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Published in IET Power Electronics Received on 4th August 2008 Revised on 12th November 2008 doi: 10.1049/iet-pel.2008.0253

ISSN 1755-4535

A DC DC multilevel boost converter

J.C. Rosas-Caro1 J.M. Ramirez1 F.Z. Peng2 A. Valderrabano1
Cinvestav Unidad Guadalajara, Av. Cientica 1145, Colonia El Bajio, Zapopan, Jalisco 45015, Mexico Michigan State University, East Lansing, MI, USA E-mail: [email protected]
2 1

Abstract: A DC DC converter topology is proposed. The DC DC multilevel boost converter (MBC) is a pulse-width modulation (PWM)-based DC DC converter, which combines the boost converter and the switched capacitor function to provide different output voltages and a self-balanced voltage using only one driven switch, one inductor, 2N 2 1 diodes and 2N 2 1 capacitors for an Nx MBC. It is proposed to be used as DC link in applications where several controlled voltage levels are required with self-balancing and unidirectional current ow, such as photovoltaic (PV) or fuel cell generation systems with multilevel inverters; each device blocks only one voltage level, achieving high-voltage converters with low-voltage devices. The major advantages of this topology are: a continuous input current, a large conversion ratio without extreme duty cycle and without transformer, which allow high switching frequency. It can be built in a modular way and more levels can be added without modifying the main circuit. The proposed converter is simulated and prototyped; experimental results prove the propositions principle.

Introduction

The transmission and distribution power systems have the natural trend to increase the voltage rating which increase the efciency, whereas microelectronics and digital systems have the natural trend to decrease the voltage rating to reduce size, increase the efciency and the speed of digital systems. Such scenario represents interesting challenges in buck-based power supply developments because of the extremely low-voltage gain; the conventional buck converter sacrice the switching frequency and the system size because of the extremely low duty cycle or the transformer requirement [1 3]. A good example of this is the computers power supply where a microprocessor needs to be fed with less than 3 V DC and the power supply is fed with 110 V/220 V AC. On the other hand, for the boost converter supplies analogue challenges are emerging. There are applications where high voltage and low current are needed such as TVCRTs, lasers, X-ray systems, ion pumps and electrostatic systems [4]. Likewise, applications in renewable energy generation systems where the low voltage of a photovoltaic (PV) panel or a fuel cell necessitates being boosted in order to feed a grid connected inverter that can push the power IET Power Electron., 2010, Vol. 3, Iss. 1, pp. 129 137 doi: 10.1049/iet-pel.2008.0253

into the grid. For telecom standard equipment for providing internet services, the 48 V of the DC battery plant has to be boosted to a 380-V intermediate DC bus [3]. The highintensity discharge (HID) lamps for automobile head lamps during their start-up require the voltage increment from the batterys 12 V to more than 100 V at 35 W [3]. A transformer with a large voltage gain is undesirable because it enhances the transformer non-idealities [4]. To reduce the DCDC converters size, the use of high switching frequency results in small inductors and capacitors with an equivalent current and voltage ripple [14]. This is the motivation to use several hundreds of kilohertz [1]. The natural switching delays in actual switches limit the switching frequency when the duty ratio is too small; a solution to this is the employment of transformers to reduce the voltage without using small duty ratios. However, the transformers losses limit the switching frequency also; along with the development of high-speed MOSFETs the switching frequency limitation becomes a transformers issue [14]. In the buck-type power supply, several topologies have been proposed to avoid the above-mentioned limitations [1 3], achieving extremely low-voltage gains without extremely low duty cycles. 129

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Figure 1 Conventional DC DC converters

a Buck followed by a push pull voltage multiplier b QBC c Switched capacitor converter with a boost stage

For the boost-type converters, there are several topologies for implementing a high-efciency transformer-less converter with high boost ratios (all of them with relatively high complexity, compared with the conventional single switch converter). For instance, (i) Fig. 1a illustrates a DC DC high-voltage converter with a buck converter followed by a push pull voltage multiplier. It may be extended to highvoltage applications with low-voltage devices by adding capacitors and diodes, without modifying the power stage. However, it requires two stages including three switches and a complex control system; the input current is discontinuous [4]. (ii) Fig. 1b shows the cascade boost, also named quadratic boost converter (QBC). It may be extended to attain a higher boost ratio using only one switch. The input current is continuous. However, the switch is rated to the total output voltage, which avoids the use of high voltage. It requires several inductors, which is the bulkiest part and it is hard to encapsulate. Furthermore, novel topologies have been recently proposed to overcome the mentioned challenge; for example, (iii) in [5] (see Fig. 1c), a converter is proposed based on the switched capacitor, which charge N capacitors to the input voltage, and connect them in series to feed a boost stage. The switched capacitor stage can operate with high efciency since it does not regulate the output voltage, which is regulated with the boost stage. However, it requires a high number of switches and the output switch is rated to the output voltage. All these topologies and others [1 3, 5] achieve high-voltage gain without an extremely high duty ratio and transformer-less, except (i), Fig. 1a, which uses a transformer. The use of the diode clamped multilevel converters (DCMLC) for renewable energy micro generation brings the promise to build compact converters made with small power MOSFETS, with a minimum ESR connected transformer-less to the utility grid. There exists the challenge to couple the low DC voltage from the renewable energy source to the high DC-link voltage of the multilevel converter. The DCMLC needs external balance of the DC link for proper operation [6]. The former topologies have limitations for this purposes: (i) For high-voltage applications, 130 & The Institution of Engineering and Technology 2009

they require high-voltage devices; this limitation leads to a novel solution in the DC AC conversion with multilevel inverters [7, 8], where high-voltage converters can be built with low-voltage rating devices, because of each device only blocks one voltage level. Multilevel converters have been studied in DC DC applications with the topologies: diode clamped, capacitor clamped and cascaded cells [9], and it has been shown that, excluding the diode clamped topology, they are suitable for such purposes. (ii) The second big limitation is that they cannot provide a voltage balancing for the DC link in the DCMLC; the use of an external balancing circuit is necessary [6]. The utilisation of combined boost converters with switched capacitors has been studied in [5, 10]. However, the output voltage is limited by the voltage rating devices. A topology that can be extended to high voltage is presented in [4]; the disadvantage is that the output voltage is negative with respect to the input. With the growing of distributed generation based on PV systems, and the advent of new sources of distributed generation DC based such as fuel cells, DCDC converters with high-voltage boost ratios are desirable to use those renewable sources in order to feed multilevel inverters and push the power into the utility for some hundreds of volts. This paper proposes a novel DC DC converter topology, initially introduced in [11]. The DC DC multilevel boost converter (MBC) is a converter that combines the boost converter and the switched capacitor function to provide an output of several capacitors in series with the same voltage and self-balanced voltage, which is important for some applications such as feeding a diode clamped multilevel inverter that cannot balance the voltage by itself. It can control the voltage by pulse-width modulation (PWM) in all the output levels with only one driven switch, one inductor, 2N 2 1 diodes and 2N 2 1 capacitors for an Nx MBC, The number of levels can be increased by adding capacitors and diodes, then it is possible to achieve modular implementations. IET Power Electron., 2010, Vol. 3, Iss. 1, pp. 129 137 doi: 10.1049/iet-pel.2008.0253

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It is proposed to be used as DC link in applications where several controlled voltage levels are wanted with selfbalancing and unidirectional current ow, such as PV or fuel cell generation systems with multilevel inverters. The major advantages of this topology are: (i) continuous input current and (ii) a large conversion ratio with low duty cycle and without a transformer. It can be built in a modular way and more levels can be added without changing the main circuit; it provides several self-balanced voltage levels and only one switch is necessary. The converters principle is proven by simulation and experimental results. The lowest part of the converter, Fig. 3, is the conventional DC DC boost converter. Thus, the voltage gain holds by the well-known boost converter equations. The difference between the MBC and the conventional one is that in the MBC, the output is Vc times N, where N 1 is the converters number of levels taking into account the zero level, Fig. 2. This behaviour is achieved, thanks to the voltage multiplier in the boost converters output that is driven by the only switch in the converter. During the switch-on state, the inductor is connected to Vin voltage, Fig. 3a. If C6s voltage is smaller than C7s voltage then C7 clamps C6s voltage through D6 and the switch S, Fig. 3b. Simultaneously, if the voltage across C4 C6 is smaller than the voltage across C5 C7 , then C5 and C7 clamp the voltage across C4 and C6 through D4 and S, Fig. 3c. In a similar way, C3 , C5 and C7 clamp the voltage across C2 , C4 and C6 , Fig. 3d. When the switch turns off, the inductor current closes D7 , and switches all diodes. During the switch-off state, the inductor current closes D7 charging C7 , Fig. 4a. When D7 closes, C6 and the voltage in Vin plus the inductors voltage clamp the voltage across C5 and C7 through D5 , Fig. 4b. Similarly, the voltage across the inductor plus Vin , C4 and C6 clamp the voltage across C3 , C5 and C7 through D3 . Finally, the voltage across C1 , C3 , C5 and C7 is clamped by C2 , C4 , C6 , Vin and the inductors voltage, Fig. 4c. It is noteworthy that D1 , D3 , D5 and D7 switch in a synchronously way, complemented with D2 , D4 , D6 and S, Figs. 3 and 4.

2 DCDC multilevel boost converter

Fig. 2 depicts the proposed topology. It is a Nx DC DC converter based on one driven switch, 2N 2 1 diodes and 2N 2 1 capacitors. One advantage of the topology is that the number of levels can be extended by only adding capacitors and diodes and the main circuit does not need to be modied.

3 Effect of the equivalent series resistance (ESR) (ResrL) on the boost ratio
Figure 2 DC DC MBC for Nx or N 1 levels Similarly to the conventional boost converter, and all converters with boost capability, the ideal maximum boost

Figure 3 Switch-on state IET Power Electron., 2010, Vol. 3, Iss. 1, pp. 129 137 doi: 10.1049/iet-pel.2008.0253 131

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Figure 4 Switch-off state ratio is innite. In actual applications, it is limited by the parasitic resistance in the passive components; in the boost converter case the main limitation is given by the ESR in the input inductor. This effect is caused by the fact that the input current is the output current times the boost ratio. It is important to emphasise that the use of high switching frequency allows using a smaller input inductance with a smaller ESR. This limitation, which appears in all converters with an input inductor, is also reduced in a converter designed to work with a high switching frequency. As aforesaid, the rst level is a usual boost converter which equations and behaviour are well known, but the total output voltage is N times VC . Equations (1) and (2) express the boost ratio and the inductor current in the boost converter, Fig. 2 VC 1 Vin 1 D IL VC (1 D)RO (1) (2) From (4) it can be noticed that the input current can be controlled with D in the PWM, which is important in some applications such as renewable energy-based distributed generation systems, where is highly desirable to track the maximum power point by controlling the input current. The following expressions can be derived from the rst level: (1) and (2) just like the conventional boost converter. Taking into account the relationship between the capacitors voltage against the output voltage and (4), (5) can be derived by the following procedure in which the inductors power losses are considered. The average voltage in the inductor VL is zero at steady state, and is equal to the voltage in both switching states times the time that each switching state holds. In the continuous mode, including the inductors ESR (ResrL) VL D(Vin IL ResrL ) (1 D)(Vin VC IL ResrL ) 0 DVin DIL ResrL (1 D)Vin (1 D)VC (1 D)IL ResrL 0 Vin (D 1 D) IL ResrL ( D 1 D) (1 D)VC Vin (1 D)VC IL ResrL Vin (1 D) Vout NVout R N (1 D)RO esrL (5) (3) From (5), the boost ratio for the novel topology may be expressed as (6) Vin 1 Vout ((1 D)=N ) (NResrL =(1 D)RO ) (6)

being RO the load resistance, considering the ideal 1x or conventional boost converter. Thus, the new voltage gain can be expressed by VC 1 Vin 1 D then Vout N Vin 1D

The input DC current can be expressed in terms of the output current and input output voltage by Vin IL Vout Iout V NVC N Vout out NVC RO RO RO
2 2 VC

V N 2 VC N 2 VC IL C Vin RO (1 D)RO 132 & The Institution of Engineering and Technology 2009

(4)

It is noteworthy that (6) is actually a general expression that includes the conventional boost converter if N 1. In the ideal model, when ResrL 0 the innite boost ratio results. IET Power Electron., 2010, Vol. 3, Iss. 1, pp. 129 137 doi: 10.1049/iet-pel.2008.0253

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Figure 5 Voltage gain against duty cycle for different values of ESR/RO in the novel MBC (N 4) Fig. 5 exhibits the case when N 4 for different cases of ResrL/RO . The boost ratio is plotted against the duty cycle. It can be noticed that the graphic shows a quasi-linear region larger than the traditional boost converter, which becomes highly non-linear when the duty cycle is near 1. Thus, the MBC can operate in the high boost ratio region, this region is around D 0.5 which is the best point to operate the multilevel strategy. Likewise, the maximum boost ratio is farther than D 1, which is an operative point difcult to implement with nonideal switches. that the actual voltage across C6 becomes VC 6 VC 7 Vswitch VDiode VC 6 VC 7 2Vd Observe that VC 5 VC 7 4Vd (8)

(7)

4 Switches and diodes voltage drop

In actual implementations the switches and diodes voltage drop must be taken into account since it avoids capacitors to be charged to VC (the voltage in the lower capacitor); this effect is studied in the present section. The voltage drop in conventional IGBTs and power diodes can be around 2 V (in low power is much smaller), and it can be ignored in medium- and high-voltage applications with several hundred volts, but in low-voltage applications must be considered. For simplicity, the voltage drop in switches and diodes is assumed to be equal to Vd . From the circuit in Figs. 3 and 4, in Fig. 6 can be noticed

It is worth noting that the current charging C5 does not go across D7 , it actually goes across the input inductor and the input voltage source, but D7 is closed during D5 is closed as it is above mentioned, then the voltage across C5 can be expressed as (8). In Fig. 7, it can be seen that the voltage across C7 and C5 clamps the voltage across C6 and C4 with two diodes voltage drop. The voltage drop in the voltage multiplier does not depend on the level after the second level, and all capacitors after the second level are charged to VC7 2 4Vd .

Figure 6 Charging C6 with diodes and switchs voltage drop IET Power Electron., 2010, Vol. 3, Iss. 1, pp. 129 137 doi: 10.1049/iet-pel.2008.0253

Figure 7 Charging C4 with diodes and switchs voltage drop 133

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The expression of the output voltage for the circuit in Figs. 3 and 4 can be obtained as (4x converter) Vout 4VC 7 12Vd (9) current in semiconductors is higher in the lower levels. This is a disadvantage for many of the DC DC multilevel converters. For instance, if a capacitor clamped multilevel converter is used as a DC DC converter the lower device would dissipate more power than the higher one. By utilising the medium source variation, this disadvantage can be reduced. Fig. 8 displays the topology variation with the input source voltage at the medium position. Similarly to Fig. 2, the topology can be easily extended to any number of levels by adding diodes and capacitors. It is noteworthy that the multilevel operation holds and the capacitors voltage are balanced, regardless on the load and conguration, non-medium, or a medium source. Thus, the DC DC MBC is an important alternative to feed multilevel inverters.

Finally, the output voltage general expression in an Nx MBC is (10). This one must be considered to design a multilevel voltage multiplier Vout NVC (N 1)4Vd (10)

where VC is the voltage of the lower capacitor, and follows the traditional boost converter equation. The efciency of the switched capacitor multiplier stage is given by (11) as in all step-up switched capacitor converters [12]

Vout NVC (N 1)4Vd (N 1)4Vd 1 (11) NVC NVC NVC

From (11) it can be seen that the converter is ideal for application with several hundred volts where Vd is negligible compared with VC; the power losses in the switch can be calculated as in the traditional boost converter. It is important to notice that the switching losses are proportional to the voltage that the switch has to block which is reduced in this topology compared with other solutions.

Design and discussion

Central source

A variation of the proposed topology is discussed in this section. As a natural extension of the voltage multiplier the negative part of the output voltage can be added and then the converter shown in Fig. 8 can be realised. One of the disadvantages of the proposed topology, Fig. 2, is that the

The output voltage will have a small ripple which can be minimised to a desired value by selecting correct values for the capacitors, a design analysis is done with a 2x MBC, Figs. 9a and 9b show the possible switching states, Fig. 9c shows a zoom in the voltage ripple of the capacitors V1 is the voltage across c1 and so on, the duty cycle is 0.5, starting the analysis when the switch is open c2 just transferred energy to c3 , and c1 has been charging during the last half a cycle, c1 has a higher voltage than c2 , right after the switch closes c1 charges c2 through d2 and they get the same voltage expressed as V1ac V2ac V1bc c1 V2bc c2 c1 c2 (12)

Where V1ac is V1 after closing the switch, V1bc is V1 before closing the switch and so on. After this happen c2 does not transfer energy to the load and its voltage keeps constant during all the next half a cycle, c1 and c3 get a voltage drop because the are feeding the load, this voltage drop is Dv1 in Fig. 9c and can be expressed as (assuming all capacitors have the same capacitance) Dv1 Dv12 1 1 I D I D c1 out t 1 c2 out t 1 (13)

During Dt1 , c1 and c3 in series feed the load, and c2 just store charge to be transferred to c3 during Dt3 , the time when the switch is open D t2 can be divided into two, Dt3 and Dt4 , right after the switch opens c2 has a voltage higher than c3 and c2 discharges whereas c3 charges until they get the same voltage, the voltage drop in c2 can be expressed as Dv4 1 I D c2 L t 3 (14)

Figure 8 Topology variation with medium source 134 & The Institution of Engineering and Technology 2009

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Figure 9 2x MBC
a Switch-on state b Switch-off state c Voltage ripple in capacitors

And the ripple Dv2 in c3 can be expressed as Dv4 1 (I Iout )Dt 3 c2 L (15)

Table 1 summarises a comparison between the proposed topology (x 2), the QBC (Fig. 1c), and the switched capacitor with the boost stage (SCBS) for n 2 (Fig. 1b). Table 1 offers a general idea about the topological comparison, although each converter presents advantages for specic applications. Some comments about individual characteristics are as follows. The SCBS has the advantage that the switched capacitor stage only multiplies the voltage that is regulated by the boost stage, which makes possible for the switched capacitor stage to operate in high efciency but it is the more complex in terms of number of components and control. It has two control variables (x and D). Additionally, it has the highest voltage gain when D and x 0.5, which is the optimum point for working at high frequency. One more advantage is that, similarly to all switched capacitor converters, the switched capacitor stage can be encapsulated in an IC creating a small design. The QBC is the least complex in terms of number of components, but it needs at least two inductors that are the bulkiest components. The gain is highly non-linear, which makes the controller design an important challenge. The 2x MBC has the lower voltage gain, but it also has the lower voltage stress in the switches and the voltage stress does not increase when more levels are added for increasing the voltage gain. A major advantage of the converter arises when feeding a DCMLC. It automatically balances the multilevel DC link. A disadvantage of such topology is that

After that, both capacitors in parallel fed the load in series with c1; it is important to note that during Dt2 c1 keeps charging with IL 2 Iout , this is clear considering the KCL in the reference node. Finally the voltage drop Dv3 in c2 and c3 can be expressed as     1 Iout 1 Iout Dt 4 Dt 4 c2 2 c3 2

Dv3

(16)

And Dv5 can be expressed as Dv5 1 1 (IL Iout )Dt 2 (IL Iout )(Dt 3 Dt 4 ) c1 c1 (17)

The output voltage is V1 plus V3 then the ripple in the output voltage can be expressed as the ripple in c1 plus the ripple in c3 , by using (12) (17) the capacitors and switching frequency can be selected to t the application and the input inductor can be calculated as in the traditional boost converter to t the desired input ripple current with the rst level voltage. This analysis can be extended to more levels. Table 1 Comparison of topologies

Converter Inductors Capacitors Switches Diodes SCBS QBC 2x MBC 1 2 1 3 2 3 4 1 1 5 3 3

Voltage gain (3 2 2xD)/(1 2 D) 1/(1 2 D)

2

Switch stress Vout Vout Vout/2

2/(1 2 D)

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the capacitors are used to transfer the energy in the voltage multiplier while feeding the load according to (12) (17). This emphasises the traditional tradeoff between the output voltage ripple and the size in the capacitor selection. Again, for feeding a DCMLC the inverter control can alleviate this fact by utilising the feed-forward control, which allows having an AC output voltage free of distortion coming from the voltage ripple in the DC link.

Experimental results
Figure 12 Actual signals from the prototype
a Switch voltage b Lower capacitor voltage c Input voltage

A low-power prototype is built to experimentally show the operating principle of this novel converter. A Freescale 8bit microcontroller is employed to provide the PWM signal in an open-loop structure with a switching frequency of 100 kHz, the duty cycle is 0.5 (measured in the IGBT terminals), the input voltage is 50V and then the output voltage is 300 V. Fig. 10 displays the prototype schematic of a 3x (four levels) MBC. Fig. 11 exhibits the test bench. The switch is the IGBT-12N60A4D and the fast recovery diodes are BY229X-800. The inductor has a value of 1.33 mH, and all capacitors are 100 mF 250 V (aluminium electrolytic) in parallel with 2 mF 250 V (polyester). The inductor is added externally to the PBC prototype. Several tests are carried out with resistive load. Figs. 12 depict the resultant waveforms. The results are within the expectations, with waveforms and values close to those

Figure 13 Efciency against output power estimated by equations and Fig. 13 shows the measured efciency against output power.

Conclusions

Figure 10 Prototype schematic: L 1.33 mH, C 100 mF

This paper proposes a DC DC converter topology. The DC DC MBC is based on only one driven switch, one inductor, 2N 2 1 diodes and 2 N 2 1 capacitors for an Nx MBC. It is proposed to be used as DC link in applications where several controlled voltage levels are needed with selfbalancing and unidirectional current ow, such as PV or fuel cell generation systems with multilevel inverters. The main advantages of this topology are: A continuous input current. A big conversion ratio without extreme duty cycle. Transformer-less. Allow high switching frequency. It can be built in a modular way and more levels can be added without changing the main circuit. IET Power Electron., 2010, Vol. 3, Iss. 1, pp. 129 137 doi: 10.1049/iet-pel.2008.0253

Figure 11 3x MBC prototype 136 & The Institution of Engineering and Technology 2009

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It provides several self-balanced voltage levels and only one driven switch, which make it ideal for feeding a diode clamped multilevel inverter. The proposed circuit is based on the multilevel converters principle, where each device blocks only one voltage level achieving high-voltage converters with low-voltage devices. The proposed converter is simulated and prototyped; experimental results prove the propositions principle. Future work will be done in the use of the MBC for balancing the DC link in the diode clamped multilevel inverter, especially for distributed generation applications based on multilevel converters. [5] ABUTBUL O., GHERLITZ A., BERKOVICH Y., IOINOVICI A.: Step-up switching-mode converter with high voltage gain using a switched-capacitor circuit, IEEE Trans. Circuits Syst. I: Fundam. Theory Appl., 2003, 50, (8), pp. 1098 1102 [6] YONETANI S. , KONDO Y., AKAGI H., FUJITA H.: A 6.6-kV transformerless STATCOM based on a ve-level diodeclamped PWM converter: system design and experimentation of a 200-V 10-kVA laboratory model, IEEE Trans. Ind. Appl., 44, (2), pp. 672 680 [7] RODRIGUEZ J., LAI J.-S., PENG F.Z. : Multilevel inverters: a survey of topologies, controls, and applications, IEEE Trans. Ind. Electron., 2002, 49, (4), pp. 724 738 [8] LAI J.-S., PENG F.Z.: Multilevel converters a new breed of power converters, IEEE Trans. Ind. Appl., 1996, 32, (3), pp. 509 517 [9] FAN Z., PENG F.Z., ZHAOMING Q.: Study of the multilevel converters in DC DC applications. IEEE 35th Annual Power Electronics Specialists Conf., PESC 04, 2004, vol. 2, pp. 1702 1706 [10] AXELROD B., BERKOVICH Y., IOINOVICI A.: A cascade boostswitched-capacitor-converter two level inverter with an optimized multilevel output waveform, IEEE Trans. Circuits Syst. I, 2005, 52, (12), pp. 2763 2770
REZ J.M., PEDRO M.G.-V. : Novel DC DC [11] JULIO C.R.-C., RAMI multilevel boost converter. Proc. IEEE Power Electronics Specialists Conf., 2008

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[12] IOINOVICI A. : Switched-capacitor power electronics circuits, IEEE Circuits Syst. Mag., 2001, 1, (3), pp. 37 42

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