Soft-Switching Active-Clamp Flyback Microinverter for PV Applications

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1 Soft-Switching Active-Clamp Flyback Microinverter for PV Applications Rasedul Hasan, Saad Mekhilef, Mutsuo Nakaoka Power Electronics and Renewable Energy Research Laboratory (PEARL), Faculty of Engineering, University of Malaya, Kuala Lumpur, Malaysia Katsumi Nishida Ube National College of Technology Ube City, Yamaguchi, Japan Abstract This paper presents an active-clamp flyback microinverter for grid connected photovoltaic (PV) ac module system. The active-clamp circuit achieves the soft switching by allowing a negative current that discharges the output capacitor of the primary switch and zero voltage switching (ZVS) turn on is achieved. The active-clamp switch is also operated in ZVS. Therefore the switching losses of the high frequency primary switches are negligible. The galvanic isolation provided by the high frequency flyback converter and the single stage operation of the microinverter improve the reliability and efficiency of the system. The simulation of the proposed scheme has been done and a 250 W prototype has been realized to verify in real time operation. Keywords microinverter; active-clamp flyback; grid connected PV; zero voltage switching (ZVS) I. INTRODUCTION Photovoltaic (PV) energy is considered one of the most promising emerging technologies among the renewable energy sources. According to the roadmap envisioned by the International Energy Agency (IEA), PV s share of global electricity will rise to 16% by 2050 [1]. On the basis of the different arrangements of PV modules, the PV system can be categorized into central, string, multistring, and ac module system [2]. In the ac module system, a low power rating gridtied inverter of W with individual maximum power point tracking (MPPT) controller is dedicated for each PV module, which is called as microinverter. The individual MPPT provides high efficiency for the PV system under partial shading. However, the microinverter is still expensive compare to other PV arrangements. Moreover, it should be compact enough so that can be easily mounted on each PV module. This paper is arranged for an efficient and low cost microinverter that also provides the galvanic isolation with the grid. The flyback topology is one of the best solutions for low power grid-tied PV microinverter because of the ease of control and minimal number of power semiconductor devices [3-7]. However, the switching losses associated with the hardswitched flyback converters and the low utilization factor is the major drawbacks to achieve a reliable grid-tied microinverter. The flyback converter operated in hard switching mode suffers from a massive switching loss in the primary switch [8, 9]. The current and voltage stress on power devices is also high. Therefore, the conventional flyback converter shows a poor performance due to hard switching. The voltage and current stress can be reduced by adopting a interleaved flyback inverter as shown in [10]. In [11], a double-stage inverter was proposed where a boost converter and flyback is combined to achieve the power decoupling, and the high frequency switches are turned on at zero current switching (ZCS) and turned off at zero voltage switching (ZVS). But the double conversion process makes the projected efficiency low. An interleaved flyback microinverter with an active-clamp circuit on each phase is proposed in [12], where the active-clamp circuits are operated based on the voltage spike across the main switch. Activeclamp circuit are also proposed in the multistage inverter presented in [4], where ZVS is achieved in the primary switch by recycling the stored energy of the leakage inductance of the transformer through the clamp circuit. The soft switching of the flyback can also be realized through bidirectional switches placed at the secondary side of the transformer, as shown in [5]. Although the above-mentioned techniques have the benefits of increasing the efficiency by either different control operation or achieving soft switching, these have the drawbacks of reducing the power density or complicating the controller. The conventional active-clamp circuit in DCM or BCM operation for the flyback topology has the limitation that it cannot completely discharge the energy stored in the parasitic capacitance of the main switch. Hence, the ZVS is not properly achieved for the main switches. In this paper, a new topology based on the flyback converter is proposed for the PV microinverter where an extra resonant inductor is inserted with the active-clamp circuit which ensures ZVS of the switches. The detailed analysis of the proposed microinverter accompanied by the simulation and experimental results is provided in the following sections. This paper is organized as follows. The operation principle of the proposed topology and the steady state analysis are described in Section II. The simulation results are provided in Section III. The performance of the proposed microinverter is verified with an experimental set-up and the efficiency comparison with load is analyzed in section IV. Finally the conclusions are drawn in section V. The authors would like to acknowledge the financial support from the Ministry of Higher Education (MoHE), Malaysia, through the Fundamental Research Grant (FRGS) under grant FP A and AUN/SEED- Net Research grant, CRC 1501, 2015-UM /16/$ IEEE 1

2 II. STEADY STATE ANALYSIS OF OPERATION Fig. 1 shows the circuit configuration of the proposed active-clamp flyback microinverter. The circuit consists of a dc input capacitor C dc, a center-tapped flyback transformer whose magnetizing inductance is L m, an unfolding circuit, and an output filter. The series connected resonant inductance L r is the sum of transformer leakage inductance and external inductance that has been added to form a resonant circuit. S m is the high switching frequency main switch and S a is the auxiliary switch that has been employed for active-clamping. C r is the resonant capacitor which is formed due to the parallel combination of the parasitic capacitance of main and auxiliary switch. The resonant capacitance C r and inductance L r are resonant during the transition between the main and auxiliary switches and achieve ZVS operation for both S m and S a. C clamp is the clamp capacitor which forms an active-clamp circuit with the auxiliary switch to limit the voltage stress of main switch. S s1 and S s2 are switched under the line frequency to inject sinusoidal ac current in the grid. The key waveforms in a single switching cycle of the proposed microinverter at discontinuous conduction mode (DCM) are illustrated in Fig. 2. There are six operation modes in a single switching cycle based on the steady-state operation. Since the switching frequency of the flyback converter is much higher than the line frequency, the grid voltage and current are assumed to be constant in a switching cycle. The steady state analysis of the modes of operation is described in the following. A. Mode I (t 0-t 1) In this mode, the main switch S m is turned on and the auxiliary switch S a is turned off. Secondary switch S s1 is turned on during the entire positive half of the line cycle and S s2 is turned on during the entire negative half of the line cycle. During this mode, the resonant capacitor voltage across the main switch is zero ( () =, =0). The input PV voltage is applied across the magnetizing inductance L m and the energy is stored in the primary winding of the transformer. The primary side current increases till the end of this mode and is following: () = () = () = ( ) ( ) (1) The primary magnetizing current keeps ramping up until the main switch is turned off at t =t 1. The peak value of the primary side current is given as _ = ( ) ( ) (2) This mode ends when the primary current reaches to its peak value _ and this value depends on the duty cycle D 1 for a particular switching cycle. The duty cycle D 1 varies with respect to the instantaneous output power so as to control the primary magnetizing current. The time interval for Mode I is = = ( )( _ ( )) (3) B. Mode II (t 1-t 2) This mode starts at time t 1 when the main switch S m is turned off whereas the secondary switch remains ON. The V PV + - C clamp C dc S a i Lr L r S m L m i Lm C r D 1 D2 S s1 S s2 Fig. 1. Circuit diagram of the proposed microinverter V gs,sm V gs,sa i Lm i Lr i Cr t 0 t 1 t 2 t 3 t 4 t 5 t 0 Fig. 2. Key waveforms of the proposed microinverter in a single L f i grid C f Grid resonant capacitor C r is charged up by the magnetizing current flowing through the primary side. The drain-source voltage of the main switch rises slowly due to the charging of the resonant capacitor C r. The circuit composed of L r, L m and C r forms a LLC resonant tank. The voltage across the resonant capacitor and the current through the clamp circuit are () = 1 cos ( ) + ( ) sin ( ( )) (4) () = ( ) cos ( )+ sin ( ) (5) where resonant frequency, =1 ( + ), and characteristic impedance, = ( + ) Since the resonant capacitor C r is very small, it is charged quickly and the time interval is very short. This mode ends at time t 2, when the voltage across the resonant capacitor reaches to its maximum value + /. 2

3 The resonant capacitor voltage and the primary current at the end of this mode can be approximately given as ( ) ( )( ) = + / (6) ( ) ( ) +. ( ) ( ) (7) The time interval of this mode can be = ( /) (8) _ C. Mode III (t 2-t 3) This mode starts when the voltage reaches ( + /) and the antiparallel diode of the auxiliary switch S a turns on. The energy stored in the magnetizing and resonant inductor starts to release and delivers to the output. The secondary diode D 1 or D 2 is turned on based on the polarity of the grid current. The clamp capacitor C clamp, resonant inductor L r and magnetizing inductor L m are resonant in this interval. The resonant current i Lr charge the clamp capacitor C clamp. The resonant current i Lr and the clamp voltage V clamp are expressed as () = ( ) cos( ) ( ) (9) () = ( )+ ( ) sin ( ) (10) where = ( ) ( + ) and = ( + ) Since the interval of this period is very small, i Lr and V clamp can be () ( ) ( ( ) ) (11) () This mode ends at time t=t 3 when the voltage of the clamp capacitor equals ( ) is + ( ) ( ) (12). The time interval of this mode = _ (13) D. Mode IV (t 3-t 4) At time t=t 3, the auxiliary switch S a is turned on. The secondary diode is remaining on and the energy stored in the magnetizing inductance is transferred to the grid through the secondary switch. To achieve ZVS, the auxiliary switch should be turned on before the resonant current changes its direction. The resonant current and magnetizing current is given as () = ( ) cos( ) ( ) ( ) (14) () = ( ) ( ) (15) where = ( ) ) and = This interval ends when the auxiliary switch S a is turned off. The time interval is = ( ( ) ( )) (16) E. Mode V (t 4-t 5) At the beginning of this interval, the auxiliary switch S a is turned off and the resonant current flows through the parasitic capacitance of the main switch S m. The negative resonant current i Lr discharges the resonant capacitor C r. The resonant capacitor voltage V Cr and resonant inductor current i Lr are () ( ) + ( ) ( )) (17) () ( ) ( )( ) ( ) (18) To ensure the ZVS turn on of the main switch S m, the resonant capacitor voltage V Cr should reach zero at the end of this stage. Therefore the energy stored in the resonant capacitor C r must be less than the energy stored in resonant inductor L r. The following condition must hold ( + ) _ (19) This interval ends when V Cr = 0. The output diode and switch are still turned on in this stage. The time interval of this stage can be = ( ) (20) ( ) F. Mode VI (t 5-t 0) At t=t 5, the resonant capacitor voltage V Cr=0 and the antiparallel diode of the main switch S m turns on. The magnetizing current flowing through the circuit is () = ( ) ( ) (21) The resonant inductor voltage V Lr and current i Lr can be = + (22) () = ( ) + / ( ) (23) To ensure the ZVS of S m, it should be turn on before the resonant current i Lr changes its direction. The interval of this mode can be = ( ( ) ( )) (24) ( ) III. SIMULATION RESULTS To verify the theoretical analysis of the proposed topology, a simulation study was carried out in MATLAB Simulink for a 250W flyback microinverter. The main components and parameters of the microinverter are summarized in Table I. In Fig. 3, the current and the drain-source voltage of the main switch of the proposed microinverter are presented. It is clearly shown that ZVS is achieved for the main switch of the flyback converter and the current starts to rise when the voltage across the switch is zero. Similarly the ZVS operation in the auxiliary switch is shown in Fig. 4. The output voltage and current of the microinverter are shown in Fig. 5. It can be observed that the output voltage and current are in phase. The THD of the output voltage is only 2.08%, shown in Fig. 6, which is within the limit (< 5%) provided by the grid authorities. 3

4 ZVS turn ON V gs,sm V grid 15*i grid 2* Time(ms) Fig. 3. ZVS operation in the main switch Time(s) Fig. 5. Output voltage and current of the microinverter V gs,sa ZVS turn ON 2* V ds,sa Time(ms) Fig. 4. ZVS operation in the auxiliary switch Fig. 6. THD of output voltage of the microinverter TABLE I. KEY PARAMETERS OF THE PROTOTYPE Parameters Symbol Value Rated Power P o 250W PV voltage V PV 35-45V DC Grid Voltage V grid 110V AC Switching frequency f sw 50kHz Decoupling Capacitor C dc 5mF Resonant inductance L r 2.4 μh Fig. 7. Laboratory setup IV. EXPERIMENTAL RESULTS A 250 W laboratory prototype, as shown in Fig. 7, is built to verify the validity of the proposed topology of the resonant microinverter. The key circuit parameters are as same as those used in the simulation as listed in Table I. SiC power MOSFETs are chosen in the high frequency primary side and MOSFET with low drain-source resistance is chosen for the secondary side switching. The ultrafast diodes are selected to reduce the diode switching losses. The dspace DS1104 R&D Controller Board was implemented to drive the switches of the microinverter. Resonant capacitance C r 1.60 nf Flyback Transformer Turn s ratio n (N p:n s) 1:2.5 No. of turns in primary N p 10 Magnetizing inductance L m 18μH Leakage inductance L k 0.4μH Air gap length l g 1.1mm Core type PQ40/40 4

5 ZVS turn ON V gs,sm Fig. 8. ZVS turn on of the primary switch (a) ZVS turn ON V gs,sa V ds,sa V ds,sa Fig. 9. ZVS turn on of the auxiliary switch The experimental waveforms present the soft-switching of the main switch and auxiliary switch of the resonant converter. In Fig. 8, the drain-source voltage and current flow of the main switch S m is presented with respect to the gate signal. It can be observed that the negative current flows due to the clamp circuit and the switch is turned on at zero voltage condition. Similarly, the ZVS turn on of the secondary switch is shown in Fig. 9. The switch is also turned off at low current value and hence lowering the turn off loss. The voltage and current stress of the main switch and the auxiliary switch through the line cycle is shown in Fig. 10. The stress on the switches varies with the change of amplitude of the grid current and is maximum at the peak value of the grid current. The output voltage and current of the proposed activeclamp microinverter is presented in Fig 11. The THD of the output current is measured by the power analyzer (Yokogawa WT1800) and found to be only 3.7%, as shown in Fig. 12, which is within the limit (< 5%) set by the international grid authorities. The experimental results confirm the validity of the proposed topology and its capability in achieving zero voltage switching and reducing voltage and current stresses. The efficiency of the proposed topology with respect to different loads is shown in Fig. 13. The efficiency of a single stage flyback microinverter using bidirectional switches in the secondary for ZVS is compared with the proposed activeclamp microinverter. It can be observed that the proposed topology shows the distinct improvement in terms of increasing the efficiency. The peak efficiency reaches up to 96.01% and high efficiency is achieved through 30% to 90% PV power condition. The European efficiency is found to be 94.87% and the California Energy Commission (CEC) efficiency is about 95.40%. (b) Fig. 10. Voltage and current stress of (a) main and (b) auxiliary switches throughout the grid cycle Vgrid io Fig. 11. Output voltage and current of the proposed active-clamp microinverter Fig. 12. THD of the output current Fig. 13. Efficiency curve 5

6 V. CONCLUSIONS In this paper, a new scheme to achieve ZVS in flyback type active-clamp microinverter for the PV ac module is proposed and verified by the theoretical analysis of steady-state, simulation, and experimental results. The active-clamp circuit achieves the soft switching by recycling the energy stored in the leakage inductance of the transformer and reduces the voltage stress by clamping the voltage spike across the primary switches. The circuit operation in resonant mode confirms the ZVS turn on of both main and clamp switch. Hence, the proposed microinverter shows much higher level of efficiency and reliability compared to the conventional flyback topology. A 250 W prototype of the proposed resonant microinverter has implemented in DCM operation to check the validity. The experimental results show a higher efficiency and lower voltage stress on the power devices of the proposed microinverter. Therefore, the proposed microinverter is fit with the single ac module PV application and can be made in the industrial field. REFERENCES [1] International Energy Agency (IEA), Technology Roadmap: Solar Photovoltaic Energy 2014 [Online]. Available: [2] S. B. Kjaer, J. K. Pedersen, and F. Blaabjerg, "A review of singlephase grid-connected inverters for photovoltaic modules," IEEE Trans Ind Appl, vol. 41, pp , [3] M. A. Rezaei, K.-J. Lee, and A. Q. Huang, "A High-Efficiency Flyback Micro-inverter With a New Adaptive Snubber for Photovoltaic Applications," IEEE Transactions on Power Electronics, vol. 31, pp , [4] W. J. Cha, Y. W. Cho, J. M. Kwon, and B. H. Kwon, "Highly Efficient Microinverter With Soft-Switching Step-Up Converter and Single-Switch-Modulation Inverter," IEEE Trans Ind Electron, vol. 62, pp , Jun [5] N. Sukesh, M. Pahlevaninezhad, and P. K. Jain, "Analysis and Implementation of a Single-Stage Flyback PV Microinverter With Soft Switching," IEEE Trans Ind Electron, vol. 61, pp , Apr [6] Y. Li and R. Oruganti, "A low cost flyback CCM inverter for AC module application," IEEE Trans Power Electron, vol. 27, pp , [7] T. Shimizu, K. Wada, and N. Nakamura, "Flyback-type singlephase utility interactive inverter with power pulsation decoupling on the DC input for an AC photovoltaic module system," IEEE Trans Power Electron, vol. 21, pp , Sep [8] H. B. Hu, S. Harb, X. Fang, D. H. Zhang, Q. Zhang, Z. J. Shen, et al., "A Three-port Flyback for PV Microinverter Applications With Power Pulsation Decoupling Capability," IEEE Trans Power Electron, vol. 27, pp , Sep [9] H. B. Hu, S. Harb, N. H. Kutkut, Z. J. Shen, and I. Batarseh, "A Single-Stage Microinverter Without Using Eletrolytic Capacitors," IEEE Trans Power Electron, vol. 28, pp , Jun [10] Z. L. Zhang, X. F. He, and Y. F. Liu, "An Optimal Control Method for Photovoltaic Grid-Tied-Interleaved Flyback Microinverters to Achieve High Efficiency in Wide Load Range," IEEE Trans Power Electron, vol. 28, pp , Nov [11] G. H. Tan, J. Z. Wang, and Y. C. Ji, "Soft-switching flyback inverter with enhanced power decoupling for photovoltaic applications," IET Electron Power Appl, vol. 1, pp , Mar [12] Y.-H. Kim, Y.-H. Ji, J.-G. Kim, Y.-C. Jung, and C.-Y. Won, "A new control strategy for improving weighted efficiency in photovoltaic AC module-type interleaved flyback inverters," IEEE Trans Power Electron, vol. 28, pp ,

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