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Non-Isolated High Step-Up DC-DC Converter with Minimum Switch Voltage

Stress

Article in International Journal for Modern Trends in Science and Technology · February 2022
DOI: 10.46501/IJMTST0802037

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International Journal for Modern Trends in Science and Technology, 8(02): 227-235, 2022
Copyright © 2022 International Journal for Modern Trends in Science and Technology
ISSN: 2455-3778 online
DOI: https://doi.org/10.46501/IJMTST0802037
Available online at: http://www.ijmtst.com/vol8issue02.html

Non-Isolated High Step-Up DC-DC Converter with

Minimum Switch Voltage Stress

Dr.M.Sarojini Devi | A.Manjula | N.Thillainayagi | P.Sujidha * | A.Usha

1 Department of Electrical and Electronics Engineering, Mohamed Sathak Engineering college , Ramanathapuram, Tamil Nadu.
* Corresponding Author Email Id:

To Cite this Article

Dr.M.Sarojini Devi, A.Manjula, N.Thillainayagi, P.Sujidha and A.Usha. Non-Isolated High Step-Up DC-DC
Converter with Minimum Switch Voltage Stress. International Journal for Modern Trends in Science and Technology 2022,
8 pp. 227-235. https://doi.org/10.46501/IJMTST0802037

Article Info
Received: 18 January 2022; Accepted: 20 February 2022; Published: 25 February 2022.

ABSTRACT
A new high step-up DC-DC converter topology combining a charge pump mechanism with a standard inductor- based Buck cell
is here presented. Its main advantages are: minimum switch voltage stress, given by the input voltage, and reduced energy in the
magnetic element compared to a conventional Boost converter designed for the same voltage gain. The proposed topology is
derived through a modification of the basic voltage-doubler charge pump cell that, thanks to a coupled inductor, allows to make
the flying capacitor voltages dependent on the switch duty-cycle. Both capacitor charging and discharging paths benefit from the
inherent leakage inductance of the coupled inductor, with consequent soft diode turn off with no reverse recovery problems and
ringing free operation. A proper design of the Buck inductance permits a quasi-square- wave operation, thus allowing a
zero-voltage turn on of the switches. Suitable design criteria are proposed so as to achieve the desired converter operation mode,
without need for any iterative process. Experimental results based on a 44V to 400V - 300W prototype confirm the theoretical
analysis and expectations, showing a quite flat efficiency curve that stays above 90% down to one tenth of the nominal power.

KEYWORDS: DC-DC converter 1, Boost converter 2, step-up DC-DC converter 3, switch voltage stress 4, step-up DC-DC
converter

1. INTRODUCTION generation.Renewable energy systems generate low

The usage of fossil fuels, such as oil, coal, and gas voltage output; thus, high step-up dc/dc converters are
results in the serious environmental mental pollution, widely employed in many renewable energy
which have a great influence in the world. Meanwhile, applications, including fuel cells, wind power, and
there is a big contradiction between the fossil fuel photovoltaic systems. Unfortunately, the output
supply and the global energy demand. Energy shortage voltages of the renewable systems are relatively low. In
and environmental pollution have been the major order to satisfy the high bus voltage requirements for
obstacles for human being development. How to find the full-bridge, half-bridge, or multilevel grid inverters
renewable energy sources is becoming , the sources has to be connected to series in order to
urgent.Renewable sources are one of the significant bring out a grater voltage ratio , which again suffers
players in the world’s energy portfolio, and it will make from the voltage mismatches and the module level
one of the biggest contributions to electricity mismatch issues .

227 International Journal for Modern Trends in Science and Technology

 Large duty cycles result in high current stress in the
boost switch. Theoretically, conventional step-up
converters, such as the boost converter and flyback
converter, cannot achieve a high step-up conversion
with high efficiency because of the resistances of
elements or leakage inductance Moreover to boost raise Fig 1. Classical boot converter.

the voltage boost the converters would require a larger

duty cycle . Large duty cycles result in high current The maximum voltage gain that can be achieved is

stress in the boost switch.Renewable energy systems constrained by the parasitic resistive components in the

are been widely used to generate energy due to their circuit and the efficiency is drastically reduced for large

clean generation . duty ratios. There are diode reverse recovery problems

Unfortunatley the renewable energy generations because the diode conducts for a short period of time.

cannot offer a high voltage ratio compared to the Also, larger ripples on the high input current and

grid.In order to connect the renewable generators to output voltage would further degrade the efficiency of

grid compatable , a high gain dc-dc converters are the converter.

required .Implementing such dc-dc converters occupy Typically high frequency transformers or coupled

high space and leads in higher cost. inductors are used to achieve high voltage conversion
ratios, the transformer design becomes more
2. CONVERTER TOPOLOGIES complicated and the leakage inductances increase for
achieving larger gains, as it requires higher number of
A.Conventional Boost converter
winding turns. This leads to voltage spikes across the
In order to meet the grid requirements a converter
switches and voltage clamping techniques are required
with a high step up gain ratio and the high efficiency
to
are more important. To achieve high voltage gains,
limit voltage stresses on the switches. Consequently, it
classical boost and buck-boost converters require large
makes the design more complicated.
switch duty ratios. Theoretically, conventional step-up
Theoretically, conventional step-up converters, such
converters, such as the boost converter and flyback
as the boost converter and flyback converter, cannot
converter, cannot achieve a high step-up conversion
achieve a high step-up conversion with high efficiency.
with high efficiency because of the resistances of
Because of the resistances of elements or leakage
elements or leakage inductance Moreover to boost raise
inductance, more over the conventional step-up
the voltage boost the converters would require a larger
converters with a single switch are unsuitable for
duty cycle . A high step-up DC-DC converter topology
high-power applications given an input large current
combining a charge pump mechanism with a standard
ripple, which increases conduction losses.
inductor based Buck cell is presented.
The conventional step-up converters, are un suitable
The proposed topology is derived through a
to achieve a high gain due to their resistances of
modification of the basic voltage-doubler charge pump
elements or leakage inductance; also, the voltage
cell .A coupled inductor, is used to make the flying
stresses are large, these converters are unsuitable to
capacitor voltages dependent on the switch
operate at heavy load given a large input current ripple,
duty-cycle.Both capacitor charging and discharging
which increases conduction losses.To achieve high
paths benefit from the inherent leakage inductance of
voltage conversion ratios, a new family of high voltage
the coupled inductor, with consequent soft diode turn
gain dc-dc power electronic converters has been
off with no reverse recovery problems and ringing free
introduced.
operation
A conventional interleaved boost converter for high
step-up and high-power application is a suitable
approach, by modifying the converter structure could
make the converter which makes it suitable to operate

228 International Journal for Modern Trends in Science and Technology

under the high gain conversion state.The conventional This approach is highly similar to the conventional
interleaved boost converter is an excellent candidate for interleaved type, with a additional voltage lifting
high-power application and power factor correction. scheme ,It obtains extra voltage gain through the
Unfortunately, the step-up gain is limited, and the voltage-lift capacitor, and reduces the input current
voltage stresses on semiconductor components are ripple, which is suitable for power factor correction
equal to output voltage. Hence, based on the (PFC) and high-power applications.
aforementioned considerations, modifying a Later an asymmetrical interleaved high step-up
conventional interleaved boost converter for high converter that combines the advantages of the
step-up and high-power application is a suitable aforementioned converters is proposed, which
approach. A high step-up DC-DC converter topology combined the advantages of both is presented which
combining a charge pump mechanism with a standard contains the both voltage lifting and step up gain with a
inductor based Buck cell is presented. minimum duty ratio control .
The proposed topology is derived through a
modification of the basic voltage-doubler charge pump C.Interleaved converter with voltage multiplier module
cell .A coupled inductor, is used to make the flying
capacitor voltages dependent on the switch duty-cycle.
Both capacitor charging and discharging paths benefit
from the inherent leakage inductance of the coupled
inductor, with consequent soft diode turn off with no
reverse recovery problems and ringing free operation
B. Modified fly back converter
There has been a lot of modifications are being
applied with the conventional converters to proposed
for high gain converter design , in this numerous
interleaved structures and some asymmetrical
interleaved structures are found to be suitable for
improving the voltage gain ratio Modifying a boost–fly
back converter, shown in Fig.is one of the simple
approaches to achieving high step-up gain; this gain is
realized via a coupled inductor.The performance of the
converter is similar to an active-clamped fly back
converter; thus, the leakage energy is recovered to the
output terminal. An interleaved boost converter with a Fig 3 Interleaved boost converter with a high step-up
voltage-lift capacitor is shown in the fig 1.3 which conversion and a voltage multiplier module.
consists a voltage multipler module to lift the voltage The high step-up interleaved converter with a voltage
level . multiplier module is shown in Fig.3 . The voltage
multiplier module is composed of two coupled
inductors and two switched capacitors and is inserted
between a conventional interleaved boost converter to
form a modified boost–fly back–forward interleaved
structure. When the switches turn off by turn, the phase
whose switch is in OFF state performs as a fly back
converter, and the other phase whose switch is in ON
state performs as a forward converter.
Primary windings of the coupled inductors with Np
turns are employed to decrease input current ripple,
Fig 2 voltage lifting scheme with a modified
and secondary windings of the coupled inductors with

229 International Journal for Modern Trends in Science and Technology

Ns turns are connected in series to extend voltage gain. which increases conduction losses.To achieve high
The turn ratios of the coupled inductors are the same. voltage conversion ratios, a new family of high voltage
converter operates in continuous conduction mode gain dc-dc power electronic converters has been
(CCM), and the duty cycles of the power switches introduced.
during steady A conventional interleaved boost converter for high
Later a converter based on the conventional step-up and high-power application is a suitable
interleaved boost converter integrated with a voltage approach, by modifying the converter structure could
multiplier module, and the voltage multiplier module make the converter which makes it suitable to operate
is composed of switched capacitors and coupled under the high gain conversion state.The conventional
inductors. The coupled inductors can be designed to interleaved boost converter is an excellent candidate for
extend step-up gain, and the switched capacitors offer high-power application and power factor correction.
extra voltage conversion ratio. In addition, when one of
the switches turns off, the energy stored in the
magnetizing inductor will transfer via three respective
paths; thus, the current distribution not only decreases
the conduction losses by lower effective current but
also makes currents through some diodes decrease to
zero before they turn off, which alleviate diode reverse
recovery losses .

D.High step up interleaving boost converter .

High step-up interleaved converter with a voltage
multiplier module is shown in Fig. 1.5. The voltage
multiplier module is composed of two coupled
inductors and two switched capacitors and is inserted
between a conventional interleaved boost converter to Fig 4 A modified interleaved high step up converter
form a modified boost–fly back–forward interleaved with a voltage multiplier module
structure
When the switches turn off by turn, the phase whose 3. TOPOLOGY DESIGN
switch is in OFF state performs as a flyback converter, The resonant capacitors Cr1and Cr2are not only
and the other phase whose switch is in ON state used as a part of the resonant tank.the rectifier and
performs as a forward converter. Primary windings of connected to the negative potential of the output
the coupled inductors with Np turns are employed to voltage V
decrease input current ripple, and secondary windings
of the coupled inductors with Ns turns are connected in
series to extend voltage gain. The turn ratios of the
coupled inductors are the same.
Because of the resistances of elements or leakage
inductance, more over the conventional step-up
converters with a single switch are unsuitable for
high-power applications given an input large current
Fig.5 Topology Design
ripple, which increases conduction losses.
This design has a Cr1, Cr2 resonant capacitors, Lr a
The conventional step-up converters, are un suitable
resonant inductor, D1and D3are output diodes, D2and
to achieve a high gain due to their resistances of
D4are regenerative diodes, Tis a high frequency
elements or leakage inductance; also, the voltage
transformer.S1and S2are the active switches through
stresses are large, these converters are unsuitable to
which the output power can be regulated. The resonant
operate at heavy load given a large input current ripple,

230 International Journal for Modern Trends in Science and Technology

tank is composed of three elements, Cr1, Cr2and Lr
.The converter can be operated either in buck or boost
mode based on the input voltage .The inductor Lm is
the magnetizing inductance of the transformer, and n is
the secondary to primary turns ratio of the transformer
T.
The resonant capacitors Cr1and Cr2are not only
used as a part of the resonant tank, but also used to
Fig 6 Back-EMF of BLDCM. (a) Ideal trapezoidal
double the output voltage, which is similar to the
back-EMF. (b) nonideal actual back-EMF.
voltage multiplier..Phase-shift control strategy is
B. Deviated commutation points detected by virtual neutral
employed to regulate the output voltage and
points method due to non-ideal back-EMF
power.Full bridge resonant voltage multiplier with
In the virtual neutral point-based position sensor-less
isolated dc –dc conversion is designed.In the circuit
ZCP detection method, when the neutral point voltage
Cr1and Cr2are resonant capacitors, Lr is a resonant
is un-measurable, three Y-type connected resistor
inductor.D1and D3are output diodes, D2 and D4 are
network are used to provide a virtual neutral voltage
regenerative diodes,. Tis a high frequency transformer
signal as shown in Fig.6. Where, g denotes ground, n
for isolation.S1- S4 are the active switches through
denotes the neutral point of the three-phase windings,
which the output power can be regulated.S5and S6are
and s denotes the virtual neutral point
placed on the underside of the rectifier and connected
to the negative potential of the output voltage Vo.

4. METHODOLOGY OF PROPOSED SYSTEM

A. Influence Of Non-Ideal Back-Emf On Commutation
Point Detection And Optimal Commutation Control
The influence of non-ideal back-EMF on the detection Fig 6 Schematic diagram of zero-crossing detection
of sensorless commutation point is firstly analyzed. method based on virtual neutral point
Then, the electromagnetic torque fluctuation and The terminal voltage mathematic model of the BLDC
efficiency of the motor commutated at different motor is written as (4.1).
commutation points driven by square current are
compared, and the optimal commutation control
(1)
method is proposed. In addition, for the low inductor
where Uxy represents the voltage difference between
motor with non-ideal back-EMF and buck converter
x and y , Lx, Rx, ix, Ex represent the inductance,
front-end drive structure, an integrated nonlinear
resistance, phase current and back-EMF of phase x,
model of motor and drive circuit including precise
respectively. Here, the three-phase resistance and
back-EMF parameters is established. Based on the
inductance are treated as constant and equal. The
nonlinear model, the feasibility of model linearization is
harmonic form expression of the three-phase non-ideal
analyzed. The linearization method based on
back-EMF of the BLDCM is as (2)
input-output feedback method is proposed, and a
steady speed controller based on linearization model is
designed. Figure 4.1 shows the ideal and non-ideal
back EMF

………(2)

231 International Journal for Modern Trends in Science and Technology

 obtained by making them equal zero. Moreover, the
theoretically ideal commutation point should be the
intersection of two adjacent back-EMFs, that is, the
points where Ea = Eb, Eb = Ec, Ec = Ea. By comparing the
Where phase relationship between the detected ZCPs and the
ωe represents the electromagnetic speed, ke ideal commutation points, the phase angle of the
represents the back-EMF coefficient, θe represents the detected ZCPs deviating from the ideal ZCPs ϕz1−6 can
electrical angle position, Axm represents the mth be obtained.
harmonic coefficient of the x phase back-EMF, Dx C. Comparison of different commutation points on
represents the DC offset of the x phase back-EMF, and instantaneous torque
ex represents the x phase back-EMF waveform shape Considering the extremely low inductance value, the
function. The corresponding coefficients can be inconsistent current change rate during the
obtained by offline measurement. According to commutation process caused by the inductance can be
Kirchhoff’s law, the terminal voltage can also be ignored. Thus, under the square current drive mode,
expressed as (3). only two phases are turned on at any time. Then, the
instantaneous torque Te of the motor can be expressed
……………………..(3)
as (8)
The following constraint equations can be obtained
according to the Y-type connection
…………..(8)

……………….(4)
where, ωmis the mechanical speed, p is the pole pairs,
exy (θe) is the back-EMF difference shape function of
…..(5) phase x and y at position θe, and im is the DC-link
The sensorless ZCP detection method based on the current.
virtual neutral point compares the terminal voltage
with the virtual neutral point voltage to obtain ZCPs of
the non-conducting phase back-EMF. Taking the phase
A as an example, when phase A is the non-conductive,
the detected voltage difference in virtual neutral point
based method can be obtained as (4.6).

..(6)
Similarly, phase B and C are as (7), respectively.

…..(7)
By taking (2) into (6) and (7) and ignoring the third Fig 7 Currents and torque waveform of BLDCM
and above harmoniccomponents that have less driven by square wave current. (a) ideal back-EMF. (b)
influence on the ZCPs detection, detailed actual non-ideal back-EMF. (c) torque waveforms
detected voltage can be expressed as the equations at commutated by different commutation points
the bottom of the page. It is well known that odd Ignoring the commutation process, AB interval is
harmonics are the main components in trapezoidal defined as the phase A and B conduction interval,
wave signals, while second or other even harmonics are where current flowing from phase A to phase B.
very few. So, after neglecting three or more harmonics, Similarly, each cycle can be divided into six intervals,
only the fundamental and DC components are left namely AB, AC, BC, BA, CA and CB. The back-EMF
when calculating the influence of actual measured difference shape function exy (θe) at different intervals
voltage on ZCP. Thus, the actual detected ZCPs can be

232 International Journal for Modern Trends in Science and Technology

are listed in Table 4.1. For current closed-loop control, it harmonic coefficients can be obtained through
can be seen that the backEMF models in each interval performing Fourier decomposition for the fitted back
are different and nonlinear in Fig. 7, which makes it EMF function.
difficult to control the current waveform in the
traditional square wave current drive mode. Fig.7(c) 5. SIMULINK MODEL
shows the instantaneous torque waveforms of the Figure 8 show the resonant based high gain converter
motor commutated according to commutation points with half bridge rectifier in the front end followed by
by different methods. Obviously, standard and high frequency transformer with the resonant cell and
detected commutation points will increase the voltage doubler circuit at the end
fluctuation of instantaneous torque near commutation
points under non-ideal back-EMF BLDCM. Although
these fluctuations are not enough to cause huge speed
fluctuations for large inertia motors, they will also
affect the current waveform and influence steady speed
accuracy.

D. Optimal commutation control

From the above analysis, it can be concluded that
among the three commutation points, the motor
commutated according to the ideal commutation point Fig 8: Simulink model of Resonance based High gain
has the lowest torque fluctuation and the highest converter-
average torque and efficiency. In addition, besides the .
influence of non-ideal back EMF on the phase deviation Figure 8 shows the boost mode Input and output
of ZCP detection method, the phase delay introduced voltages and PWM signal of the switches in the front
by LPF in various signal processing circuits is the main full bridge rectifier and back end voltage multiplier
part of commutation deviation. LPF cut-off frequency circuit.
used to eliminate noise interference to avoid false The steady state waveforms of the resonant inductor,
detection is very low, so a large phase delay is resonant capacitor and driving voltages of S1and S6 in
introduced. Based on the analysis of commutation the boost mode. It can be seen that the driving signal of
deviation, this paper presents a new optimal S1, vGS1, lags the driving signal of S6, vGS6, which
commutation method. The optimal commutation means dφP<1 and the converter operates in the boost
method is an improved commutation compensation mode.
method, which considers low-pass filter delay and The primary side switches S1 & S4 operates with a
non-ideal back-EMF factors. duty of 50% whereas S2 & S3 operates with phase shift
The proposed optimal commutation method consists control of 1µs with 30% duty. The secondary side
of the following steps: 1) Estimate LPF delay phase: The switches operates with 45% duty.
LPF is generally approximated to a first-order inertia
unit as LPF(s) = s+ ωω c c , ωc is the cutoff frequency The soft switching patterns for the primary side S1
speed, then LPF delay phase ϕLPF can be estimated and secondary side switch S6 which operates with the
according to the phase characteristics ϕLPF = static zero voltage switching pattern , makes the
−arctan(ωe/ωc). 2) Calculate deviation phase ϕz1−6: primary conversion more efficient , after the secondary
firstly, obtain the actual back-EMF waveforms by becomes zero.
offline measurement at constant speed and normalize
6. SIMULATION RESULT
back-EMF waveform function.
Then, a 1- 2-9-1 structure 4 layers feed-forward back This paper presented a high step-up topology
propagation neural network is used for fitting the featuring minimum switch voltage stress as well as
accurate back-EMF waveform function. The back-EMF reduced magnetic energy, compared with an equivalent

233 International Journal for Modern Trends in Science and Technology

gain conventional Boost converter. The conversion (roughly 3.4nF each), that acts as a loss- less snubber,
process explores both a magnetic coupling and a charge especially at the S2 turn off, where the switched current
pump mechanism to efficiently transfer The conversion is quite low (≈ −2.5A from Fig. 8). However, the
efficiency (power stage only) was calculated measuring forecasted total S1 losses of 1.37W are not unrealistic,
input and output powers using digital multimeters since the temperature measured on the device package
(Keysight 34461A), for input/output voltages and in the same operating point was 83◦C without forced air
output cur- rent, while the input current was read circulation (ambient temperature TA ≈ 20◦C). With a
directly on the DC power supply Chroma thermal resistance from junction to ambient of the
62050P-100-100. The overall relative error on the TO263-7 package ranging between 40K/W with 6cm2 of
efficiency calculation is lower than 0.5%, the main cooling area and 62K/W with minimal footprint, it
contribution coming from the input current means a dissipated power in the range 1÷1.6W. Turn-on
measurement (0.1% of reading plus 0.1% of range). The switching losses have been neglected for both switches,
measured efficiency at different input voltage values thanks to the quasi-square-wave operation imposed by
and for two different power constant levels is shown in a proper selection of the magnetizing inductance Lb,
values above 95% are achieved at nominal power even if this condition is not completely met for S1, as
except at the lower part of the input voltage range (Vg = can be inferred from the rising edge of voltage vDS2(t)
42V). Here, the slight efficiency reduction is caused by in Fig. 7b. However, the small switched current and
the different operating condition mentioned above residual voltage (≈ 10V), give a negligible contribution
according to which Tr1/2 > (1 − Dmax)Ts, that is causing to the overall losses. The core loss was estimated based
an increase of S1 turn-on losses, as revealed by the on the manufacturer data of the used N87 ferrite
vDS2(t) waveform in Fig. 7a. At lower output current material.
values, the efficiency remains above 90% down
approximately to one tenth of the nominal power, as 7. CONCLUSION
revealed by the measurement reported in Fig. 13 for The high RMS current value flowing in the devices,
two different input voltage values (Vg = 44V and Vg = which is the price to pay for having the minimum
48V). switch voltage stress, makes the control of any parasitic
resistance in the current path crucial in order to limit
the conduction losses. This is the reason why the input
and the buck stage capacitances were implemented by
connecting in parallel more lower value capacitors, as
revealed in table II. For the same reasons, the SiC
diodes used in the experimental prototype are not the
best choice for this circuit, where they are naturally
turned off by the resonant current id. Looking at their
Fig 9 : Boost mode output voltage stress (see table III), lower voltage rating and,
consequently, lower voltage drop Si devices could be
The relative losses distribution between the different used for a better overall efficiency.
components was calculated based on the stress analysis
Conflict of interest statement
reported in Section IV at the nominal operating point,
Authors declare that they do not have any conflict of
and the result is shown in Fig. 14. The total power loss
interest.
was estimated as PEstimated Loss = 10W, lower than
the measured one PMeasured Loss = 15.8W. As we can
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