Battery powered high output voltage bidirectional flyback converter for cylindrical DEAP actuator

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1 Downloaded from orbi.du.dk on: Oc 11, 218 Baery powered high oupu volage bidirecional flyback converer for cylindrical acuaor Huang, Lina; Thummala, Prasanh; Zhang, Zhe; Andersen, Michael A. E. Published in: Proceedings of he Inernaional Power Modulaor Symposium and High Volage Workshop Link o aricle, DOI: 1.119/IPMHVC Publicaion dae: 212 Link back o DTU Orbi Ciaion (APA): Huang, L., Thummala, P., Zhang, Z., & Andersen, M. A. E. (212). Baery powered high oupu volage bidirecional flyback converer for cylindrical acuaor. In Proceedings of he Inernaional Power Modulaor Symposium and High Volage Workshop IEEE. DOI: 1.119/IPMHVC General righs Copyrigh and moral righs for he publicaions made accessible in he public poral are reained by he auhors and/or oher copyrigh owners and i is a condiion of accessing publicaions ha users recognise and abide by he legal requiremens associaed wih hese righs. Users may download and prin one copy of any publicaion from he public poral for he purpose of privae sudy or research. You may no furher disribue he maerial or use i for any profimaking aciviy or commercial gain You may freely disribue he URL idenifying he publicaion in he public poral If you believe ha his documen breaches copyrigh please conac us providing deails, and we will remove access o he work immediaely and invesigae your claim.

2 Baery Powered High Oupu Volage Bidirecional Flyback Converer for Cylindrical Acuaor Lina Huang, Prasanh Thummala, Zhe Zhang, Michael A. E. Andersen Technical Universiy of Denmark, Deparmen of Elecrical Engineering, DK28 Kgs. Lyngby, Denmark ABSTRACT (Dielecric Elecro Acive Polymer) acuaor is essenially a capaciive load and can be applied in various acuaion occasions. However, high volage is needed o acuae i. In his paper, a high volage bidirecional flyback converer wih low inpu volage is presened. The fundamenal operaing principle for boh energy ransfer process and energy recovery process is analyzed in deail. In order o verify he analysis, criical simulaion resuls are provided. So far, a unidirecional flyback converer, which can realize he energy ransfer process, has been implemened in he lab. The design parameers for flyback ransformer and snubber circuis are illusraed. Moreover, he experimenal waveforms are provided. Index Terms acuaor, high volage, flyback, bidirecional 1 INTRODUCTI (Dielecric Elecro Acive Polymer) is a new ype of polymer maerial, which consiss of a sof silicone polymer, sandwiched beween wo complian meallic elecrodes [1]. The similar srucure o a capacior enables o be fundamenally considered as a capaciive load. Figure 1 shows he measured impedance of maerial a low frequency. The 9 degrees phase an angle can sufficienly illusrae he capaciive propery of. Impedance (ohm) Impedance Phase Frequency (Hz) Figure 1. Impedance measuremen of maerial When a volage is applied o maerial, he polymer will Phase (deg) compress in hickness and expand in area due o he elecric field [2]; herefore, can be used as an acuaor. Compared o radiional elecromagneic, pneumaic or hydraulic acuaors, capaciive acuaor possesses many advanages, such as high power densiy, low weigh, fas and direc acuaion, high acuaing precision, exremely low seadysae power consumpion, low noise, ec. Because of he simple design and immense applicable occasions, cylindrical acuaor, which only performs linear moion, will be an effecive replacemen for many convenional acuaors. Figure 2 shows a cylindrical acuaor [3]. Figure 2. Cylindrical acuaor The srokevolage response of cylindrical acuaor shown in Figure 2, is demonsraed in Figure 3 [4]. I is obvious ha acuaor needs high volage o be fully elongaed. Sroke (mm) Volage (V) Figure 3. Srokevolage characerisic of cylindrical acuaor Owing o he low weigh of acuaor, i can be used in he porable or auonomous sysems, where he baery will be he only power source. Therefore, for simulaing, a DCDC converer which can conver low inpu volage o high oupu volage will be necessary. Combined wih he capaciive propery

3 of maerial and he objecive o exend he lifeime of baery, a bidirecional flyback converer can be a good choice, which can no only boos he low volage o several housand vols, bu also can recover he sored elecrical energy when acuaor is released. Furhermore, due o he simple opology of flyback, he converer can be realized in small size, which is vial in he porable or auonomous applicaions. This paper analyzes he working principle of bidirecional flyback converer o drive cylindrical acuaor and validaes he feasibiliy hrough simulaion in Secion 2. Unil now, only he unidirecional flyback converer was realized in he lab, which can boos he oupu volage o 2.5kV from a 3V baery and will be addressed in Secion 3. And conclusion is drawn in Secion 4. 2 BIDIRECTIAL FLYBACK ANALYSIS For acuaor, only a small porion of sored elecrical energy is convered ino mechanical response [5]; herefore, i can approximaely be considered as a pure capacior load in order o simplify he analysis. 2.1 TOPOLOGY AND WORKING PRINCIPLE The bidirecional flyback converer is shown in Figure 4, consising of coupled inducors in he middle and acive power swiches in boh primary and secondary side. 3V Baery V G1 1:N I Lp T I Ls V ou S 1 S 2 V G2 Acuaor Vou ( ) = Vou () cos LS C (2) L S il () sin S C LS C where is he inducance of secondary coupled inducor, C is he capaciance of acuaor, and i Ls (), V ou () are he iniial curren and volage for inducor and acuaor, respecively. In order o reduce he charge ime of fully elongaing acuaor and compleely ransfer he energy sored in he flyback ransformer in each cycle, a boundary mode conrol sraegy can be used [6]. When he curren hrough he body diode of S 2 accomplishes freewheeling in he previous cycle, he nex cycle immediaely sars. In addiion, primary peak curren conrol is employed o guaranee he sufficien uilizaion of magneic core as well as o avoid is sauraion. The fixed inpu volage from baery and he applicaion of peak curren conrol make primary conducion ime a consan value. However, wih he increasing of oupu volage, he freewheeling ime in secondary side will decrease. Tha means he swiching frequency is variable, and in he early sage of charge, he converer operaes in low frequency, whereas a he end, he working frequency becomes high. Alhough he unfixed operaing frequency acceleraes he charging process, i also brings some challenges in designing he ransformer and analyzing he power loss. The waveforms of firs several cycles in charging process are shown in Figure 5. V G1 () I Lp () Figure 4. The opology of bidirecional flyback converer a) Energy ransfer process analysis When driving acuaor, he elecrical energy is ransferred o capaciive load from baery. Acually, he energy ransfer process includes a series of swiching cycles. For each cycle, he primary inducor is magneized in he onime of S 1 o accumulae magneic energy. Then in he offime of S 1, hrough body diode of S 2, he sored energy will be ransferred o acuaor from coupled secondary inducor. Ideally, he magneic energy of is oally ransformed ino elecrical energy in he capaciive acuaor. Moreover, based on he basic principle of LC resonan circui, in every offime of S 1, inducor curren of and oupu volage V ou can be expressed in (1) and (2), respecively. il ( ) = i () cos S L S LS C (1) C Vou () sin L S LS C I Ls () V ou () Figure 5. Waveforms in he energy ransfer process b) Energy recovery process analysis For he purpose of increasing he service life of baery, i is pivoal o recover he energy sored in acuaor when i is released. Like he charge process, he energy recovery process also consiss of many successive swiching cycles. Only S 2 and he body diode of S 1 work in he discharging process. In each cycle, obains magneic energy from acuaor in he onime of S 2 and releases he sored energy o primary side in he offime of S 2.

4 Similar o energy ransfer sage, boundary mode conrol scheme and secondary peak curren conrol are also adoped in discharge process. The waveforms of firs several cycles in he energy recovery process are shown in Figure 6. V G2 () I Lp () I Ls () In he firs several cycles, he curren waveforms for boh primary and secondary side are shown in Figure 8, which indicaes ha he boundary mode operaion is achieved. Owing o he employmen of boundary mode, he charge ime is shor, only less han 8ms. Primary Curren (A) Secondary Curren (A) V ou () Figure 6. Waveforms in energy recovery process 2.2 SIMULATI VERIFICATI For validaing he analysis menioned above, a bidirecional flyback converer simulaion model has been esablished wih PLECS. In addiion, a boundary operaion mode and peak curren conrol module is also buil up. The deailed simulaions parameers are shown in Table 1. Table 1. Simulaion parameers for bidirecional flyback converer Simulaion Parameers Values 9 μh mh Capaciance of acuaor 142 nf Vin 3 V Primary peak curren 3.9 A Secondary peak curren 8 ma N 48.7 a) Energy ransfer process simulaion Figure 7 shows he whole charge process, in which he oupu volage increases from o 2.5kV. Vou (V) Figure 7. Simulaed oupu volage waveform in he energy ransfer process Figure 8. Simulaed curren waveform in he energy ransfer process b) Energy recovery process simulaion The oupu volage decreases from 2.5kV o in he energy recovery process, shown in Figure 9. And he curren waveforms are provided in Figure 1, which also demonsraes he realizaion of boundary mode in discharge process. Vou (V) Figure 9. Simulaed oupu volage waveform in he energy recovery process Primary Curren (A) Figure 1. Simulaed curren waveform in he energy recovery process 3 UNIDIRECTIAL FLYBACK DESIGN AND REALIZATI.1 Secondary Curren (A)

5 A unidirecional flyback converer o drive acuaor, shown in Figure 11, has been realized in he lab. Because of he volage sress issue of S 1, a RC snubber and a RCD clamp circuis are employed [7]. The peak curren conrol can be validaed in Figure 13 and he whole energy ransfer process is shown in Figure 14. 3V Baery I in Ccp Dcp C in S 1 Rcp Llk D 1 T 1 Coss Cs Rs V ou Figure 11. Unidirecional flyback converer Acuaor Figure 13. Experimenal waveforms (CH1primary winding curren; CH2charge conrol signal for converer; CH3inpu volage; CH4oupu volage) 3.1 DESIGN PARAMETERS The deailed design parameers are shown in Table 2, including he parameers of ransformer, RC and RCD circui. Table 2. Design parameers for unidirecional flyback converer Parameers Values Turns raio (primary urns : secondary urns) 7:341 Core ype (Core maerial) EF2 (N67) Air gap lengh 25 μm Lp 9 μh Ls mh Leakage inducance L lk 75 nh Capaciance of acuaor 142 nf Rs of RC snubber circui 68.1 Ω Cs of RC snubber circui 22 pf Rcp of RCD clamp circui 2 kω Ccp of RCD clamp circui 1 μf 3.2 EXPERIMENTAL WAVEFORMS The experimenal waveforms are shown in Figure 12, Figure 13 and Figure 14. From Figure 12, i is clear o see he variable swiching frequency which is caused by he boundary mode operaion. Figure 12. Experimenal waveforms (CH1inpu curren I in; CH2charge conrol signal for converer; CH3gae signal of S 1; CH4oupu volage) Figure 14. Experimenal waveforms (CH1inpu curren I in; CH2charge conrol signal for converer; CH3inpu volage; CH4oupu volage) 4 CCLUSI A high volage bidirecional flyback converer driving acuaor is presened. The deailed analysis for boh he energy ransfer and he recovery process is discussed. The simulaion resuls are provided o suppor analysis. In addiion, a unidirecional flyback prooype has been implemened in he lab, which can charge acuaor o 2.5kV. REFERENCES [1] M. Y. Benslimane, H. E. Kiil and M. J. Tryson, Elecromechanical properies of novel large srain PolyPower film and laminae componens for acuaor and sensor applicaions, Proceedings of SPIE, Vol. 7642, 21. [2] M. Y. Benslimane, H. E. Kiil and M. J. Tryson, Dielecric elecroacive polymer push acuaors: performance and challenges, Polymer Inernaional, Vol. 59, No. 3, pp , 21. [3] T. Andersen, M. S. Rødgaard, O. C. Thomsen and M. A. E. Andersen, Low volage driven dielecric elecro acive polymer acuaor wih inegraed piezoelecric ransformer based driver, Proceedings of SPIE, Vol. 7976, 211. [4] R. Sarban, R. W. Jones, B. R. Mace and E. Rusighi, A ubular dielecric elasomer acuaor: Fabricaion, characerizaion and acive vibraion isolaion, Mechanical Sysems and Signal Processing, Vol.25 No. 8., pp , 211. [5] M. J. Tryson, R. Sarban, K. P. Lorenzen, The dynamic properies of ubular acuaors, Proceedings of SPIE, Vol. 7642, 21. [6] LT375 Capacior Charger Conroller Daashee, Linear Technology Corporaion, USA. [7] Applicaion Noe AN4147 Design Guidelines for RCD Snubber of Flyback Converers, Fairchild Semiconducor Corporaion, USA, 26.

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