Design and Implementation of Single-Stage Grid-Connected Flyback Microinverter Operates in DCM for Photovoltaic Applications

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1 Design and Implementation of Single-Stage Grid-Connected Flyback Microinverter Operates in DCM for Photovoltaic Applications Turki K. Hassan 1 and Mustafa A. Fadel 2 1 PhD, Electrical Engineering Department, Faculty of Engineering, Al-Mustansiriya University, Iraq. 2 MSc, Electrical Engineering Department, Faculty of Engineering, Al-Mustansiriya University, Iraq, Baghdad. Abstract In this paper, a single-stage grid-connected flyback microinverter is proposed. The proposed flyback microinverter has some advantages such as high voltage gain, high efficiency, low cost, small size, simple control and high power factor. The proposed system is used to connect the PV panel to the grid with achieving maximum Power Point Tracking (MPPT) control. The converter operates in DCM to inject a sinusoidal current into the grid with unity power factor. A complete system has been simulated using PSIM program and the hardware is build using analog and digital devices. The simulation and experimental results are obtained to validate the system. Keywords: Single-Stage, Grid-Connected, Microinverter, Flyback, DCM, MPPT. 1. Introduction In the last decades the fossil fuels have been widely used in order to cover the human needs of energy. Moreover, extraction and transportation of fossil fuels cause environmental pollution along with serious consequences such as air pollution, global warming, soil degradation and water deterioration. Because of the risks of environmental contamination above, the searching for clean renewable sources of energy are gaining more and more interest such as wind power, solar power, biomass, geothermal power, wave and tidal power, and nuclear power. Now days the higher interest is concentrate in solar energy exploitation, at present the power injection to the utility grid using photovoltaic panels (PV) is gaining more attention [1, 2]. The photovoltaic panel is a device that converts luminous energy into electric energy through the photoelectric effect. The electric energy is available at the terminals of the PV panel in the same instant that the sunlight reaches it, most of the electric equipment of standard use cannot connected directly, this because the generated current from the PV panel is continuous (dc) and at low voltage (generally between 12 and 68 volts, depending on the technology used in the panel construction) and the majority of the equipment operates at alternating current (ac), at higher voltages [3]. This brings the need for power interface between the PV panel and the grid through power electronic inverters. The latest technology for grid-connected PV systems is the ac-pv module [4-6], where the inverter is integrated in the PV panel and both works as a single unit that operates as an ac generator used to inject ac current to the grid.

2 The ac-pv module can be easily installed at any place such as rooftop and open areas without needs to any special technical knowledge or extreme safety caution. The power converter unit of an ac-pv module is usually a single-phase inverter, ranging from 50 to 400W. There are many single or multistage topologies about grid-connected inverters for PV modules [2]. As shown in Figure (1) single stage inverters boost the input voltage and convert it into ac voltage in the same stage. Multistage inverters consist of two cascaded stages, the first stage is a boost dc-dc converter and the second one is an inverter. Single stage inverters have some advantages over multistage inverters; such as low cost, high power density, small size, high efficiency and high reliability. [7]. Figure (1): Single stage and multistage configurations. The proposed inverter in this paper consists of flyback inverter with PWM modulation. The inverter operates in the DCM to inject a naturally sinusoidal current into the grid with unity power factor. 2. The Proposed Inverter System The flyback inverter shown in Figure (2) performs energy flow from the dc side (PV panel) to the ac side (utility grid), by using transformer with two identical secondary windings. Each of them is able to transfer energy to the ac side during a utility grid half cycle. For this reason, a semiconductor switches (S 2 and S 3 ) are placed in each secondary winding and they appropriately controlled to turn on and off to ensure an ac output waveform synchronized with the grid. The output LC filter is used to filter the output produced by the rest of the converter so that the appropriate final output current is produced and fed to the grid. Figure (2):Single-Stage Flyback inverter.

3 While the main switch semiconductor S 1 is modulated in high frequency ( khz), the switches S 2 and S 3 are modulated in 50 Hz. The switching sequence of each semiconductor can be observed in Figure (3). S 1 gate pulses S 3 gate pulses S 2 gate pulses Figure (3): Current waveforms and switching sequence diagram [8]. Figure (4) shows the operation of this converter during a line half cycle is as follows: When the primary switch, S 1, is on, the full PV panel input dc voltage is impressed across the transformer, thus putting energy into its magnetizing inductance and making its magnetizing current rise. When S 1 is off, the stored energy in the transformer s magnetizing inductance will transferred to the output, which is the grid. Since the output is ac, which means it is either transferred through D 1 and S 2 when the voltage output is positive or through D 2 and S 3 when the voltage output is negative.s 1 duty cycle should be made to vary throughout the ac voltage line cycle so that it is at its minimum when the ac voltage is at its minimum and it is at its maximum when the ac voltage is at its peak.

4 (a) (b) (c) Figure (4): Equivalent circuit of the current source flyback inverter during a line half cycle. (a) Each line half cycle. (b) During S 1 on time. (c) During S 1 off time.

5 In the following analysis, only discontinuous conduction mode (DCM) is considered due to its simplicity of control. To ensure the inverter operates in DCM [9]. t off _p T s t on _p (1) Wheret off _p is the off time of S 1 in the switching cycle when the primary current reaches its peak value of I pri _p and t on _p is the on time of S 1 during the same switching cycle. The on time can be expressed as: t on _p = d p T s = d p f s (2) Where f s is the switching frequency and d p is the duty cycle. The current in L m can drop to zero when S 1 is turned off and the energy that is stored in it is transferred to the output. When S 1 is turned off, the voltage across the transformer is the output voltage that appears across the secondary winding and is reflected to the primary. This voltage can be expressed as v grid t = V grid _p sin ω g t (3) Where V grid _p is the peak value of output voltage and ω g is the grid frequency in rad/sec. Considering this voltage reflected to the primary, the fall of current in L m can be expressed as di pri (t) N v grid t = L m (4) dt Where N is the turns ratio. So that t off can be expressed as: t off _p = L m I pri _p (t) N V grid _p (5) To determine the turn off time t off _p the peak primary current flowing through the flyback inverter I pri _p needs to be determined. This can be done by considering the fact that the input dc voltage V in is impressed on the transformer primary when S 1 is on. The rise in current when S 1 is on can be expressed as: di pri (t) V in = L m (6) dt

6 Substituting (2) into this equation gives the following expression for I pri _p I pri _p = V in d p f s L m (7) Substituting this equation into equation (5) gives, t off _p = V in d p V grid _p f s N (8) It can be seen from equation (8) that t off _p dependent on various parameters. Assuming a fixed switching frequency f s, these parameters are fixed except for peak duty cycle d p and turns ratio N. Values for d p and N need to be chosen so that the converter remains in DCM. This can be done by considering the expression for DCM operation given in equation (1) and substituting equation (8) into this equation to get V in d p V grid _p f s N T s t on _ p (9) Equation (9) can be rearranged to give the following expression for peak duty cycle d p V in N V grid _p (10) The next step is to determine an appropriate value of magnetizing inductance L m that can store sufficient energy to be fed to the grid, for a rated output power P o. Once this has been determined, the final step is to confirm that the converter can operate with DCM with this value of L m. The value of magnetizing inductance L m can be calculated using the following equation: L m = 1 2 d 2 2 p V grid _rms f s P o V in V grid _p 2 (11) The flyback inverter transferred power P o is expressed by the following equation [8]: P o = 1 V 2 2 in d p (12) 4 L m f s

7 3. The Proposed Control The proposed control is based on DCM operation. It requires the achievement of MPPT and unity power factor for the output current of the inverter in addition to boosting the input voltage into its required level. Figure (5) shows the schematic of the proposed control system, as shown in the figure, grid voltage is sensed to provide control signal for the flyback inverter to operate in synchronization with grid voltage, PV panel s voltage and current (V in and I in ) are provided to the MPPT controller to generate reference signal (E o ). To provide sinusoidal modulation, grid voltage is rectified (S(t)) and then multiplied by the output signal from the preoperational-integral controller (P-I controller), comparing its output with fixed sawtooth signal to generate converter control signal (PWM signal for the main switch S 1 ). Figure (5): Proposed control circuit. PV generation efficiency and power quality are the fundamental issues. PV power sources are usually integrated with control algorithms that have the task of ensuring maximum power point (MPP) operation. Many algorithms have been developed for tracking the maximum power point of a solar array [10-12]. Most commonly used are perturb and observe (P&O) algorithm [13, 14] and the incremental conductance algorithm [15]. The main advantages of these algorithms are easy to build and low cost instruction. Consequently, researchers have been focused on the improvement of maximum power point tracking (MPPT) control and the reduction of total harmonic distortion (THD). It is very important to design the MPPT controller, so that the voltage ripple at the terminals of the PV panel is a minimum. The Perturb and observe (P&O) method also called Hill-Climbing is the most widelytechnique used for MPPT because of their simplicity and effectiveness. The perturbation in the operating voltage of the dc link between the PV array and the power converter is repeatedly done. In this method, PV power P(k) is measured and compared with the previous measured PV power P(k-1).

8 If the power increases, the same perturbation is applied in the same direction to get the next PV powerotherwise perturbationis made in opposite direction. By this process, the operating point of the system gradually moves towards the MPP and oscillates around it. Based on these facts, the algorithm is implemented. The process is repeated until the MPP is reached [16]. P&O maximum power point tracking algorithm is used in this paper. Figure (6) shows the flowchart of the used MPPT control technique. Figure (6): P&O algorithm for MPPT.

9 4. Simulation Results The proposed system as shown in Figure (7) is simulated using PSIM software. Table (1) shows the simulated system specifications. Figure (7): Proposed system simulation using PSIM program. Table (1): System design specifications. Parameters Symbol Value unit Rated output power P o(max) 100 W Switching frequency f s 20 khz Grid voltage V grid_rms 220 V Input voltage V in 22 ~ 33 V Grid frequency f grid 50 Hz Total input capacitance C dc μf Turns ratio of transformer N Output filter capacitance C f 3 μf Output filter inductance L f 2 mh Proportional constant gain k p Integral constant gain k i 50 - Figure (8) shows the input dc voltage from the PV panel, V in =32.5 V, Which is not pure dc voltage and it has a little value of ripple about V ripple =1V. However, any voltage ripple on the dc link will create distortion on the output current waveform, and increase the total harmonic distortion (THD). In addition, the

10 increased voltage ripple on the dc link introduces utilization losses on PV power. Therefore, a pure or low-ripple dc-link voltage is necessary. The main factor that causes the voltage ripple in single phase grid-connected inverters is the instantaneous power fluctuation with a magnitude twice that of the average power and a frequency twice that of the grid frequency. Employing a power decoupling device is essential to filter this power fluctuation. Using a large electrolytic capacitor (10000μF) at the input is a simple method for power decoupling in flyback type microinverters [17, 18]. Figure (9) shows the PV output current, whose value I in =3.09 A, and it has a little value of current ripple of I ripple =0.048A. Figure (10) shows the output power from the PV panel P in =100 W, for S=530 W/m 2 sunlight radiation and T=25 C temperature. (V) Figure (8): The output voltage from the PV panel. Figure (9): The output current from the PV panel.

11 Figure (10): PV output power. Figure (11) shows the gate pulses sequence for the main switch S 1 (MOSFET) and switches pulses S 2, S 3 for the IGBTs. (a) (b) (c) Figure (11): (a) S 1 gate pulses. (b) S 2 gate pulses. (c) S 3 gate pulses. Figure (12) shows the drain-source voltage (V ds ) for the MOSFET main switch S 1, which has a

12 spike voltage of V spike =78.73 V. The spike voltage appears due to the leakage inductance of the transformer. As shown in Figure (13), the switch S 1 current (I S1 ) and D 1 current (I D1 ). Due to the spike s high voltage, it may damage the MOSFET and it should be reduced, this is done by adding a snubber circuit to the switch between the drain and the source. V spike V in +NV o V in Figure (12): Drain-Source voltage (V ds ) of S 1. I S1 I D1 Figure (13): Switch S 1 current and diode D 1 current. The primary current can be seen in Figure (14), as shown, the current has a shape like a rectified sine due to the sinusoidal modulation. The peak current value of the primary currentis I pri. =19.43A.

13 I pri =19.43 A Figure (14): Primary current for flyback microinverter operates in DCM. Figure (15) shows the voltage stress on the switches S 1, S 2 and S 3. As shown in these figures, all switches have lower stresses. (a) (b) (c) Figure (15):MOSFET Switch S 1 voltage. (a) IGBT1 Switch S 2 voltage. (b) IGBT2 Switch S 3 voltage. Figure (16-a) shows S 2 output current I o1, Fig. (16-b) shows S 3 output current I o2 and Fig. (16-c) shows the output current I o before the output LC filter.

14 (a) (b) (c) Figure (16):(a) Switch S 1 current. (b) Switch S 2 current. (c) Output current before the output filter. For flyback microinverter which operates in DCM. Figure (17) shows the simulation result for the output current fed to grid after filtering, whose value of I o(rms) =0.44 A, and it almost in-phase with the grid voltage by power factor of P.F= and the output current has a low value of (THD), which is 3.916% for 530 W/m 2 sunlight radiation and 25 C. Figure (17):Current fed to grid multiplied by 100 and grid voltage. 5. Experimental Results The experimental results are obtained based on the prototype setup illustrated in Figure (18). A flyback microinverter operates in DCM scheme experimentally examined on a 100 W PV panel with 33 V dc input voltage. The prototype is tested to feed 100 W maximum power transferred to the network with 220 V rms, 50 Hz. Measurements are obtained by using the oscilloscope spectrum analyzer (RIGOL digital oscilloscope DS1102E 100 MHz, 1 Gsa/s sampling, USB storage) and probes (Hantek 2 X

15 100MHz oscilloscope clip). The sunlight radiation is measured using auto digitallux meter (victor 1010A), and the temperature is measured by infrared thermometer (AR827D -50 C ~ 1050 C). The design parameters of the implemented inverter are presented in Table (2). Power Circuit HF Transformer G 1 Control Circuit S 1 LC Filter G 2 G 3 C dc S 2 S 3 MPPT Control Circuit PIC Microcontroller Current Sensor EMI filter v Voltage Sensor Figure (18): Flyback microinverter prototype setup. Table (2): Implemented inverter parameters. MOSFET S 1 : APT5015BVR Core Material: 3F3 IGBT S 2, S 3 : G40N150D N= 0.17 Diode D 1,D 2 : RHRG75120 C f =3 μf f s =20 khz L f = 2 mh N p =17 Turn, (L m =50.5 μh) Standard aria wire gauge=19 l g = cm No. of primary strands=2 Core type: EE No. of primary strands=1 Figure (19) shows the output voltage from the PV panel (V in ) for S=530 W/m 2 and T=25 C. As

16 shown, the voltage carries a little value of voltage ripple V ripple =3.2 V, which discussed before how to reduce its value.figure (20) shows the output current from the PV panel (I in ) for S=530 W/m 2 and T=25 C. As shown, the current carries a little value of current ripple I ripple =29 ma. Figure (21) shows the triangular wave signal, which is internally generated by the PWM IC. The triangular wave peak voltage V tri. =3.2 V and the frequency is f S =20 khz. Figure (22) shows the rectified sine wave signal S(t), which is generated by the precision diode rectifier circuit. V in =30 V I in =3.09 A V ripple =3.2 V I ripple =29 ma Figure (19): output voltage from PV panel(1v/div.). Figure (20): output current from the PV panel. Figure (21): The triangular wave signal for (1V/div.) and 20 khz switching frequency. Figure (22): The rectified sine wave signal S(t) (1V/div.). Figure (23) shows the gate pulses sequence for the main switch S 1, and Figure (24) shows the gate pulse for both S 2 and S 3 switches. Figure (25) shows the primary current, whose shape like a rectified sine wave. The peak value of the primary current is I pri.=19.2 A. Figure (26) shows the drain-source voltage (V ds ) of the main switch S 1, the value V ds =60.8 V, for S=109.5 W/m 2 and T=25 C.

17 Figure (23): Gate pulses sequence for the main switch S 1 (5V/div.). Figure (24): Gate pulses sequence for switch S 1 and S 2 (5V/div.). I pri._p =19.2 A Figure (25): The primary current I pri (10A/div.). Figure (26): drain-source voltage (V ds ) of S 1 switch. The figures below shows experimental results for sinusoidal ac current fed to the grid by the single stage flyback microinverter which operates in DCM with the grid voltage for different values of sunlight radiation. Figure (27-a) shows the injected current to grid in phase with the grid voltage for S=515 W/m 2, T=25 C and the power generated from PV panel is P in =93 W with respect to the given sunlight radiation. Figure (27-b) shows the signals for S=357 W/m 2, T=25 C and P in =69 W. Figure (27-c) shows the signals for S=257 W/m 2, T=25 C and P in =49 W. Figure (27-d) shows the signals for S=109 W/m 2, T=25 C and P in =16.5 W.

18 I o =0.381 AV grid /10 I o =0.294 A V grid /10 (a) (b) I o =0.21 AV grid /10 I o =0.105 AV grid /10 (c) (d) Figure (27): The ac current fed to grid (0.2 A/div.), 50 Hz in phase with voltage grid (10 V/div.) (a) Io=0.381 A, P.F= 0.98 (b) Io=0.294 A, P.F= (c) Io=0.21 A, P.F= 0.93 (d) Io=0.105 A, P.F= The figures below shows comparison between the simulation results from the PSIM software and the experimental results measured from the hardware device, the comparison is made for the power factor, efficiency and total harmonic distortion, as shown in Figure (28) the power factor between the current injected to the grid and the grid voltage in both simulation and experimental measurements almost unity power factor at high power level, but at low power levels the power factor is poor due to the capacitor of the output filter. Figure (29) shows very good efficiency for both simulation and experimental results about 94.5% efficiency at 100 W input power from the PV panel. Figure (30) shows small values of THD (below 5%) at high power levels for both simulated and experimental results, the THD increases above 5% at low power levels.

19 Efficiency (%) Power Factor SAUSSUREA (ISSN: ), Expreimental Power Factor PSIM Power Factor Output Power Po (W) Figure (28):Calculated and measured P.F versus output power PSIM Efficiency Expreimental Efficiency Output power Po (W) Figure (29): Calculated and measured efficiency versus output power.

20 Total Harmonic Distortion (%) SAUSSUREA (ISSN: ), Experimental THD PSIM THD Output power Po (W) Figure (30): Calculated and measured THD versus output power. 6. Conclusion In this paper a single phase current-source flyback microinverter for grid-connected PV systems has been investigated and implemented to inject alternating current to the national grid via a 100 W photovoltaic panel. A design strategy for the operation scheme has been proposed in order to achieve highpower density. Moreover, this paper has highlighted, both experimentallyandsimulation, the optimum inverter behavior when thedcm operation mode is used, leading to a global and high-efficiency solution for wide power range ac PV module applications. The complete DCM system was verified and a hardware prototype is build using analogue devices and microcontroller for the flyback microinverter control. Based on the simulation and experimental results the following aspects can be concluded: 1. Sinusoidal output current injected into the grid with approximately unity power factor is obtained at high sunlight radiation (high output power from PV panel). 2. The output power of the microinverter depends on the solar energy absorbed by photovoltaic panel, which is converted to electric energy. The maximum power point tracking algorithm (Perturb and Observe method) is used to extract the maximum power from the PV panel. 3. Low THD of the output current is obtained due to the efficient control method and low-pass output filter (LC filter). The suggested flyback microinverter has high efficiency, high reliability, small size and low cost due to single-stage of dc/ac conversion.

21 References [1] S. B. Kjaer, J. K. Pedersen, and F. Blaabjerg,"A Review of Single-Phase Grid-Connected Inverters for Photovoltaic Modules", IEEE Transactions on Industrial Application, vol. 41, no. 5, pp , Sep [2] J. Gow and C.Manning, Photovoltaic converter system suitable for use in small scale stand-alone or grid-connected applications, IEE Proc. Electr. Power Appl., vol. 147, no. 6, pp , Nov [3] L. J. Sheng, "Power conditioning systems for renewable energies", International Conference on Electrical Machines and Systems, pp ,Seoul, Oct. (8-11), [4] Y. Fang and X. Ma, A novel PV microinverter with coupled inductors and double-boost topology, IEEE Trans. Power Electron., vol. 25, no. 12, pp , Dec [5] Z. Liang, R. Guo, J. Li, and A. Q. Huang, A high-efficiency PV module integrated DC/DC converter for PV energy harvest in FREEDM systems, IEEE Trans. Power Electron., vol. 26, no. 3, pp , Mar [6] A. Ch. Kyritsis, E. C. Tatakis, and N. P. Papanikolaou, Optimum design of the current-source flyback inverter for decentralized grid-connected photovoltaic systems, IEEE Trans. Energy Convers., vol. 23, no. 1, pp , Mar [7] S. Jain and V. Agarwal,"A Single-Stage Grid Connected Inverter Topology for Solar PV Systems with Maximum Power Point Tracking", IEEE Transaction on Power Electronics, vol. 22, no. 5, pp , Sep [8] C. Nanakos, Emmanuel, C. Tatakis and N. P. Papanikolaou, "A Weighted-Efficiency-Oriented Design Methodology of Flyback Inverter for AC Photovoltaic Modules", IEEE Transaction on Power Electronics, vol. 27, no. 7, pp , July [9] A. Ch. Kyritsis, E. C. Tatakis, and N. P. Papanikolaou, "Optimum Design of the Current-Source FlybackInverter for Decentralized Grid-Connected Photovoltaic Systems", IEEE Transactions On Energy Conversion, vol. 23, no. 1, pp , Mar [10] J. S. C. M. Raj and A. E. Jeyakumar, "A Novel Maximum Power Point Tracking Technique for Photovoltaic Module Based on Power Plane Analysis of I V Characteristics", IEEE Transaction on Industrial Electronics, vol. 61, no. 9, pp , Sep

22 [11] C. Kalpana et al., "Design and Implementation of different MPPT Algorithms for PV System", International Journal of Science, Engineering and Technology Research (IJSETR), vol. 2, no. 10, pp , Oct [12] D. P. Hohm and M. E. Ropp, "Comparative study of maximum power point tracking algorithms using an experimental, programmable, maximum power point tracking test bed", 28 th Annual IEEE Photovoltaic Specialists Conference, pp ,Anchorage, AK, Sep. (15-22), [13] N. Femia et al., "Optimization of Perturb and Observe Maximum Power Point Tracking Method", IEEE Transaction on Industrial Electronics, vol. 20, no. 4, pp , Jul [14] A. M. Atallah et al., "Implementation of Perturb and Observe MPPT of PV System with Direct Control Method Using Buck and Buck-Boost Converter", Emerging Trends in Electrical, Electronics & Instrumentation Engineering: An international Journal, vol. 1, no. 1, pp , Feb [15] A. Safari and S. Mekhilef,"Simulation and Hardware Implementation of Incremental Conductance MPPT With Direct Control Method Using Cuk Converter", IEEE Transaction on Industrial Electronics, vol. 58, no. 4, pp , Apr [16] S. Jain, et al., "Comparative Analysis of MPPT Techniques for PV in Domestic Applications", 6 th IEEE Power India International Conference (PIICON), pp. 1-6, Delhi, Dec. (5-7), [17] H. Hu, et al., "A Review of Power Decoupling Techniques for Microinverters With Three Different Decoupling Capacitor Locations in PV Systems", IEEE Transactions on Power Electronics, vol. 28, no. 6, pp , Jun [18] H. Hu, et al. "A Three-port Flyback for PV Microinverter Applications With Power Pulsation Decoupling Capability", IEEE Transactions on Power Electronics, vol. 27, no. 9, pp , Sep

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