Professional Documents
Culture Documents
Final Year Project Vincent Flaherty Supervisor: Dr. Maeve Duffy March 2009
I hereby declare that this thesis is my original work except where stated.
Signed: _______________________________________
Date: ________________
ii
Abstract
In modern society most renewable sources of electrical energy feed onto an AC grid before being applied to supply different electrical loads. For example, DC power produced by domestic photovoltaic (PV) panels or wind turbines feeds into the grid through an AC inverter. For several loads, the power is then converted from AC back into DC in order to supply digital circuit loads, such as personal computers, flat screen TVs, LED lighting and computer gaming equipment.
The aim of this project is to investigate if the efficiency of power delivered from a domestic PV installation can be improved by supplying such DC loads through a DC bus instead of through an AC grid connection. A DC bus connection between a typical domestic PV installation will be developed for a range of DC loads.
The work will involve circuit modeling of the source and load components through an AC grid connection, where the main focus will be on determining the efficiency of the system. As a first step, the source energy will be assumed to be coincident with the load demand. The design of DC/DC converter stages to replace a grid inverter will then be investigated, where significant consideration will be given to the choice of DC voltage level (safety issues vs. battery levels vs. efficiency). Again, the main objective will be to improve the efficiency of the system. The issue of energy storage to ensure that loads can be supplied when the source is not available will be considered if time permits.
iii
Acknowledgements
I would like to thank my supervisor Dr. Maeve Duffy for the time and effort she put into helping me with all aspects of my project throughout the year.
I would also like to thank the lab technicians at Nuns Island Myles, Martin and Aodh for all their help during my four years in NUI Galway.
I would like to give a special thank you to my family and friends for all their help, guidance and support throughout time in college.
iv
Table of Contents
Declaration of Originality ........................................................................................................... ii Abstract ..................................................................................................................................... iii Acknowledgements................................................................................................................... iv Table of Figures ........................................................................................................................ vii Chapter 1.................................................................................................................................... 1 1.1 Introduction ............................................................................................................ 1 1.2 Project Aim ............................................................................................................. 2 1.3 Flow of System ....................................................................................................... 2 1.4 Proposals for Tackling the Project .......................................................................... 4 1.5 Layout of Thesis ...................................................................................................... 5 Chapter 2 Project Overview .................................................................................................... 6 2.1 Photovoltaics .......................................................................................................... 6 2.2 Solar Inverters ........................................................................................................ 9 2.3 Maximum Power Point Tracking (MPPT) ............................................................. 11 2.4 Domestic Power Usage......................................................................................... 12 2.5 Switching Mode Power Supplies .......................................................................... 14 2.5.1 Boost Converter .......................................................................... 15 2.5.2 Buck Converter ........................................................................... 17 2.5.3 Synchronous Buck Converter...................................................... 19 2.5.4 Buck-Boost Converter ................................................................. 20 2.5.5 Flyback Converter ....................................................................... 22 Chapter 3 Simulation and Testing of Efficiency of AC/DC adapter.......................................... 25 3.1 OrCad .................................................................................................................... 25 3.2 Circuit Simulation ................................................................................................. 26
Final Year Project April 1, 2009 3.2.1 Full Wave Rectifier ......................................................................... 26 3.2.2 Choice of DC Bus Level .................................................................. 28 3.2.3 Specifications of DC to DC Converter Voltage Level ..................... 29 3.2.4 Flyback Converter .......................................................................... 29 3.2.5 Buck Converter .............................................................................. 32 3.2.6 Efficiency of Buck Converter ......................................................... 39 Chapter 4 Conclusion ............................................................................................................... 41 References ............................................................................................................................... 43 Appendix A ............................................................................................................................... 45 Appendix B ............................................................................................................................... 47 Appendix C ............................................................................................................................... 59
vi
Table of Figures
Figure 1.1 - Flow of Domestic PV Installation Figure 1.2 - Flow of Proposed System Figure 2.1 - Ideal Solar Cell Figure 2.2 - Real Solar Cell Model Figure 2.3 - I-V Characteristic of PV Panel Figure 2.4 - Table of Inverter Efficiency Figure 2.5 - MPPT Characteristic Curve Figure 2.6 - Power Usage of Appliances Figure 2.7 - Boost Converter Figure 2.8 - Continuous Operation Figure 2.9 - Discontinuous Operation Figure 2.10 - Buck Converter Figure 2.11 - Continuous Operation Figure 2.12 - Discontinuous Operation Figure 2.13 - Synchronous Buck Figure 2.14 - Buck-Boost Converter Figure 2.15 - Continuous Operation Figure 2.16 - Discontinuous Operation Figure 2.17 - Flyback Converter Figure 2.18 - Continuous Operation Figure 2.19 - Discontinuous Operation Figure 3.1 - PSPICE Schematic of Full Wave Rectifier Figure 3.2 - Voltage Waveforms of Full Wave Rectifier Figure 3.3 - Input Current Waveform Figure 3.4 - Output Current Waveform Figure 3.5 - Flyback PSPICE Model Figure 3.6 - Full Load Efficiency for IRISMPS5 Figure 3.7 - Efficiency vs Output Power for IRISIMPS5 Figure 3.8 - Basic Buck PSPICE Circuit vii 3 3 7 7 8 10 11 12 16 16 16 18 18 18 19 21 21 21 23 24 24 26 27 28 28 30 31 32 33
Final Year Project April 1, 2009 Figure 3.9 - Buck Using Schottky Diode Figure 3.10 - Synchronous Buck PSPICE Model Figure 3.11 - Input and Output Voltage Waveforms Figure 3.12 - Average Values of Input and Output Current Figure 3.13 - Current across Switch 1 Figure 3.14 - Voltage across Switch 1 Figure 3.15 - Gate Voltage on Switch 2 Figure 3.16 - Voltage across Switch 2 Figure 3.17 - Current across Switch 2 Figure 3.18 - Efficiency vs Output Power of Buck Converter Figure 3.19 - Efficiency vs Output Power For Varying Frequency Figure A.1 - Values used to Calculate Basic Buck Efficiency Figure A.2 - Values used to Calculate Buck Efficiency with Inductor Resistance Figure A.3 - Values used to Calculate Buck Efficiency with Frequency = 100K Figure A.3 - Values used to Calculate Buck Efficiency with Frequency = 25K Figure B.1 - Datasheet of MOSFET Used in Buck Converter Figure B.2 - Manual of IRISMPS5 34 34 35 36 37 37 38 38 38 39 40 45 45 46 46 47 48
viii
ix
There has been a large increase in the amount of research being done in the field of renewable energy; much of this research is being done with the aim to improve the efficiency of existing renewable energy sources. The use of photovoltaic arrays for energy generation has risen greatly in recent years. At this present the small scale use of photovoltaics (PV) is not very viable due to the high cost of installation and upkeep of PV modules. This results in it taking several years for PV modules to return the costs involved with installing and using them.
At the moment more and more domestic dwellings are being built to incorporate the use of PV modules as a principal or secondary source of electricity, typically as a secondary source. The modules are usually fitted into the roof of the building by using special roof tiles with integrated PV cells . As time passes more and more advances are being made in the field of PV this means that we are coming closer and closer to a stage where PV modules become a truly viable option for everyone.
DC/DC converter used to convert to level suitable for the load to be driven
Electricity enters the house and is converted back to DC to feed certain loads
a. Review of domestic PV systems Panel characteristics and circuit models Commercial inverter circuits: efficiency vs. power levels
b. Determine the power consumption of a range of DC loads Review range of loads: TVs, computers, gaming equipment, lighting, etc. Determine details of power stages of one application where the device is configured to operate with AC or DC; e.g. laptop PC, outdoor LED
c. Determine the efficiency of power conversion from the AC grid to a typical load Desktop / laptop PC or lighting Determine operating voltage and current levels for different conditions SPICE model of AC/DC conversion stages Analysis of conversion losses; switches vs. magnetic
d. Investigate standard DC/DC topologies for the chosen load Consider different bus voltage levels, including common battery voltages Apply SPICE modeling to compare the efficiency of different circuits with that achieved with AC/DC conversion Consider the implications for higher power levels than proposed for testing
e. Build and test a DC/DC solution to illustrate the highest level of efficiency possible Demonstrate for one load device (e.g. laptop / lighting) Bench design with power supply input and DC load output Test efficiency over a range of power levels typical for the demonstrator device operation
Final Year Project April 1, 2009 f. Design of DC/DC converter for solar panel to DC bus conversion Assume load power levels match those of a typical solar installation Apply solutions proposed to provide MPPT SPICE modeling of different solutions with accurate component models Analysis of losses vs. grid inverter losses
g. Build and test DC/DC stage for load DC bus conversion Demonstration of complete system with source load connection Analysis of efficiency and losses for different power levels, and comparison with losses in grid connected systems
Solar cells produce direct current from lights; this can be used to supply loads. The first practical use of photovoltaics was to power orbiting satellites and other spacecraft. Today the majority of modules are used for grid connected power generation [3]. In this case an inverter is requires to convert the DC produced by the solar panel to AC which is compatible with the grid. There is however a smaller market for off grid power for remote dwellings and roadside emergency phones etc.
As PV installations are quite expensive it is important to protect the cells from the environment in order to ensure a longer life cycle for the array. In order to provide this protection the cells are normally packaged tightly behind a glass sheet.
Photovoltaic cells are made from semiconductors, most commonly polycrystalline silicon and amorphous silicon. These semiconductors consist of p-n junction diodes capable of generating electricity from light sources and they usually have an efficiency of between 6% and 20% [4].
When the light strikes the cell a certain portion is absorbed by the semiconductor. This means the energy of the light is transferred to the semiconductor, this energy knocks electrons loose and due to electric fields in the photovoltaic cells the freed electrons are 6
Final Year Project April 1, 2009 forced to flow in a certain direction. This flow of electrons is a current. By placing metal contacts on top and bottom of the photovoltaic cell this current can be drawn off and used externally.
An ideal solar cell can be modelled using a current source in parallel with a diode; a schematic of this simple model is shown in figure 2.1.
As with most electronic components however no solar cell is ideal, so a parallel resistance and a series resistance are added to the model circuit. The true model circuit is shown in figure 2.2.
amount of light falling on it. When there is no load connected to the output the generated current flows through diode D. The resistors and
Final Year Project April 1, 2009 due to the connections and leakage respectively. There is very little change in for most
instances of load current. However, if a load is connected to the output then the load current draws current away from the diode, D. As the load current increases more and more current is diverted away from the diode, D. So, as the output load varies so too does the output current, while the output voltage remains largely constant. That is until so much
current is being drawn by the load that diode D becomes insufficiently biased and the voltage across it diminishes with increasing load. This results in an I-V characteristic as shown in Figure 2.3.
Solar power is pollution free during use. PV installations can operate with little maintenance after initial setup. Solar electric generation is economically superior where grid connection or fuel transport is difficult, costly or impossible. After the initial cost of the array has been paid, operating costs are extremely low compared to existing technologies. Compared to fossil and nuclear energy sources, very little research-money has been invested in the development of solar cells, so there is much room for improvement.
Final Year Project April 1, 2009 The disadvantages of PV systems are: Depending on the cost of the installation and local electric rates the payback can be 1420 years. Solar electricity is more expensive based on current rates. (As fossil fuels stores decline this will change.) Solar cells produce DC which must be converted to AC in order to be fed onto the grid.
Stand alone inverters: These are used in isolated systems where the inverter draws its DC energy from batteries charged by PV arrays. These inverters normally dont interface with the grid. Grid-tie inverter (GTI): These match the phase of the utility grid supplied sine wave. Grid-tie inverters are designed to shut down automatically upon loss of the utility supply, for safety reasons. They do not provide backup power during utility outages. These are the type of inverters which this section will deal with. Battery backup inverters: These are special inverters which are designed to draw energy from a battery, manage the battery charge via an onboard charger, and export excess energy to the utility grid. These inverters can provide backup power during a utility outage by supplying AC energy to selected loads.
Grid-tie inverters work by regulating the amount of voltage and current that is received from the solar panels in the form of DC energy and converting it into AC. This is done by taking the DC energy created by the PV module and chopping it by turning it on and off at
Final Year Project April 1, 2009 the grid supply frequency using a local oscillator and a power transistor. The chopped circuit is then filtered to make it a sine wave then applying a transformer to it to make to up the voltage to on grid levels.
The main difference between a GTI and a standard inverter is that GTIs match the phase of the AC produced with that of the grid. GTIs have an in built feature where they disconnect from the grid if the grid voltage is turned off. As the power output of a PV module varies as a function of the voltage in a way that power generation can be optimized by varying the system voltage to find the 'maximum power point'. Most inverters therefore incorporate 'maximum power point tracking'.
GTIs are very useful as owners of PV installations which are producing surplus power can sell this excess power back onto the grid. This is often called turning the meter backwards due to the fact that for each unit sold onto the grid the individuals meter turns back a unit.
Figure 2.4 below shows the efficiency levels of some commonly used solar inverters from a company called Fronius International.
Fronius IG IG 15 IG 20 IG 30
10
11
LCD TV Plasma TV Playstation 3 Xbox 360 Average PC Nintendo Wii Wireless Router
213 Watts 339 Watts 197 Watts 187 Watts 78 Watts 19 Watts 7 Watts
These were the type of loads which would be fed by the DC bus. It can be seen that perhaps the most common of all household appliances the television is the highest user of power in the list given. In order to find the average power usage of a TV one hundred and thirty nine TVs of different technology types were tested.
These TVs were tested by simulating the conditions they would be under in actual use. This was done by connecting the TVs to a DVD player and playing a specific ten minute clip from a DVD six times and taking the average of the power consumption over the three tests. All TCs were set to approximately the same picture settings to give a good comparison between TVs. The TVs were then put into standby mode to observe their power consumption.
The main factors of TV power consumption are screen size, technology type and picture settings. Due to the fact that the size of the TV affects its power usage is divided by its screen area to give a watts per square inch reading. One feature of TVs which varies widely the amount of power they use when in standby mode; this can vary between a few watts to anything over ten watts.
12
As games consoles and PCs can carry out several different functions several different aspects of them had to be tested. Most games consoles can now play movies, browse the web and download news etc. Four different tests were carried out in order to test each aspect of the consoles operation. These tests were as follows: Power consumption when playing games - several games were played, and a sampling of 30 minutes of gameplay was used to determine the average, peak, and minimum power usage of each console. Power consumption during movie playback - The same 3 chapters of a selected DVD were played on each console. The data sample is taken from approximately the middle 30 minutes of that. Power consumption in the console menu - To test how much power these consoles use when at idle, each machine was left in its console mode, with no games or videos being played. Power consumption used by console in standby - The consoles were left in standby mode, and power consumption was tested.
13
While a linear regulator maintains the desired output voltage by dissipating excess power in a pass power transistor, the switched-mode power supply switches a power transistor between saturation (full on) and cutoff (completely off) with a variable duty cycle whose average is the desired output voltage. It switches at a much-higher frequency (tens to hundreds of kHz) than that of the AC line, which means that the transformer that it feeds can be much smaller than one connected directly to the mains.
The main advantage of this method is greater efficiency because the switching transistor dissipates little power in the saturated state and the off state compared to the semiconducting state (active region). Other advantages include smaller size and lighter weight and lower heat generation due to higher efficiency.
Some disadvantages include greater complexity and the generation of high amplitude, high frequency energy that the low-pass filter must block to avoid electromagnetic interference (EMI).
This section of the report will outline the different switching mode topologies which were investigated as part of the project.
14
The step up Boost converter can be seen in Figure 2.1. It consists of a DC voltage source Vi, input inductor L, a controlled switch S, diode D, filter capacitor C and a load Resistance R. The Boost converter has two distinct states an on- state and an off-state. In the on-state, the switch S is closed, resulting in an increase in the inductor current, in the off-state, the switch S is open and the only path offered to the inductor current is to flow through the diode D, the capacitor C and the load resistance R. This results in the energy accumulated during the On-state being transferred into the capacitor.
The input current is discontinuous, varying between a very high inductor current and zero. This large ripple usually requires a large input bypass capacitor to reduce the source impedance. (This capacitor is not shown in the basic circuit).
Battery powered systems often stack cells in series to achieve a higher voltage. In many high voltage applications due to a lack of space it is not possible to stack a sufficient number of cells. In applications such as this a Boost converter is used to increase the voltage and reduce the number of cells needed. One application which uses the Boost converter is portable lamps. An LED typically takes 3.3 volts to emit light, and a boost converter can be used to step up the voltage from a single 1.5 volt battery to power the lamp.
The boost converter could be used as part of the project in applications where the DC voltage required to drive the load was higher than the voltage level of the DC bus being implemented.
15
16
The step-down buck converter can be seen in Figure 4. It consists of a DC input voltage source Vi, controlled switch S, diode D, filter inductor, filter capacitor C and resistance R. When the switch S is in the ON state the diode D is reverse biased. When the switch S is in the OFF state the diode conducts to support an uninterrupted current in the inductor. The Buck converter can operate in two distinct modes with respect to the inductor current iL. These modes are Continuous Conduction Mode (CCM) seen in Figure 5 in which the inductor current is always greater than zero and Discontinuous Conduction Mode (DCM) seen in Figure 6 in which the inductors current is zero during a portion of the switching period. The CCM is preferred for high efficiency and good utilization of the semiconductor switches. The DCM may be used in applications with special control requirements. The energy stored in the inductor is zero at the beginning and at the end of each switching period. In the buck converter, it is the value of the filter inductance which determines the boundary between the CCM and the DCM.
The input and output DC voltages (the duty cycle) and a range of load resistances are usually determined by preliminary specifications. The designer will have to determine the values of the inductance, the capacitance and of the switching frequency.
As will be discussed later in chapter 3 the DC bus level chosen was 42 volts. As many DC driven applications operate on lower voltage levels than this, the buck converter will form an important part of the system being developed.
17
18
The forward voltage drop of a diode, VD, (usually about 0.7 volts for a normal diode) contributes to a decrease in efficiency in the buck converter. This contribution is especially significant in low output voltage power supplies e.g. 3.3 volt power supplies for microprocessors. Even with a Schottky diode, which has a lower VD (about 0.4 volts) the power lost in the diode can exceed 10% of the total power delivered to the load. To reduce conduction losses in the diode, a low on resistance switch can be added in parallel for a buck converter as shown in Figure 2.13
The input switch and the switch parallel to the diode must be turned ON and OFF alternately. The arrangement in Figure 2.13 is called a synchronous converter or synchronous rectifier. Modern low voltage MOSFETs have an on resistance of only several milliohms. A synchronous converter may exhibit higher efficiency than a conventional one at output currents as large as tens of amperes. This increase in efficiency however comes at a price as more complicated circuitry for the switches are required. Special care must be taken to avoid having both switches on simultaneously as this would short the input voltage source. As power semiconductor devices usually have longer turn off times than turn on times, a dead time must be introduced in PWM (pulse width modulation) driving signals.
19
, a
controlled switch S, an inductor L, a diode D, a capacitor C and a load resistance R. The basic operation of the buck-boost converter is similar to the buck and boost converters. While in the on state the input voltage source is directly connected to the inductor L. this results in energy accumulating in the inductor. In this stage, the capacitor supplies energy to the output load. While the buck-boost is on the off state, the inductor is connected to the capacitor and output load, so energy is transferred from the inductor to the capacitor and the resistor. Compared to the buck and boost converters the main characteristic of the buck-boost converter is that the output voltage can vary continuously from 0 to ideal converter). The output voltage ranges for a buck converter is 0 to converter it is to . (for an
It was necessary to investigate the buck-boost converter in order to gain a greater understanding of the flyback converter, which is explained later in this chapter. The flyback converter is basically a buck-boost converter which has electrical isolation between the input and output. This is supplied by means of a transformer.
20
21
The circuit schematic of the flyback converter can be seen in Figure 13. It is the equivalent of a buck-boost circuit, with the inductor split to form a transformer. As a result the operating principle of the flyback is very similar to that of the buck-boost. When the switch S is on, the primary side of the transformer is directly connected to the input source voltage. This increases the magnetic flux in the transformer. The voltage across the secondary winding is negative, so the diode is reverse biased and the output capacitor supplies energy to the load on the output. When the switch is off, the energy stored in the transformer is transferred to the output.
As the flyback is an isolated power converter, isolation of the control circuitry is also needed. There are two control methods commonly used with the flyback these are current mode control and voltage mode control. Both methods require a signal related to the output voltage. There are two ways to generate this voltage; the first is to use an optocoupler on the secondary circuit to send a signal to the controller. The second is to wind a separate winding on the coil and rely on cross regulation of the circuit.
As with the other SMPS the flyback operates in two modes, continuous mode conduction and discontinuous mode conduction. Both of these modes have certain disadvantages. When using a flyback in DCM the main disadvantages is that the design has high RMS( )
and peak current values. This limits the efficiency of the converter. When the converter is operating in CCM the disadvantages are as follows: The current feedback loop used in current mode control needs slope compensation in many cases. The power switches are switching on with positive current flow.
22
Final Year Project April 1, 2009 These problems result in the control of the converter becoming more complicated.
The flyback converter has many applications some of which are listed below: Low power SMPS such as mobile phone chargers and standby power supplies on a PC. Low cost multiple output power supplies. (e.g. main PC power supplies for power levels of below 250W) High voltage supply in cathode ray tube (CRT) televisions. Isolated gate drivers.
The flyback is often used in AC/DC adapters due to the fact that the input on the converter can span from 90 to 250 VAC. As a result of the flexibility of the flyback converter it was chosen to be used as part of the system.
23
24
SPICE (Simulation Program with Integrated Circuit Emphasis) is a general purpose analogue circuit simulator that is used in IC and board level design to check circuit design integrity and predict circuit behaviour. SPICE was developed over thirty years ago in the Electronics Research Laboratory of the University of California, Berkeley in 1975 by Larry Nagle and Donald Pederson.
Orcad, called after the company that produced it, is another software package used in the production of electronic systems ranging from printed circuit boards (PCBs) to integrated circuits, from which it creates electronic prints for manufacturing of PCBs and also to manufacture electronic schematics and diagrams. The Orcad product line is fully owned by Cadence Design Systems, San Jose, California.
All of the software simulation carried out over the course of the project was done in Orcad using the Capture CIS tool. This tool can be used to build and simulate circuit design, in order to test expected results before the circuit is implemented in hardware so that you can see what results you can expect when you build your circuit in hardware. A PSPICE model for many specific components can be downloaded from the manufacturer.
25
Figure 3.1 shows the circuit diagram for a full wave rectifier.
D6 D1N4002
D7 D1N4002
D5 D1N4002
D8 D1N4002
26
It can be seen from Figure 3.1 that the diodes used were model D1N4002 while the smoothing capacitor had a value of 200 . Choosing the size of the output capacitor
represents a tradeoff. For a given load, a larger capacitor will reduce ripple but will cost more and will create higher peak currents in the supply feeding it. The resister R2 with a value of 1 k represents an output load.
Figure 3.2 shows the input and output voltage waveforms for the rectifier. The yellow waveform represents the input voltage while the blue waveform represents the output voltage, due to the high capacitor value it can be seen that the ripple on the output is quite small. Figure 3.3 shows the input current waveform for the rectifier. It can be seen that the peak current is coincident with the positive and negative peaks of the input voltage. Figure 3.4 shows the output current waveform, it can again be seen that the peaks in the current are coincident with the other waveforms.
27
28
The first calculation which had to be done was to choose the duty cycle of the controlled switch. This was done using the following equation:
Where, for the specifications of the project. = Voltage out = 19V = Number of windings on secondary side = 1 = Number of windings on the primary side = 2 = Duty cycle of switches = 0.6 = Voltage in = 42 From this equation D worked out to be approximately 0.6.
Other important parameters which had to be calculated were the minimum value of the flux on the primary side of the transformer to ensure continuous flux which is given by the equation below:
29
And also a value for the capacitance, this was given by:
While the circuit for the flyback converter was being investigated and tested it was discovered that there was a pre-existing power supply whose circuit consisted of a fullwave rectifier followed by a flyback converter. As the simulation of the flyback was proving very difficult the decision was taken to use the existing circuit as a basis for further design of different topologies and there efficiency. Below is the PSPICE schematic of the flyback converter which was being designed.
M2 IRF151
D1
D10D2
C2 1n
R2 1k
0
Figure 3.5 Flyback Spice Model
The power supply (PSU) which was used was the IRISMPS5 which is manufactured by International Rectifier Ltd. The main specifications of the PSU are as follows: 1. AC Input: V = 90-265V, f=50-60Hz 2. Typical efficiency = 83% 3. 4. (14.55 15.45)
30
Final Year Project April 1, 2009 The efficiency graphs for the IRISMPS5 are shown below:
31
These graphs are taken from the user guide of the IRISMPS5 PSU which is included in the appendices at the end of this thesis.
The next value calculated was the minimum value of inductance to ensure continuous conductance. This was given by the equation: 32
Where: Voltage out Current out Switching frequency = Duty cycle of switches
Originally it was decided to build a buck converter where one of the switches was an n channel MOSFET while the other switch was a normal diode. The resulting circuit is shown below.
M1 IRF151
L1 200u
R1 1k
After further investigation into switches and diodes it was decided that in order to increase the efficiency of the system it may be useful to try and simulate the system using a Schottky diode instead of the normal diode previously used. This was due to the fact that the voltage drop across a diode is normally somewhere between 0.7 and 1.7 volts while the voltage drop across a Schottky diode is between 0.15 and 0.45 volts. Schottky diodes can also switch faster than conventional diodes. The resulting schematic can be seen below:
33
V1 42Vdc
D17 C1 BZ-085 V2 V1 = 0 V2 = 7 TD = 0 TR = 10n TF = 10n PW = {duty cy cle/f switch} PER = {1/f switch} 200u
R1 1k
This change improves the circuits efficiency but as further research had previously led to the inclusion of the Schottky diode, once again further investigation into buck converters revealed what proved to be the final variation on the circuit. This was the concept of a synchronous buck converter which used two MOSFETs as the switches. This method was chosen as the voltage drop across the MOSFETs was very small which would improve efficiency yet again and also the fact that the switches could withstand a high reverse current which would provide additional safety to the circuit. The resulting circuit is shown below. R2 in the circuit represents the DC resistance of a real inductor of value 200 H.
M2 IRF151 L 200uH R2 out .05 V2 V1 42 TD = 0 TF = 100n PW = 18.6us PER = 40us V1 = 0 TR = 100n V2 = 7 M3 IRF151 C 200u R1 4
V3
34
The figure seen below shows the input and output voltages of the buck converter. It can be seen that the bus remains constant at 42 volts while after an initial unsteady state the output levels out to a steady 19 volts.
Figure 3.12 below shows the average values for the input and output currents of the converter. It can be seen that the output current is significantly higher than the input current. This is important when working out the systems efficiency as due to the output voltage being lower than the input voltage it was important for the output current to be higher in order to keep the efficiency high.
35
The choice of the switches to be used was an important factor to be considered. It was eventually decided to use the IRF151 MOSFET. This switch was chosen as it could comfortably withstand the voltage and current levels present in the circuit and was capable of very fast switching. As the threshold voltage of the switch was 2-4 volts, a voltage of 7 volts was chosen to drive the gate. Before adding the switches to the circuit some additional design had to be done.
It was very important that both switches were not to be switched on at the same time as this would cause the converter to operate outside its specifications and probably eventually fail. This was done by inverting the drive voltages on the MOSFETs, in other words where the drive voltage for switch 1 is initialised at zero volts where as the gate voltage for switch 2 is initialised at 7 volts. This ensures that the two switches are never turned on simultaneously.
The voltage and current waveforms for switch 1 are shown below. It can be seen that when the switch is closed the 42 volts are applied across it and also that while the switch is closed that the current rises linearly.
36
The current and voltage waveforms for switch 2 are shown below. Figure 3.15 shows the gate voltage this voltage is necessary to drive the MOSFET. When this voltage is high the MOSFET is on, when low the MOSFET is off. It can be seen in Figure 3.16 that the voltage across switch 2 is also 42 volts when the switch is on. Figure 3.17 shows the current across the switch, it can be seen that when the switch is closer the current spikes initially then falls until the switch is opened again.
37
38
0.95
0.9
0.85
0.8
20
40
60
80
100
It can be seen from the chart that without including the DC resistance of the inductor the efficiency of the system was higher. Even though the resistance value was only 0.5 it still caused quite a drop in efficiency, although the system is still very efficient overall. This is mainly due to the small losses incurred in the switches as opposed to if a diode had been used.
39
Final Year Project April 1, 2009 It was then necessary to investigate the effect of varying the switching frequency of the circuit. This was done first by halving the switching frequency to 25 KHz and then by doubling the frequency to 100 KHz. The results of these comparisons are shown below.
It can be seen that the efficiency was better when the switching frequency was at 25 KHz as opposed to 100 KHz. It was seen however that the efficiency was at its highest when the switching frequency was at its original frequency of 50 KHz and the power out was between 60 and 90 watts. However at lower outputs the switching frequency of 25 KHz was the best option.
40
Chapter 4 Conclusion
The official aim of this project was to investigate if the efficiency of power delivered from a domestic PV installation can be improved by supplying such DC loads through a DC bus instead of through an AC grid connection.
The first part of this years project was spent on researching photovoltaics and there characteristics and circuit models, the efficiency and power levels of solar inverters and concepts such as MPPT were also investigated. After this background research was carried out it was important to gain some understanding of what levels of power everyday domestic appliances actually use, the results of this research were shown in chapter 2. The AC/DC conversion stages of appliances were also investigated
The next part of the project was to learn about DC-DC switch mode power converters and how they can operate in two modes: 1. Continuous conduction mode 2. Discontinuous conduction mode
Several different types of these converters were researched and different equations for calculating specific parameters such as inductance and capacitance were also found. The converters which were researched were: Boost converter Buck Converter Buck Boost converter Flyback converter
The next step of the project was to begin the SPICE simulation of circuits. The first circuit to be modeled was the full wave rectifier. This was useful in many ways, as the full wave rectifier is a relatively simple circuit this was useful to give an initial understanding of using the many tools and functions available in PSPICE. The next circuit modeled was the flyback converter. This was a far more complicated circuit as it had a transformer and also a 41
Final Year Project April 1, 2009 switching MOSFET. This circuit took a long time to simulate as the correct components had to be chosen and implemented correctly. Once the flyback was implemented the next circuit modeled was that of the basic buck converter, using a switch and normal diode. The buck was then modeled using the same switch but with a schottky diode instead of the previous diode. The final buck converter simulated was a synchronous buck incorporating two separate MOSFETs.
The efficiency of the buck converter was tested under different conditions. These included using different components to those already used, testing the efficiency of the circuit while varying its output power and testing the efficiency of the buck while varying its switching frequency.
The circuit was now ready to be built and tested in hardware but unfortunately although the parts were ordered there was insufficient time for the circuit to be built.
This project has been of valuable experience to me as it had shown me how a project should be organised and carried out. It also shown how important it is to keep all the information and test results gathered throughout the project so they can be referred to after the project has been finished.
42
References
1. http://www.socialfunds.com/news/article.cgi/2639.html 2. http://www.prlog.org/10198293-global-solar-photovoltaic-market-analysisand-forecasts-to-2020.html 3. http://www.huliq.com/18313/ge-invests-delivers-one-of-worlds-largestsolar-power-plants 4. http://www.renewableenergyworld.com/rea/partner/sunpowercorporation-1887/news/article/2005/12/sunpower-announces-330-millionglobal-solar-supply-agreement-with-powerlight-corp-40618 5. http://org.ntnu.no/solarcells/pics/intro/circuit.png&imgrefurl=http://org.ntn u.no/solarcells/pages/introduction.php%3Fpart%3D2&usg=__Dy8dmtWu4hZ iXlMvh1OzO2jP31A=&h=218&w=380&sz=9&hl=en&start=2&um=1&tbnid=6 WHThXROfIozIM:&tbnh=71&tbnw=123&prev=/images%3Fq%3Dideal%2Bsol ar%2Bcell%2Bcircuit%26hl%3Den%26client%3Dfirefoxa%26rls%3Dorg.mozilla:en-US:official%26sa%3DG%26um%3D1 6. http://chuck-wright.com/SolarSprintPV/Image4.gif&imgrefurl=http://chuckwright.com/SolarSprintPV/SolarSprintPV.html&usg=__5ELq1r0mqyysYB1ZkL Hu3Gxt6dI=&h=353&w=533&sz=8&hl=en&start=6&um=1&tbnid=U2AKtm8P 2i7t9M:&tbnh=87&tbnw=132&prev=/images%3Fq%3Di%2Bv%2Bcharacterist ic%2Bof%2Bpv%2Bpanel%26hl%3Den%26client%3Dfirefoxa%26rls%3Dorg.mozilla:en-US:official%26sa%3DG%26um%3D1 7. http://www.fronius.com/cps/rde/xchg/SID-2C5EAA88F135F8D9/fronius_international/hs.xsl/83_362_ENG_HTML.htm 8. http://www.scielo.br/scielo.php?pid=S010317592008000400009&script=sci_arttext 9. http://en.wikipedia.org/wiki/File:Boost_conventions.svg 10. http://en.wikipedia.org/wiki/File:Buck_conventions.svg 11. http://en.wikipedia.org/wiki/File:Buckboost_conventions.svg 12. http://en.wikipedia.org/wiki/File:flyback_conventions.svg 13. http://www.irf.com/technical-info/refdesigns/irismps5.pdf 43
Final Year Project April 1, 2009 14. http://www.onsemi.com 15. http://radionics.ie 16. http://howstuffworks.com 17. http://powerdesigners.com 18. http://www.coilcraft.com 19. http://ieeexplore.ieee.org/Xplore/dynhome.jsp
44
Appendix A
Voltage In Voltage Out Current In Current Out Power In Power Out Efficiency 42 19.591 0.309 0.544 12.978 10.6575 0.821198 42 19.526 0.551 1.08 23.142 21.08808 0.911247 42 19.45 0.789 1.62 33.138 31.509 0.950842 42 19.41 1.025 2.15 43.05 41.7315 0.969373 42 19.35 1.291 2.76 54.222 53.406 0.984951 42 19.29 1.487 3.21 62.454 61.9209 0.991464 42 19.223 1.76 3.84 73.92 73.81632 0.998597 42 19.185 1.938 4.26 81.396 81.7281 0.998635 42 19.153 2.16 4.78 90.72 91.55134 0.999352
Figure A.1 - values used to calculate basic buck efficiency.
Voltage In Voltage Out Current In Current Out Power In Power Out Efficiency 42 19.2 0.309 0.556 12.978 10.6752 0.822561 42 19.15 0.551 1 23.142 19.15 0.8275 42 19.07 0.789 1.6 33.138 30.512 0.920756 42 18.975 1.025 2.11 43.05 40.03725 0.930017 42 18.91 1.291 2.7 54.222 51.057 0.941629 42 18.86 1.487 3.15 62.454 59.409 0.951244 42 18.77 1.76 3.75 73.92 70.3875 0.952212 42 18.725 1.938 4.16 81.396 77.896 0.957 42 18.63 2.16 4.65 90.72 86.6295 0.954911
Figure A.2 - values used to calculate buck efficiency including inductor resistance.
45
Voltage In Voltage Out Current In Current Out Power In Power Out Efficiency 42 19.88 0.31 0.553 13.02 10.99364 0.844366 42 19.7 0.57 1.09 23.94 21.473 0.896951 42 19.59 0.829 1.63 34.818 31.9317 0.917103 42 19.48 1.08 2.16 45.36 42.0768 0.927619 42 19.37 1.37 2.76 57.54 53.4612 0.929114 42 19.28 1.59 3.2 66.78 61.696 0.923869 42 19.171 1.88 3.83 78.96 73.42493 0.9299 42 19.092 2.08 4.23 87.36 80.75916 0.924441 42 18.995 2.322 4.74 97.524 90.0363 0.923222
Figure A.3 - values used to calculate buck efficiency with f = 100KHz
Voltage In Voltage Out Current In Current Out Power In Power Out Efficiency 42 19.48 0.29 0.543 12.18 10.57764 0.868443 42 19.423 0.543 1.08 22.806 20.97684 0.919795 42 19.37 0.795 1.61 33.39 31.1857 0.933983 42 19.248 1.04 2.14 43.68 41.19072 0.943011 42 19.17 1.32 2.74 55.44 52.5258 0.947435 42 19.11 1.53 3.18 64.26 60.7698 0.945686 42 19.065 1.82 3.8 76.44 72.447 0.947763 42 19 2.015 4.215 84.63 80.085 0.946296 42 18.88 2.25 4.723 94.5 89.17024 0.9436
Figure A.4 - values used to calculate buck efficiency with f = 25KHz
46
Appendix B
47
48
49
50
51
52
53
54
55
56
57
58
Appendix C
Fullwave Rectifier with R-C load
59
.PARAM INPUT = 10 .PARAM DUTY = 0.5 .PARAM RLOAD=3.3 .PARAM L=.625mH .PARAM C=41.7uF .PARAM FREQUENCY=20K ;Switching Frequency
VS 1 0 DC {INPUT} SW 1 3 2 0 SMOD ;Ideal Switch D1 0 3 DMOD L 3 4 {L} IC=0 C 4 0 {C} IC=0 R 4 0 {RLOAD}
*Control for switch VPULSE 2 0 PULSE (-1 1 0 1nS 1nS {DUTY/FREQUENCY} {1/FREQUENCY}) .MODEL SMOD VSWITCH (RON= 0.001 VON=0.1 VOFF=-0.1 .MODEL DMOD D(N=0.001) .OPTIONS NOPAGE ITL5=0
60
.PARAM VS=24 ; Source Voltage .PARAM D=0.4 ; Duty Ratio .PARAM R=5 .PARAM C=80UF .PARAM F=30K .PARAM Lm=1000UH .PARAM N1N2=2 ;Load Resistance ;Output Filter Capacitance ;Switching Frequency ;Primary Magnetizing Inductance ;n1/n2 of Transformer
*Initial conditions assuming continuous current. .PARAM VO={VS*(D/(1-D))/N1N2} .PARAM IAVG={VO*VO/(VS*R*D)} .PARAM DELTAILM={VS*D/(Lm*F)}ICLM={IAVG-DELTAILM/2} .PARAM DELTAVO={VO*D/(R*C*F)} .PARAM ICCAP={VO+DELTAVO/2} VS 1 0 DC {VS} LP 1 2 {Lm} IC={ICLM} LS 0 3 {Lm/(N1N2*N1N2)} K LP LS {1-1p} S 2 0 20 0 SMOD D 3 4 DMOD C 4 0 {C{ IC={ICCAP} R 4 0 {R} VPULSE 20 0 PULSE (-1 1 0 {0.01/F} {0.01/F} {D/F} {1/F}) .MODEL SMOD VSWITCH (RON=0.001 VON=0.1 VOFF=-0.1) .MODEL DMOD D(N=0.001) .TRAN 0.1US 1000US UIC .OPTIONS NOPAGE ITL5=0 .PROBE .END ;Transformer Primary ;Transformer Secondary ;Coupling between Primary and Secondary
61