Analysis of Multi-Phase
Analysis of Multi-Phase
Analysis of Multi-Phase
Differently from other multi-phase solutions, that are be introduced, highlighting the benefit in terms of output
greatly susceptible to resonant component mismatch and filter current ripple reduction. The effect of resonant
consequently can be affected by a considerable current component mismatch will also be explored and a suitable star
imbalance among modules, the proposed topology connection solution will be investigated to overcome current
exhibits an inherent balancing capability. Small-signal derating limits by means of intrinsic balancing. Section IV X X
analysis is presented and the possibility to turn-off one or will investigate the feasibility of phase-shedding for the three
two modules (phase shedding) at reduced output current phase LLC resonant converter with star connection exploring
levels is discussed, highlighting the trade-off between the benefits in terms of converter efficiency, effects on
converter efficiency and output capacitor current ripple current ripple reduction and switching frequency design.
reduction. Measurements on a prototype will be included Measurements on a prototype will be included in the paper as
in the paper as validation of assertions and proposals. validation of assertions and proposals.
Keywords – LLC resonant converter, multi-phase II. LLC RESONANT CONVERTER PROTOTYPE
2B
interleaved converters.
In this section the prototype of LLC resonant converter,
I. INTRODUCTION
1B
with half-bridge topology, will be briefly introduced. The
design of the power section of such converter is not the aim
Resonant converters have been confined in the last thirty of the paper and more details can be found in literature [2,6-
years to niche applications such as very high-voltage 8]. The basic scheme of the prototype is depicted in Figure 1
X X
applications or high fidelity audio systems while much effort and specifications listed in Table 1. As can be seen from the
X X
was spent in research by industries and universities because specifications, the LLC converter is intended to operate in
of its attractive features: smooth waveforms, high efficiency conjunction with a boost PFC stage that regulates the
and high power density. In recent times the LLC resonant resonant converter input voltage at 400V nominal. The
converter [1,2], in particular in its half-bridge isolation transformer uses the magnetic integration approach,
implementation, has been widely and successfully applied to incorporating the resonant series (LR) and shunt (LM)
flat panel TV, 80+ ATX and small form factor PC, where the inductances. Thus, no additional external coils are needed for
requirements on efficiency, power density and EMC the resonance inductance. The transformer configuration
compliance of their switching mode power supplies (SMPS) chosen for the secondary windings is center-tap, and the
are getting more and more stringent. However future SMPS output rectifiers are Schottky type diodes, in order to limit
requirements will have to face one of the few remaining power losses. The output capacitor size is chosen quite large
drawbacks of LLC resonant converter topology that is related to conveniently reduce the output voltage ripple. The
to the output filter capacitors volume that represents the rectified “sine wave” output current presents indeed a large
major limit for such applications. The injection of rectified peak to peak ripple. Three identical modules were
sine wave currents into the output filter capacitor can be manufactured to fulfill the research purposes of this paper.
adequately mitigated by the parallel use of multiple modules
such as in interleaved buck solutions for voltage regulator III. INTERLEAVED THREE PHASE LLC RESONANT
3B
modules. This topology has been presented in [3,4] for two CONVERTER
modules operating with 90 degrees phase shift. One of the
drawbacks of this solution is represented by the inherent LLC resonant converters exhibit a large voltage ripple on
current unbalance caused by resonant component mismatch output filter capacitor because of the rectified sine-wave
that may cause one of the two modules to reduce its output current injected through the transformer secondary windings.
power down to zero, thus requiring mandatory workarounds In order to reduce the capacitor size and/or the steady-state
to overcome the problem [5]. output voltage ripple, the interleaved approach can be
M DN COUT
same frequency but with 120 degrees phase-shift of their CR
LM
driving signals. D2
TABLE 2
Average currents supplied by each module at different operating conditions (CR3 = CR + 2.7 nF).
SIMPLE PARALLEL CONNECTION STAR CONNECTION
(Figure 2) (Figure 3)
VIN =320 V VIN =320 V VIN =400 V VIN =400 V VIN =320 V VIN =320 V VIN =400 V VIN =400 V
IOUT = 6 A IOUT = 8 A IOUT = 6 A IOUT = 8 A IOUT = 6 A IOUT = 8 A IOUT = 6 A IOUT = 8 A
IOUT-1 [A] 4.2 5.2 4.1 5.2 2.1 2.8 2.1 2.8
IOUT-2 [A] 1.8 2.8 1.7 2.6 2.0 2.7 2.0 2.6
IOUT-3 [A] 0 0 0.2 0.2 1.9 2.5 1.9 2.6
4
2 MODULES MUP2 LR2 N1:N2,N2
2
3 MODULES
MDN2 LM2
CR2
0
0 2 4 6 8 10 12 14 16 18
OUTPUT CURRENT [A]
MUP3 LR3 N1:N2,N2
Fig. 3. Simulated peak to peak current injected on output filter
capacitor as a function of output current: one module, two modules MDN3 LM3
with 90° phase-shift and three modules with 120° phase shift. CR3
(@ VIN = 400V)
Module 1 Module 3
MAGNITUDE
analytical Bode Diagram derived using the generalized state- -100
ANALYTICAL
[dB]
APPROACH
space averaging method. Figure 6 depicts this comparison,
for a 400 V input voltage, 6 A output current condition, -120
PHASE
switching frequency and the output voltage.
[deg]
-100
Using the same simulation approach, the three-phase LLC
-150
converter with star connection transfer function was obtained
for different operating points. It is interesting to notice that -200
100 1k 10k
such transfer functions look pretty similar to the ones for a FREQUENCY [Hz]
(star connection)
[deg]
-100
implemented through a DSP by Texas Instruments. Figure 8
depicts the small-signal transfer function Bode diagrams of -150
T(s)
X
-45
from 18 A to 0.2 A. The system exhibits a small over-shoot
-90
and a reasonable step response time. The recovery-time is -135
however really long being the system after load-step at very -180
low current absorption. 100 1k FREQUENCY (Hz) 10k 100k
S LR1
S
LM1
CR1
OUTPUT
CURRENT
CR2
LM2
Fig. 10. Measurement on three modules with star connection for a S
load step from 18 A to 0.2 A. Ch1: converter output voltage (50
mV/div); Ch4: output current (10 A/div); time scale: 200 µs/div. S LR2
for phase-shedding.
Using the phase-shedding solution discussed above, a set of The first drawback of phase-shedding is related to the
efficiency measurements was performed on the 3-phase LLC output current ripple applied to the capacitive filter. While
prototype with star connection. The results of such analyses the interleaved solution allows to greatly reduce the output
are depicted in Figure 13. The measurements are initially X X current ripple, both the full-bridge “two-phase” and half-
performed on the three-phase LLC with all modules active. bridge “one-phase” solutions exhibit a large output current
The output current is varied from 18 A (full load) to 1.8 A ripple because a rectified sine wave current is applied to the
(10 % of the maximum power). A second series of the capacitive filter. While for low output current this is not
measurements is then performed in the full-bridge “two- really a problem because also the peak to peak ripple
phase” solution varying the output current from 12 A, that decrease, for medium currents a trade-off between efficiency
represents the maximum output power for two modules, to improvement and output current ripple is mandatory. Figure
1.2 A. It can be noticed that at 45 % of the maximum power 14 shows the comparison of the total peak to peak current
(respect to the three-phase LLC converter) the two-phase ripple injected into the output filter capacitor in the three
solution equals the efficiency of the three-phase topology, phase-shedding conditions. It is evident that the benefits of
suggesting the better condition to activate phase-shedding. the interleaved topology are lost when shutting-down one or
Finally, the third efficiency measurements are performed on two phases, with a large increase of total ripple. In the case
the “one-phase” solution for output current from 6 A to 0.6A. of a phase-shedding implementation that maximize the
Also in this case an optimal condition can be found to switch converter efficiency, the output filter capacitor must be sized
from “two-phase” to “one-phase” (25 % of the maximum in the worst peak to peak ripple condition. In the case under
power). test, COUT must be designed to adequately filter 15 A peak to
The implementation of phase-shedding allows to improve peak (maximum ripple current if “one-phase” condition is
the converter efficiency over a wide output current range. turned-on at 25 % output power level and “two-phase”
However, the necessary topology and modulation strategy topology is activated at 45 % output power level).
modifications, compared to the initial three-phase interleaved
solution, have two major drawbacks, that are analyzed
hereafter.
C. Effect on Switching Frequency
10B
95
The second drawback introduced by phase-shedding and
94
3 MODULES topology modifications is related to the switching frequency
1 MODULE
range.
CONVERTER EFFICIENCY [%]
2 MODULES
93 In order to correctly investigate such effect, let’s initially
introduce the power-supply voltage conversion ratio for a
92
classical LLC resonant converter based on a unique module,
91
as the one depicted in Figure 1 [6]. This converter can be
conveniently described using the First Harmonic
90 Approximation (FHA) technique which enables the analysis
of resonant converters by means of classical complex ac
89
10 20 30 40 50 60 70 80 90 100
circuit analysis. Figure 15 depicts the FHA equivalent circuit
NORMALIZED OUTPUT POWER [%] of the single module LLC converter focusing, in particular,
to the ac resonant tank.
Fig. 13. Measured efficiency curves (@ VIN = 400 V) as a function The resonant devices are expressed as:
of the normalized output power (100% for IOUT = 18 A): interleaved
C R* = C R L*R = LR L*M = LM , (2)
three-phase; “two-phase” full bridge and “one phase”.
while the ac-equivalent load resistance in the FHA circuit
can be evaluated as:
*8 VOUT .
25 R EQ = (3)
π 2 I OUT
20 Finally, the FHA RMS values of input and output voltages
PEAK TO PEAK RIPPLE [A]
"ONE-PHASE"
for the ac resonant tank can be generally expressed as:
OPUTPUT CURRENT
2 MODULES
15 "FULL-BRIDGE" 2 2
VO− FHA = VOUT (4)
π
10
⎧ 2
⎪⎪ VIN − HB −
5
3 MODULES VIN −FHA =⎨ π (5)
⎪2 2 V − FB −
⎩⎪ π
IN
0
0 2 4 6 8 10 12 14 16 18
In particular, it must be noticed the doubled RMS input
OUTPUT CURRENT [A]
voltage applied to the resonant tank by means of the full-
bridge switching topology (exploited in the “two-phase”
Fig. 14. Simulated peak to peak current injected on output filter
capacitor as a function of output current (@ VIN = 400V ):
solution for phase-shedding).
interleaved three-phase; “two-phase” full bridge and “one-phase”.
n:1
FB In this paper a three-phase interleaved LLC resonant
+ + converter topology is described and analyzed. The proposed
VIN-FHA LM* VO-FHA *
REQ topology is made by three half-bridge LLC converters with
HB - - transformer primary windings star connection. This solution
allows to drastically reduce the output current ripple
compared to a single module, and exhibits an intrinsic
Fig. 15. First Harmonic Approximation circuit for a single module. balancing capability that is not common to other resonant
interleaved solutions. Small-signal analysis of the proposed
converter has been performed and a suitable digital control
CR1 LR1 implemented. The possibility of turning off one or two
n:1 phases depending on the overall output current level, is
+ investigated, and the trade off between converter efficiency
LM1 REQ VO-FHA
+ and output capacitor current ripple is discussed.
-
Experimental results have confirmed the theoretical
VIN-FHA expectations.
n:1
-
LM2 REFERENCES
CR2 LR2
6B
LLC-3
M @ NO-LOAD
0.09 LLC-2
M
LLC-3
@I
MAX “Paralleling of LLC resonant converter using frequency
M @ 2/3 ⋅ I
0.08 LLC-2 MAX M
MAX
=V
OUT
/V
IN-MIN controlled current balancing”, IEEE PESC 2008, June
M = VOUT / VIN