High-Step-Up and High-Efficiency Fuel-Cell Power-Generation System With Active-Clamp Flyback-Forward Converter
High-Step-Up and High-Efficiency Fuel-Cell Power-Generation System With Active-Clamp Flyback-Forward Converter
High-Step-Up and High-Efficiency Fuel-Cell Power-Generation System With Active-Clamp Flyback-Forward Converter
_
t
16
_
t
0
i
L1a
(t)
2
dt
T
s
= 33 A. (14)
As a result, the Koolmu magnetic core 0077109A7 from
Magnetics is selected for the coupled inductors. The primary
winding has 15 turns, and the secondary winding has 90 turns.
The measured magnetizing inductance is 35.4 H. The leakage
inductance reected to the primary side is about 0.39 H.
B. Selection of Power Devices
From the steady-state operation, it can be derived that the
voltage stresses of the primary power devices are equivalent to
the voltage on the clamp capacitor, which are given by
V
ds_M
= V
ds_C
= V
Cc
=
V
in
1 D
V
out
2 N
= 32 V. (15)
LI et al.: FUEL-CELL POWER-GENERATION SYSTEM WITH ACTIVE-CLAMP FLYBACKFORWARD CONVERTER 605
The rms current of the main and clamp switches can be
derived step by step according to a similar procedure to that
of the primary winding rms current analysis. They are de-
rived by
I
S_RMS
=
_
t
9
_
t
0
i
L1a
(t)
2
dt +
t
16
_
t
15
i
L1a
(t)
2
dt
T
s
32 A (16)
I
Sc_RMS
=
_
t
5
_
t
2
i
Cc1
(t)
2
dt
Ts
=
_
t
5
_
t
2
[I
Lm1
i
Lk
(t)]
2
dt
T
s
7.4 A. (17)
Therefore, two pieces of FDP047AN (75 V, 4 m at 80 A)
in parallel are employed as the main switches to reduce the
conduction losses. One piece of FDP047AN is adopted as the
clamp switch.
The voltage stress of the output diode is the output volt-
age. Moreover, the peak current of the output diode can be
obtained by
I
D_Peak
=
N V
Cc1
V
out
/2
L
Lk
(1 D)T
s
5.2 A. (18)
As a result, MUR1560 is used as the output diodes.
C. Selection of Clamp Capacitors
One of the design considerations for the clamp capacitor is
to guarantee that the maximum voltage on the power devices
is lower than its rated voltage once the converter is under
OC operation. Under this situation, both the main and the
clamp switches should be turned off. In addition, the energy
stored in the magnetizing inductor transfers to the corre-
sponding clamp capacitor. The energy balance relationship is
given by
1
2
L
Lm
I
2
Lm
=
1
2
C
c
_
V
2
Cc max
V
2
Cc
_
. (19)
Three 4.7-F capacitors in parallel are employed as clamp
capacitors.
D. Design of Inverter
For the full-bridge inverter, MUR460 (500 V, 0.27 at
20 A) is selected as the full-bridge switch. The low-pass lter
can eliminate the high-order harmonics and provide low-total-
harmonic-distortion (THD) voltage to the load. A large inverter
lter inductor can suppress the harmonics effectively. However,
the inductor with a high value may increase the magnetic core
size and the copper losses. One of the industrial design criteria
for the inverter lter inductor is to make its maximum current
ripple lower than about 25% output ac current. As a result,
5.5 mH is selected for the lter inductor in the simulation
results. Once the lter inductor is determined, the lter capac-
itor can be selected by the cutoff frequency of the low-pass
lter. For the lter capacitor to make its cutoff frequency about
1 kHz, 4.7 F is selected, which is a compromise between the
harmonics reduction and the inverter dynamic performance.
VI. EXPERIMENTAL RESULTS
In order to verify the effectiveness of the proposed system,
a 500-W prototype is built and tested with the specications
shown in Table IV and the component selections discussed in
Section V. The experimental results of the proposed converter
are shown in Fig. 6 under 500-W full-load condition with
V
in
= 12 V.
The ZVS soft-switching performance of the main and clamp
switches is shown in Fig. 6(a) and (b). ZVS turn-on and turnoff
operations are achieved for both the main and clamp switches,
which reduce the switching losses greatly. The voltage and
current waveforms on the clamp capacitors C
c1
and C
c2
are
shown in Fig. 6(c). The voltage ripple on the clamp capacitors
is small, which can suppress the turnoff voltage spikes on the
main switches. The input current i
in
and the current through
the primary inductors i
L1a
and i
L2a
are shown in Fig. 6(d).
The input current is the current summation of the two primary
inductors. Although the current ripple on the primary inductors
is large, the input-current ripple is very small due to the current-
ripple cancelation caused by the interleaved operation. The
voltage waveforms on the output diodes D
o1
and D
o2
are
shown in Fig. 6(e). The voltage stress of the output diode is
equivalent to the converter output voltage. The detailed turnoff
current waveforms of the output diode D
o1
are shown in
Fig. 6(f). The diode reverse-recovery current of the proposed
converter is small because its turnoff current is controlled by
the leakage inductance of the coupled inductors.
The experimental results of the inverter are shown in Fig. 7.
The input voltage V
in
, the input current I
in
of the proposed
converter, the ac output voltage v
ac
, and the ac output
current i
ac
of the inverter at 500-W resistor load are shown in
Fig. 7(a). The measured rms ac output voltage is 221 V. The
THD of the ac output voltage is below 1.5% by employing
the proper inverter control strategy. The low-frequency input-
current ripple is suppressed to about 5 A by employing the
solution introduced in [13], which benets the fuel cells. In fact,
the low-frequency input-current ripple can be further reduced
by adopting some other control strategies [25][29]. The exper-
imental waveforms at 180-W rectiercapacitordiode (RCD)
load are shown in Fig. 7(b). There is some distortion on the
ac voltage due to the high crest factor of the RCD load. In
order to verify the dynamic response of the proposed system,
the experimental results of the ac voltage v
ac
and ac current i
ac
are shown in Fig. 7(c) from 50- to 500-W resistor load. It can be
seen that the dynamic response of the proposed system is fast
to satisfy the load requirements.
The measured efciency of the proposed ZVS yback
forward converter at different input voltages and power levels is
shown in Fig. 8. When the converter operates with V
in
= 12 V,
the maximum efciency is nearly 97% and the efciency at
500-W full load is about 93%. When the input voltage increases
to 16 V, the efciency at 500-W load is over 95%. A high
efciency can be achieved during a wide load range.
606 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 59, NO. 1, JANUARY 2012
Fig. 6. Experimental results of proposed ZVS ybackforward converter: (a) ZVS operation of main switch S
1
. (b) ZVS operation of clamp switch S
c1
.
(c) Voltage and current waveforms on clamp capacitors C
c1
and C
c2
. (d) Current waveforms of primary side. (e) Voltage waveforms on output diodes D
o1
and
D
o2
. (f) Detailed turnoff current across output diode D
o1
.
In order to further show the advantages of the proposed
converter, another 1-kW prototype is built and tested with the
following parameters:
V
in
: 4056 V; V
out
: 380 V; P
out
: 1 kW;
f
s
: 100 kHz; n
2
/n
1
: 21/13;
L
m
: 48 H; L
Lk_primary
: 0.9 H; C
c1
, C
c2
: 4.7 F;
C
s1
, C
s2
: 3 nF;
S
1
, S
2
: IRFP4227PbF; S
c1
, S
c2
: IRFP4227PbF;
D
o1
, D
o2
: MUR1560; C
o1
, C
o2
: 470 F.
The advanced magnetic integration technology can be em-
ployed here to further improve the circuit power density [22]
[24]. The concept for the magnetic integration is shown in
Fig. 9. A three-leg magnetic core with air gaps in the two outer
legs is adopted here to integrate the two coupled inductors. The
coupled inductor L
1
is wound around one outer leg, and the
coupled inductor L
2
is wound around another outer leg.
The two coupled inductors are decoupled magnetically due to
the short magnetic reluctance of the center leg without air gap.
An EE55 core is adopted to integrate the two coupled inductors
to implement the designed 1-kW prototype.
Fig. 10 shows the experimental results with 40-V input at
1-kW full load. ZVS soft-switching performances of the main
and clamp switches are shown in Fig. 10(a) and (b). The
primary current is introduced in Fig. 10(c) to show the input-
current distribution and current-ripple reduction due to the
interleaved operation. The voltage and current waveforms of the
secondary output diodes are illustrated in Fig. 10(d) to show
the output-diode reverse-recovery-problem alleviation.
LI et al.: FUEL-CELL POWER-GENERATION SYSTEM WITH ACTIVE-CLAMP FLYBACKFORWARD CONVERTER 607
Fig. 7. Experimental results of full-bridge inverter: (a) AC output-voltage and
output-current waveforms at 500-W resistor load. (b) AC output-voltage and
output-current waveforms at 180-W RCD load. (c) Dynamic response from 50-
to 500-W resistor load.
Fig. 8. Measured efciency of proposed ZVS ybackforward converter.
Fig. 9. Magnetic integration concept.
The measured efciency of the tested 1-kW prototype with
different input voltages is shown in Fig. 11. With 48-V input
voltage, the maximum efciency is about 96% and the ef-
ciency at full load is over 95%. The efciency at full load
with 56-V input voltage is 95.8%. Even the input voltage
is decreased to 40 V. The maximum efciency of the tested
prototype is still higher than 95.5%.
VII. CONCLUSION
In this paper, an interleaved high-step-up ZVS yback
forward converter has been proposed for the fuel-cell power-
generation system. The voltage doubler rectier structure is
employed to provide a large voltage-conversion ratio and to
remove the output-diode reverse-recovery problem. Further-
more, ZVS soft-switching operation is realized for all the
primary active switches to minimize the switching losses. In
addition, the input-current ripple is small due to the interleaved
operation and the current-fed-type conguration. The steady-
state operation analysis and the main circuit performance are
discussed to explore the advantages of the proposed converter
in a high-efciency high-step-up power-generation system. Fi-
nally, a 500-W 12-V dc to 220-V ac system is employed
and another 1-kW prototype operated at 100 kHz is tested as
examples to illustrate the important design guidelines of the
proposed converter. Experimental results have demonstrated
that the proposed systemis an excellent power-converter system
for fuel-cell applications, featuring high efciency, high-step-
up ratio, and high power density.
APPENDIX A
In order to obtain the voltage-gain derivation easily, the cir-
cuit operational analysis can be simplied by assuming that the
parallel capacitors are zero. Furthermore, the current increasing
and falling rates of the leakage inductance can be taken as
constant values. The simplied waveforms are shown in Fig. 12.
During [t
b
, t
c
], the current on the leakage inductance is
increased linearly. Its current in this stage can be derived by
i
Lk
(t) =
N V
Cc2
V
Co1
L
Lk
(t t
b
). (A1)
At t
c
, the clamp switch S
c2
turns off and then the antiparallel
diode of the main switch S
1
begins to conduct. The output
diode D
o1
is still in the turn-on state. The leakage inductance
608 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 59, NO. 1, JANUARY 2012
Fig. 10. Experimental results of 40380-V 1-kW prototype: (a) ZVS of main switch S
1
. (b) ZVS of clamp switch S
c1
. (c) Current waveforms of primary side.
(d) Voltage and current waveforms on output diodes D
o1
and D
o2
.
Fig. 11. Test efciency of 1-kW prototype.
is discharged by the voltage on the output capacitor C
o1
. The
leakage current in the stage [t
c
, t
d
] is given by
i
Lk
(t) =I
Lk
(t
c
)
V
Co1
L
Lk
(t t
c
) (A2)
I
Lk
(t
c
) =
N V
Cc2
V
Co1
L
Lk
(1 D
2
) T
s
. (A3)
At t
d
, the output diode D
o1
turns off. The time interval [t
c
, t
d
]
can be obtained by
t
d
t
c
=
N V
Cc2
V
Co1
V
Co1
(1 D
2
) T
s
. (A4)
Fig. 12. Simplied waveforms for voltage-gain derivation.
The electric charge delivered to the output capacitor C
o1
during the stage [t
b
, t
d
] is given by
Q
Co1
=
1
2
I
Lk
(t
c
) (t
d
t
b
)
=
(N V
c2
V
Co1
)
2
2 V
Co1
L
Lk
(1 D
2
)
2
T
2
s
. (A5)
The total electric charge to the load is
Q
Ro
=
V
out
R
o
T
s
. (A6)
Due to the symmetry of the proposed converter, the total
electric charge to the load is twice that of C
o1
. Moreover, the
LI et al.: FUEL-CELL POWER-GENERATION SYSTEM WITH ACTIVE-CLAMP FLYBACKFORWARD CONVERTER 609
Fig. 13. Simplied circuit for voltage gain analysis affected by parasitic
parameters.
following assumptions are reasonable:
Q
Ro
=2 Q
Co1
(A7)
D
1
=D
2
= D (A8)
V
Cc1
=V
Cc2
=
V
in
1 D
(A9)
V
Co1
=V
Co2
=
V
out
2
. (A10)
From (A5)(A10), the output voltage can be derived by
V
out
= N V
in
_
R
2
o
(1 D)
2
+ 16 R
o
f
s
L
Lk
R
o
(1 D)
4 L
Lk
f
s
.
(A11)
APPENDIX B
In order to obtain the voltage gain affected by the parasitic
parameters, the leakage inductance is taken as zero and the
circuit parameters are assumed to be symmetrical to simplify
the analysis. The simplied circuit is shown in Fig. 13, where
R
1
represents the primary winding resistor, R
2
is the secondary
winding resistor, R
ds
is dened as the conduction resistor of the
main switches, and V
d
and R
d
are the forward voltage and the
parasitic resistor of the output diode, respectively. The active-
clamp circuits can be removed once the leakage inductance is
assumed to be zero.
When S
1
and S
2
are both in the ON state, the voltage on
L
1a
is
V
L1a_1
= V
in
I
in
2
(R
1
+R
ds
). (B1)
When S
1
is in the ON state and S
2
is in the OFF state, all of
the input current ows through L
1a
and S
1
and the voltage on
L
1a
is
V
L1a_3
= V
in
I
in
(R
1
+R
ds
). (B2)
Assuming that the voltage on L
1a
is V
L1a2
when S
1
in the
OFF state, based on the voltage-second balance principle, the
following equation can be derived:
V
L1a_1
(2D 1) +V
L1a_3
(1 D)=V
L1a_2
(1 D).
(B3)
When S
1
or S
2
is in the OFF state, the primary energy is
transferred to the load. The secondary current is derived by
I
2
(1 D) = I
out
=
V
out
R
o
. (B4)
The secondary voltage relationship is given by
N (V
La1_2
+V
La1_3
) +I
2
(2R
2
+R
d
) V
d
=
1
2
V
out
.
(B5)
The input current is approximately derived as
I
in
2N V
out
R
o
(1 D)
. (B6)
From (B1)(B6), the voltage gain is derived by
M =
V
out
V
in
=
2N
1D
2V
d
V
in
1 +
2N
2
(32D)
R
o
(1D)
2
(R
ds
+R
1
)
2(2R
2
+R
d
)
R
o
(1D)
.
(B7)
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Wuhua Li (M09) received the B.Sc. and Ph.D.
degrees in applied power electronics and electrical
engineering from Zhejiang University, Hangzhou,
China, in 2002 and 2008, respectively.
From September 2004 to March 2005, he was an
Intern, and from January 2007 to June 2008, a Re-
search Assistant, with GE Global Research Center,
Shanghai, China. From July 2008 to April 2010,
he was with the College of Electrical Engineering,
Zhejiang University, as a Postdoctoral Fellow. In
May 2010, he became a faculty member of Zhejiang
University as a Lecturer. Since July 2010, he has been a Ryerson University
Postdoctoral Fellow with the Department of Electrical and Computer Engineer-
ing, Ryerson University, Toronto, ON, Canada. His research interests include
high-efciency power converters and renewable-energy power-conversion
systems.
Lingli Fan was born in Hubei, China, in 1984. She
received the B.Sc. degree from the School of Elec-
trical Engineering and Automation, Hefei University
of Technology, Hefei, China, in 2007 and the M.Sc.
degree with a major on power electronic and motor
drives from Zhejiang University, Hangzhou, China,
in 2010.
She is currently with Philips Lighting Electron-
ics Company, Ltd., Shanghai, China. Her research
interests include dc/dc converters and ac/dc power
systems.
Yi Zhao (S10) was born in Liaoning, China,
in 1983. He received the B.Sc. degree from the
College of Electrical and Electronic Engineering,
Huazhong University of Science and Technology,
Wuhan, China, in 2006. He is currently working
toward the Ph.D. degree in the College of Electrical
Engineering, Zhejiang University, Hangzhou, China.
His research interests include dc/dc converters and
photovoltaic power systems.
Xiangning He (M95SM96F10) received the
B.Sc. and M.Sc. degrees from Nanjing University
of Aeronautical and Astronautical, Nanjing, China,
in 1982 and 1985, respectively, and the Ph.D. de-
gree from Zhejiang University, Hangzhou, China,
in 1989.
From 1985 to 1986, he was an Assistant Engi-
neer with the 608 Institute of Aeronautical Industrial
General Company, Zhuzhou, China. From 1989 to
1991, he was a Lecturer with Zhejiang University.
In 1991, he obtained a Fellowship from the Royal
Society of U.K. and conducted research in the Department of Computing and
Electrical Engineering, Heriot-Watt University, Edinburgh, U.K., as a Postdoc-
toral Research Fellow for two years. In 1994, he joined Zhejiang University as
an Associate Professor, where he has been a Full Professor with the College
of Electrical Engineering since 1996 and is currently the Vice Dean. He was
the Director of the Power Electronics Research Institute and the Head of the
Department of Applied Electronics. His research interests are power electronics
and their industrial applications. He is the author or coauthor of more than
200 papers and one book Theory and Applications of Multi-level Converters.
He is the holder of 12 patents.
Dr. He is the recipient of the 1989 Excellent Ph.D. Graduate Award,
the 1995 Elite Prize Excellence Award, the 1996 Outstanding Young Staff
Member Award, and 2006 Excellent Staff Award from Zhejiang University
for his teaching and research contributions. He is also the recipient of ve
Scientic and Technological Progress Awards from the Zhejiang Provincial
Government and the State Educational Ministry of China in 1998, 2002, and
2009, respectively, and ve Excellent Paper Awards. He is a Fellow of The
Institution of Engineering and Technology (formerly IEE), U.K.
Dewei (David) Xu (S99M01) received the B.Sc.,
M.A.Sc., and Ph.D. degrees in electrical engineering
from Tsinghua University, Beijing, China, in 1996,
1998, and 2001, respectively.
He has been with Ryerson University, Toronto,
ON, Canada, since 2001, where he is currently an
Associate Professor. His research interests include
renewable energy systems, high-power converters,
electric motor drives, and advanced digital control
for power electronics.
Bin Wu (S89M92SM99F08) received the
Ph.D. degree in electrical and computer engineer-
ing from the University of Toronto, Toronto, ON,
Canada, in 1993.
After being with Rockwell Automation Canada,
Cambridge, ON, as a Senior Engineer, he joined
Ryerson University, Toronto, where he is currently
a Professor and the Natural Sciences and Engineer-
ing Research Council (NSERC)/Rockwell Industrial
Research Chair in Power Electronics and Electric
Drives. He has published more than 200 technical
papers and authored two WileyIEEE Press books. He is the holder of more
than 20 issued/pending patents in the areas of power conversion, advanced
controls, adjustable-speed drives, and renewable energy systems.
Dr. Wu is the recipient of the Gold Medal of the Governor General of Canada,
the Premiers Research Excellence Award, the Ryerson Distinguished Scholar
Award, the Ryerson Research Chair Award, and the NSERC Synergy Award
for Innovation. He is a Fellow of The Engineering Institute of Canada and the
Canadian Academy of Engineering. He is an Associate Editor of the IEEE
TRANSACTIONS ON POWER ELECTRONICS and IEEE CANADIAN REVIEW.