clear that a design compromise must be made concerning the capacitor value and the maximum permissible input current distortion. An alternative solution to matching optimal conditions in both operating modes is the use of two capacitors (a small-value capacitor for normal mode and large-value capacitor for charging mode) and adding an extra switch, which will place the shunt capacitance necessary for the charging mode. V. EXPERIMENTAL RESULTS In order to verify the performance of the proposed topology, an experimental prototype has been built with the following specifications: V ; 48 V ; 50 W; 24 V. The flyback transformer designed has the following magnetizing inductances: H, H, and H. The filter section is formed with an inductance mh and a capacitor nf. The
5 AGUILAR et al.: INTEGRATED BATTERY CHARGER/DISCHARGER 601 Fig. 7. Power-factor evolution in charging mode. Fig. 5. mode. Power factor and THD of the proposed topology in normal Fig. 8. Input current and voltage waveforms in charging mode under half-load condition. Fig. 6. Experimental efficiency for different load conditions in normal mode. switching frequency for both power transistors and is 100 khz. Fig. 4 shows input current and voltage waveforms for fullload condition, when the converter operates in normal mode. The experimental power factor and THD obtained for different load conditions in the normal operation mode is shown in Fig. 5 and. The efficiency of the prototype is shown in Fig. 6. The efficiency obtained could be higher through the use of an active-clamp circuit. Fig. 9. Input current and voltage waveforms in charging mode under low-load condition. Fig. 7 shows the power-factor evolution when the converter is operating in charging mode, and Figs. 8 and 9 show the input current and voltage waveforms under the same operation mode. The effect of the change in the operating mode during a semicycle, in order to limit battery current through modulation, can be seen in the input current waveforms. The distortion introduced depends on where the operating mode change occurs (respecting to the sinusoidal waveforms). It is
6 602 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 44, NO. 5, OCTOBER 1997 on-board converters, when this topology is used as part of a distributed power-supply system. Extensions of the proposed topology to other buck-boostderived topologies, such as Sepic, Cuk, and zeta converters were also presented. REFERENCES [1] W. A. Tabisz, M. M. Jovanovic, and F. C. Lee, Present and future of distributed power systems, in Proc. Virginia Power Electronics Center Conf., 1991, pp [2] K. Ma and Y. Lee, A novel uninterruptible dc-dc converter for UPS applications, IEEE Trans. Ind. Applicat., vol. 28, pp , July/Aug [3] K. Ma and Y. Lee, An integrated flyback converter for DC uninterruptible power supply, in Proc. IEEE Applied Power Electronics Conf., 1994, pp [4] C. Aguilar, Analysis of a novel scheme of an integrated battery charger/discharger with high power factor, M.S. thesis, Dep. Electron. Eng., Centro Nacional de Investigación y Desarrollo Tecnológico, Cuernavaca, México, Feb [5] R. Erickson, M. Madigan, and S. Singer, Design of a simple highpower-factor rectifier based on the flyback converter, in Proc. IEEE Applied Power Electronics Conf., 1990, pp Fig. 10. mode. THD and efficiency of the proposed converter in charging supply systems. Carlos Aguilar (S 94) was born in Tres Valles, Veracruz, México, in He received the B.Sc. degree in electromechanical engineering in 1992 from the Instituto Tecnológico de Tuxtepec, Tuxtepec, México, and the M.Sc. degree in electronic engineering in 1995 from the Centro Nacional de Investigación y Desarrollo Tecnológico (CENIDET), Cuernavaca, México, where he is currently working toward the Ph.D. degree in power electronics. His research interests include active power-factor correction, dc power supplies, and distributed power important to note that, for all the results shown in Figs. 7 9, modulation is present in order to protect the battery. Fig. 8 presents a case of half load, when the change occurs close to the middle of the sinusoidal waveform producing the lowest power factor obtained (see Fig. 7). On the other hand, when the change occurs close to the voltage peak (Fig. 9) or to the zero crossing (low or full load), the effect on the current distortion is lowest, and the power factor is higher, as can be seen in Fig. 7. The THD and efficiency results obtained for different load conditions are shown in Fig. 10 and, when the converter is functioning in charging mode. The efficiency obtained could be improved through the use of an active-clamp circuit. VI. CONCLUSION Nowadays, characteristics such as power-factor correction, galvanic isolation, and efficient charging/discharging schemes need to be compatible with actual trends in distributed powersupply systems, keeping in mind the cost factor, which means that it is necessary to develop simple structures with a minimum component count. This paper has presented a novel approach to an integrated battery charger/discharger which offers power-factor correction and battery galvanic isolation in a simple structure. Placing the battery into the primary side, it overcomes the need of galvanic isolation integration in each one of the dc/dc Francisco Canales (M 96) received the B.Sc. degrees in mechanical and electrical engineering from the Universidad Veracruzana, Veracruz, México, and the M.Sc. degree in electronic engineering from the Centro Nacional de Investigación y Desarrollo Tecnológico (CENIDET), Cuernavaca, México, in 1989 and 1994, respectively. Since 1994, he has been with the Department of Electronic Engineering, CENIDET, where he is involved in teaching and research in the areas of high-frequency power conversion, distributed power systems, and power-factor correction techniques. Jaime Arau (M 91 SM 97) was born in Veracruz, México, in He received the B.Sc. degree in electronic engineering from the Instituto Tecnológico de Minatitlan, Minatitlan, México, and the Ph.D. degree in electrical engineering from the Universidad Politécnica de Madrid, Madrid, Spain, in 1982 and 1991, respectively. He is currently a Professor at the Centro Nacional de Investigación y Desarrollo Tecnológico (CENIDET), Cuernavaca, México, where he teaches and conducts research in the area of power electronics. His fields of interest are power-factor correction and soft-switching techniques, electronics ballast, and other topics related to power electronics. Dr. Arau was the founding President of the IEEE Morelos, México, Section Power Electronics Chapter and is currently serving as the PELS AdCom Region No. 9 Liasion. He is also the President of the Mexican Academy of Research in Electronic Engineering.
7 AGUILAR et al.: INTEGRATED BATTERY CHARGER/DISCHARGER 603 Javier Sebastián (M 87) was born in Madrid, Spain, in He received the M.Sc. degree from the Polytechnical University of Madrid, Madrid, Spain, and the Ph.D. degree from the University of Oviedo, Oviedo, Spain, in 1981 and 1985, respectively. He was an Assistant Professor at the Polytechnical University of Madrid in 1982 and at the University of Oviedo from 1983 to He was an Associate Professor at the University of Oviedo from 1987 to 1989 and at the Polytechnical University of Madrid from 1990 to In 1992, he again joined the University of Oviedo, where he is currently a Professor. His research interests include switching-mode power supplies, resonant power conversion, converter modeling, and high-power-factor rectifiers. Javier Uceda (M 83 SM 91) was born in Madrid, Spain, in He received the M.Sc. and Ph.D. degrees in electrical engineering form the Universidad Politécnica de Madrid, Madrid, Spain, in 1976 and 1979, respectively. From 1976 to 1981, he was an Assistant Professor at the Universidad Politécnica de Madrid. In 1982, he became a Professor at the Universidad de Oviedo, Oviedo, Spain. Since 1986, he has been a Professor at the Universidad Politécnica de Madrid. His research interests include high-frequency high-density power converters, high-power-factor rectifiers, and modeling of magnetic components. Dr. Uceda is a member of the Editorial Board of the European Power Electronics and Drives Journal and of the Steering Committee of the European Power Electronics and Drives Association. From 1988 to 1991, he was an Associate Editor of the IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS. He was also the Vice President of Technical Activities of the IEEE Industrial Electronics Society for He was Technical Program Committee Chairman of the IEEE Power Electronics Specialist Conference in 1992 and General Chairman of the European Conference on Power Electronics and Applications in He is a member of the AdComs of the IEEE Power Electronics and IEEE Industrial Electronics Societies.
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