High-Step-Up and High-Efficiency Fuel-Cell Power-Generation System With Active-Clamp Flyback-Forward Converter

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IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 59, NO.

1, JANUARY 2012 599


High-Step-Up and High-Efciency Fuel-Cell
Power-Generation System With Active-Clamp
FlybackForward Converter
Wuhua Li, Member, IEEE, Lingli Fan, Yi Zhao, Student Member, IEEE, Xiangning He, Fellow, IEEE,
Dewei Xu, Member, IEEE, and Bin Wu, Fellow, IEEE
AbstractA high-efciency fuel-cell power-generation system
with an active-clamp ybackforward converter is presented in
this paper to boost a 12-V dc voltage into a 220-V 50-Hz ac voltage.
The proposed system includes a high-efciency high-step-up inter-
leaved soft-switching ybackforward converter and a full-bridge
inverter. The front-end active-clamp ybackforward converter
has the advantages of zero-voltage-switching performance for all
the primary switches, reverse-recovery-problem alleviation for the
secondary output diodes, large voltage-conversion ratio, and small
input-current ripple. Furthermore, there are two coupled induc-
tors in the proposed converter. Each coupled inductor can work
in the yback mode when the corresponding main switch is in the
turn-on state and in the forward mode when it is in the turnoff
state, which takes full use of the magnetic core and improves the
power density. In addition, the full-bridge inverter with an LC
low-pass lter is adopted to provide low-total-harmonic-distortion
ac voltage to the load. Therefore, high-efciency and high-power-
density conversion can be achieved in a wide input-voltage range
by employing the proposed system. Finally, a 500-W prototype and
another 1-kW converter are implemented and tested to verify the
effectiveness of the proposed system.
Index TermsActive clamp, ybackforward converter, fuel-
cell generation system.
I. INTRODUCTION
D
EVELOPMENTS and applications of the fuel-cell power-
generation system become one of the most effective
solutions to compensate the fossil-fuel energy shortage and
to protect the global environment because the fuel cell is a
clean and renewable energy source with high efciency, high
reliability, and easy modularization performance [1], [2].
Commonly, a lot of low-voltage cells are integrated to a
fuel-cell stack to improve the output power level. The output
voltage of the fuel-cell stack is lower than 40 V due to the
Manuscript received August 16, 2010; revised November 7, 2010 and
January 6, 2011; accepted March 3, 2011. Date of publication March 22, 2011;
date of current version October 4, 2011. This work was supported in part
by the National Natural Science Foundation of China under Grant 50907058
and in part by the Power Electronics S&E Development Program of the Delta
Environmental and Education Foundation under Grant DREM2009001.
W. Li, L. Fan, Y. Zhao, and X. He are with the College of Electrical Engi-
neering, Zhejiang University, Hangzhou 310027, China (e-mail: woohualee@
yahoo.com.cn; fany.gy@163.com; zhao.yi@foxmail.com; hxn@zju.edu.cn).
D. Xu and B. Wu are with the Department of Electrical and Computer
Engineering, Ryerson University, Toronto, ON M5B 2K3, Canada (e-mail:
dxu@ee.ryerson.ca; bwu@ee.ryerson.ca).
Color versions of one or more of the gures in this paper are available online
at http://ieeexplore.ieee.org.
Digital Object Identier 10.1109/TIE.2011.2130499
cost and reliability issues in the household stand-alone power-
generation applications [3], [4]. This means that a front-end
dc/dc converter is necessary to boost the low voltage of the
fuel-cell stack to a standard high bus voltage before being
inverted into a 220-V ac output. The required dc/dc converter
should have the advantages of large voltage-conversion ratio,
high efciency, and small input-current ripple.
The widely employed isolated voltage-fed converters are not
the optimal candidates for the high-step-up fuel-cell generation
system because they have a step-down conversion feature,
large input-current ripple, and high output-diode voltage stress
[5][8]. The large transformer turns ratio, an additional LC
input lter, and the heavy output-diode losses are the main
obstacles for their efciency and power density improvements.
Compared with the voltage-fed converters, the isolated current-
fed converters have the clear advantages of input-current-ripple
reduction and high-step-up voltage ratio in the low-input high-
output-voltage conversion system.
The conventional current-fed pushpull converters are wel-
comed in the high-step-up and low-power applications due
to their simple structure and exible ux balance for the
transformer [9]. Furthermore, some improvements have been
made to realize a soft-switching performance [10]. However,
the voltage stress of the primary switches is relatively high.
The current-fed full-bridge converters are suitable for the large-
current applications [11], [12]. Unfortunately, the duty cycle of
the primary main switches should be greater than 0.5 because
a current path should be provided for the input inductor in any
operation condition. Therefore, an additional start-up solution
should be designed to reduce the inrush current during the
start-up operation. The dual boost converters can distribute the
input current due to the interleaved operation. In addition,
the active-clamp circuits can be inserted to achieve a zero-
voltage-switching (ZVS) soft-switching performance and to
recycle the leakage energy [13][15]. Unfortunately, there are
two input inductors and one transformer in the dual boost con-
verters, which limits the power density improvements. Some
interleaved boost converters with winding cross-coupled induc-
tors and active-clamp circuits are proposed for large-current and
high-output-voltage conversion [16], [17].
In this paper, a high-step-up interleaved ybackforward
converter with active-clamp circuits is proposed for the house-
hold fuel-cell power-generation system. Boost-type conversion
is realized by employing two coupled inductors to obtain a
0278-0046/$26.00 2011 IEEE
600 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 59, NO. 1, JANUARY 2012
Fig. 1. Proposed high-efciency fuel-cell power-generation system.
large voltage-conversion ratio, where each coupled inductor
can work in the yback mode when the corresponding main
switch is in the turn-on state and in the forward mode when
it is in the turnoff state. As a result, the magnetic core is
fully utilized and the power density is enhanced. Furthermore,
by introducing the active-clamp scheme, a ZVS soft-switching
operation is carried out for the primary main and clamp
switches. The diode reverse-recovery problem is alleviated
for the secondary rectier diodes. Hence, the power-device
switching losses are reduced to improve the circuit efciency.
Moreover, the input current is distributed and the input-current
ripple is minimized by the interleaved operation and the
current-fed conguration. All the aforementioned distinguished
features make the proposed converter an optimal candidate
for the high-step-up, high-efciency, and high-power-density
conversion.
II. SYSTEM STRUCTURE AND ANALYSIS
A. Circuit Conguration and Description
The proposed high-efciency fuel-cell power-generation
system, which is shown in Fig. 1, consists of an interleaved
high-step-up ZVS ybackforward converter and a single-
phase full-bridge inverter.
For the interleaved high-step-up ZVS ybackforward con-
verter, the main switches S
1
and S
2
work in the interleaved
mode to handle the large input current. The active-clamp cir-
cuits are composed of the auxiliary switches S
c1
and S
c2
and
the clamp capacitors C
c1
and C
c2
, which are employed to re-
cycle the leakage energy, suppress the turnoff voltage spikes on
the main switches, and realize ZVS soft-switching performance
for all the primary power devices. The clamp switches S
c1
and S
c2
are driven complementarily with the main switches S
1
and S
2
, respectively. There are two coupled inductors in the
proposed converter, which are named L
1
and L
2
. The primary
inductors L
1a
and L
2a
with n
1
turns are coupled with their
secondary inductors L
1b
and L
2b
with n
2
turns. The coupling
references are plotted as and . The secondary windings
of the two coupled inductors are in series to achieve boost-
type conversion. L
Lk
is the leakage inductance summation of
the two coupled inductors, which is reected to the secondary
side. L
m1
and L
m2
are the magnetizing inductors. N is dened
as the turns ratio n
2
/n
1
. The parallel capacitors C
s1
and C
s2
are used to implement the ZVS soft-switching operation. The
voltage-doubler conguration is employed in the secondary
side to achieve high-step-up conversion, which contains the
Fig. 2. Waveforms of the proposed converter.
output diodes D
o1
and D
o2
and the output capacitors C
o1
and
C
o2
. Each of the output capacitors sustains half of the output
bus voltage.
The single-phase full-bridge inverter is composed of four
MOSFETs S
3
, S
4
, S
5
, and S
6
and an LC low-pass lter. The
full-bridge inverter is controlled by a microchip Mega16A to
provide high-quality sinusoidal voltage.
B. Operational Analysis of Proposed Converter
Two 180

out-of-phase gate signals with the same duty cycle


are applied to the main switches S
1
and S
2
. The gate signals
of the clamp switches S
c1
and S
c2
are complementary with the
corresponding main switches S
1
and S
2
. Based on the steady-
state operation, there are 16 operational stages in a switching
period. Due to the symmetry of the circuit, only eight stages
are described briey. The steady-state waveforms are shown in
Fig. 2, and the corresponding equivalent circuits are shown in
Fig. 3.
Stage 1 [t
0
, t
1
]: During this stage, the main switches S
1
and
S
2
are in the turn-on state. The clamp switches S
c1
and S
c2
are in the turnoff state, and the output diodes D
o1
and D
o2
are both reverse-biased. The two coupled inductors operate in
the yback mode to store the energy. The energy to the load is
provided by the secondary output capacitors C
o1
and C
o2
.
Stage 2 [t
1
, t
2
]: At t
1
, the turnoff gate signal is applied to the
main switch S
2
, which makes its drainsource voltage increase
LI et al.: FUEL-CELL POWER-GENERATION SYSTEM WITH ACTIVE-CLAMP FLYBACKFORWARD CONVERTER 601
in a nearly linear way due to the parallel capacitor C
s2
. This
interval is very short because the primary winding current is
large and the parallel capacitor is small.
Stage 3 [t
2
, t
3
]: At t
2
, the drainsource voltage of S
2
in-
creases to make the diode D
o1
conduct. During this stage,
the coupled inductor L
1
operates in the forward mode and L
2
works in the yback mode to transfer energy to the load.
Stage 4 [t
3
, t
4
]: At t
3
, the voltage on the parallel capacitor
C
s2
increases to that on the clamp capacitor C
c2
. As a result, the
antiparallel diode of the clamp switch S
c2
begins to conduct.
Stage 5 [t
4
, t
5
]: At t
4
, the turn-on gate driver signal is given
to conduct the clamp switch S
c2
with ZVS turn-on operation.
The current through the antiparallel diode of the clamp switch
S
c2
transfers to S
c2
quickly.
Stage 6 [t
5
, t
6
]: At t
5
, the turnoff gate signal is provided to
the clamp switch S
c2
. Due to the parallel capacitor C
s2
, the
drainsource voltage of the main switch S
2
decreases linearly
and that of the clamp switch S
c2
increases in an approximately
linear way. As a result, S
c2
turns off under ZVS condition. One
part of the leakage energy continues to be delivered to the load
and another part of the leakage energy is recycled to the input
source.
Stage 7 [t
6
, t
7
]: At t
6
, the drainsource voltage of the main
switch S
2
decreases to zero. Therefore, its antiparallel diode
starts to conduct. The leakage current falls due to the voltage
on the capacitor C
o1
.
Stage 8 [t
7
, t
8
]: At t
7
, the main switch S
2
turns on with
ZVS soft-switching performance. The secondary diode D
o1
still remains in the conduction state. At t
8
, the leakage current
decreases to zero and the diode D
o1
turns off with zero-current-
switching operation. The two primary inductors are charged
linearly by the input voltage again.
A similar operation works in the rest stages of a switching
period. The auxiliary switch S
c1
and the clamp capacitor C
c1
can absorb the turnoff voltage spikes on the main switch S
1
and
recycle the leakage energy.
III. STEADY-STATE CIRCUIT PERFORMANCE ANALYSIS
A. Voltage-Gain Derivation
Under the ideal condition, which means that the leakage
inductance is zero, the power devices are ideal with zero
conduction resistance and conduction voltage drop, the voltages
on the clamp capacitors and output capacitors are constant, the
parallel capacitors are zero, and the voltages on the main and
clamp switches are equal to those on the clamp capacitors. They
are given by
V
ds_S
= V
ds_Sc
= V
Cc
=
V
in
1 D
(1)
where D is dened as the duty cycle of the main switches.
Due to the voltage-second balance on the magnetizing induc-
tor, the output capacitor voltage can be easily obtained by
V
Co1
= V
Co2
=
N V
in
1 D
. (2)
The output voltage is the summation of the voltages on
the two output capacitors. Therefore, the voltage gain of the
proposed converter under the ideal condition is
M
ideal
=
V
out
V
in
=
2 N
1 D
. (3)
Unfortunately, the leakage inductance has some impact on
the voltage gain. Once the leakage inductance is considered, the
voltage gain is given by (4), as shown at the bottom of the page.
The detailed derivation process for the voltage gain is intro-
duced in Appendix A.
From (4), it can be concluded that the voltage gain of the
proposed converter is determined by the turns ratio of the
coupled inductors, the main switch duty cycle, the leakage
inductance, the switching frequency, and the output load. The
relationship of the voltage gain, the duty cycle, and the leakage
inductance at a certain turns ratio is shown in Fig. 4, where the
turns ratio is 6, the output voltage is 380 V, the output power
is 500 W, and the switching frequency is 50 kHz. As the duty
cycle increases, the voltage gain extends greatly. The leakage
inductance degrades the voltage-conversion ratio a little. The
smaller the leakage inductance, the smaller the voltage gain loss
for the proposed ybackforward converter.
In addition, the winding resistors of the coupled inductors,
the conduction resistors, and the diode forward voltage of the
power devices have a little impact on the voltage gain. The
leakage inductance is taken as zero to simplify the voltage-
gain analysis affected by the parasitic parameters. The derived
voltage gain is given 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)
. (5)
The detailed analysis is illustrated in Appendix B.
From (5), it can be seen that the voltage gain drops a little as
the winding resistors of the coupled inductors, the power-device
conduction resistors, and the diode forward voltage increases.
Once the circuit components are ideal, (5) can be simplied into
(3). In fact, the parasitic resistors of the circuit components are
rather smaller than the output resistor. As a result, their impact
on the voltage gain can be ignored in practical industrial design.
B. Current Sharing Performance of Proposed Converter
The secondary windings of the two coupled inductors are
in series to realize the boost-type conversion. The secondary
series conguration is convenient for the primary input-current
autosharing.
M
Lk
=
V
out
V
in
= N
_
R
2
o
(1 D)
2
+ 16 R
o
f
s
L
Lk
R
o
(1 D)
4 L
Lk
f
s
(4)
602 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 59, NO. 1, JANUARY 2012
Fig. 3. Operational stages of the proposed converter: (a) Stage 1 [t
0
t
1
].
(b) Stage 2 [t
1
t
2
]. (c) Stage 3 [t
2
t
3
]. (d) Stage 4 [t
3
t
4
]. (e) Stage 5
[t
4
t
5
]. (f) Stage 6 [t
5
t
6
].
Fig. 3. (Continued) (g) Stage 7 [t
6
t
7
]. (h) Stage 8 [t
7
t
8
].
Fig. 4. Voltage-gain performance of the proposed converter.
TABLE I
CURRENT SHARING PERFORMANCE WITH ASYMMETRICAL
MAGNETIZING INDUCTOR (V
in
= 12 V, N = 6, D = 0.75,
P = 500 W, AND f
s
= 50 kHz)
From the voltage-gain expression shown in (4), it can be
drawn that the magnetizing inductors of the coupled inductors
are independent of the voltage-conversion ratio. As a result, the
difference of the magnetizing inductors is unrelated to the pri-
mary current sharing performance. Although the current ripple
on the magnetizing inductor varies as the magnetizing inductor
changes, the difference of the root mean square (rms) current on
the two magnetizing inductors is small. The simulated current
sharing performance induced by the asymmetrical magnetizing
inductor is given in Table I, where I
rms1
and I
rms2
represent
the rms input currents of each phase. In spite of large difference
on the magnetizing inductors, the rms primary input current is
nearly the same.
The leakage inductance has a clear variation, owing to the
large-scale industrial manufacture. Thus, the current sharing
LI et al.: FUEL-CELL POWER-GENERATION SYSTEM WITH ACTIVE-CLAMP FLYBACKFORWARD CONVERTER 603
TABLE II
CURRENT SHARING PERFORMANCE WITH ASYMMETRICAL
LEAKAGE INDUCTANCE (V
in
= 12 V, N = 6, D = 0.75,
P
out
= 500 W, AND f
s
= 50 kHz)
TABLE III
CURRENT SHARING PERFORMANCE WITH ASYMMETRICAL DUTY
CYCLE (V
in
= 12 V, N = 6, L
Lk1
= L
Lk2
= 0.44 H,
P
out
= 500 W, AND f
s
= 50 kHz)
performance caused by the asymmetrical leakage inductance
should be discussed carefully to explore the inherent circuit per-
formance. From the equivalent circuit of the proposed converter
shown in Fig. 1, it can be found that the leakage inductance
L
Lk
represents the reected leakage inductance summation
on the secondary side. The voltage-gain expression (4) shows
that the leakage inductance has some inuence on the voltage-
conversion ratio. Fortunately, once the total leakage inductance
is the same, the voltage gain and the current sharing perfor-
mance nearly stay the same. The simulation results of the cur-
rent sharing performance caused by the asymmetrical leakage
inductance are illustrated in Table II, where L
Lk1
and L
Lk2
are
the primary leakage inductances of the two coupled inductors.
It can be found that the difference on the leakage inductance
has a small effect on the current sharing performance.
In practice, the duty cycle has some variation due to the
parasitic parameters of the power devices and the signal cir-
cuits. The simulation current difference with asymmetrical duty
cycles is introduced in Table III, where D
1
and D
2
are the duty
cycles of the main switches S
1
and S
2
. As the duty cycle varies,
the energy stored in the magnetizing inductors changes, which
has a little effect on the output voltage gain and the current
sharing performance. When D
1
= D
2
= 0.75, the current dif-
ference (I
rms1
I
rms2
)/I
rms2
is nearly zero. When D
1
is 0.7
and D
2
is 0.8, the current difference is about 16%. Once D
1
is decreased to 0.65 and D
2
is increased to 0.85, the current
difference changes to 29%. Compared with the conventional
boost converter [18], the current sharing performance caused
by the asymmetrical duty cycle is improved due to the cross-
coupling conguration of the coupled inductors.
Therefore, the proposed converter has good current sharing
performance, which can simplify the control circuit design and
improve the system reliability.
C. Performance Comparison
In the classic current-fed full-bridge converters, the duty
cycle of the primary main switches should be greater than 0.5
in any load condition to provide the current path for the input
inductor. As a result, an additional start-up circuit should be
designed to minimize the inrush current during the start-up
operation. Furthermore, the switch conduction losses in the
primary side are large because the primary current should ow
through two primary switches in most operation stages. In
addition, the current stress on the input inductor is high because
it should sustain the whole input current. Fortunately, a two-
phase interleaved boost converter exists in the primary side
of the proposed converter, except that the diodes in the con-
ventional boost converter are replaced by the active switches.
This means that the main-switch duty cycle of the presented
converter can vary from 0 to 1. When the duty cycle is lower
than 0.5, the proposed converter may operate in discontinuous
current mode with light load. As a result, ZVS performance is
lost because the leakage energy is not sufcient to discharge
the energy stored in the parallel capacitor when the corre-
sponding clamp switch turns off. A wide duty-cycle operation
range is achieved in the proposed converter to remove the
additional start-up circuit compared with the classic current-
fed full-bridge converters. Moreover, the large input current
is distributed to two interleaved phases, which decreases the
current stress on the magnetizing inductors. Finally, the primary
current ows through only one switch and the average current
stress on the active-clamp switches is relatively low, which
reduces the primary switch conduction losses. As a result, the
proposed converter is more suitable for high-efciency, high-
step-up, and high-power-density dc/dc conversion compared
with the classic current-fed full-bridge converters.
IV. CONTROL STRATEGY
In order to regulate the output voltage of the proposed
interleaved ZVS ybackforward converter and provide high-
quality ac energy to the load, the effective control strategy
should be employed. The control block diagram of the proposed
power-generation system is shown in Fig. 5. The conventional
peak-current-mode control scheme cannot be adopted in the
proposed converter, because the coupled inductors operate in
the yback mode and the forward mode alternatively, which
does not make the peak current of the main switch occur
at its turn-off moment. Fortunately, the average-current-mode
control strategy can be introduced to obtain a fast dynamic
response and an accurate voltage regulation. Only the total input
current, which is the summation of the current across both the
primary coupled inductors, is required due to the ne current
autosharing performance. From the analysis in Section III, it
can be concluded that the voltage gain and the small signal
model of the proposed converter are quite similar to those of
the dual boost converters. As a result, the design criterion of the
dual boost converters can be directly employed in this paper
to achieve a good circuit performance [13][15]. Generally
speaking, a tradeoff should be made for the consideration of the
current controller between the circuit stability and the dynamic
performance. This can be implemented by simulation analysis
or Bode plot derivation [18]. Furthermore, the protect function,
such as the undervoltage, the overvoltage, the overcurrent (OC),
and the overtemperature, is realized to improve the system
reliability. The gate driver signals are implemented by SG3525.
The output voltage of the inverter V
ac
and its lter inductor
current I
ac
are sampled and employed to realize a high steady
604 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 59, NO. 1, JANUARY 2012
Fig. 5. Control block diagram of the proposed power-generation system.
TABLE IV
SYSTEM SPECIFICATIONS
and dynamic response sinusoidal voltage. The published ad-
vanced control strategies can be implemented by the microchip
Mega16A to improve the system performance [13], [19][21].
V. DESIGN CONSIDERATIONS
A 500-W fuel-cell power-generation system is adopted as an
example to explore the main design considerations. The system
specications are given in Table IV.
A. Design of Coupled Inductor
The turns ratio of the coupled inductor can be designed
from (4). The duty cycle D can be set as 0.8 when the fuel-
cell voltage is 10 V. Therefore, the turns ratio of the coupled
inductors is nearly 6.
Once the turns ratio of the coupled inductors is 6, the total
leakage inductance L
Lk
should satisfy the following:
L
Lk

2 R
o
N
2
M N R
o
(1 D)
2 M
2
f
s
= 52.8 H. (6)
Therefore, the maximum total leakage inductance reected
to the secondary side L
Lk_max
is 52.8 H. Assuming that
each coupled inductor has the same leakage inductance, the
maximum leakage inductance reected to the primary side is
L
Lk_primary
=
L
Lk_max
2 N
2
= 0.73 H. (7)
The magnetizing inductor can be determined by setting an
acceptable current ripple on the magnetizing inductor, which is
given by
L
m
=
V
in_min
D
0.2 I
Lm
f
s
= 33.6 H. (8)
The primary winding rms current of the coupled inductor can
be derived as follows.
During the whole switching transition, the current ripple on
the magnetizing inductor is taken as zero and each magnetizing
inductor shares half of the input current to simplify the rms
current derivation.
During stages 1 and 2 [t
0
, t
2
], as shown in Fig. 2, the current
across the primary winding L
1a
is that of the magnetizing
inductor
i
L1a
(t) = I
Lm1
, [t
2
t
0
(D 0.5)T
s
] . (9)
From stage 3 to stage 5 [t
2
, t
5
], the leakage inductance is
charged by the reected clamp capacitor voltage minus half
of the output voltage. The current on the leakage inductance
increased in an approximately linear way. The leakage current
i
Lk
and the primary winding current i
L1a
are given by
i
Lk
(t) =
N V
Cc2

V
out
2
L
Lk
(t t
3
) (10)
i
L1a
(t) =I
Lm1
+N i
Lk
(t), [t
6
t
3
(1 D)T
s
] .
(11)
From stage 6 to stage 8 [t
6
, t
8
], i
L1a
decreases linearly
because the current of the output diode is controlled by the
leakage inductance. i
Lk
and i
L1a
are obtained by
i
Lk
(t) =I
Lk
(t
6
)
V
out
2 L
Lk
(t t
6
) (12)
i
L1a
(t) =I
L1a
(t
6
) N i
Lk
(t),
_
t
8
t
6

2N V
Cc1
V
out
V
out
(1 D)T
s
_
. (13)
The current derivation of the rest operational stages can be
achieved in a similar way. Therefore, the primary winding rms
current can be obtained by
I
L1a_RMS
=

_
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.

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