E1EEFQ 2016 v11n2 383
E1EEFQ 2016 v11n2 383
E1EEFQ 2016 v11n2 383
Abstract – This paper proposes the design considerations of resonant network and transformer
magnetics for 500 kHz high switching frequency LLC resonant converter. The high power density can
be effectively achieved by adopting high switching frequency which allows small size passive
components in the converter. The design methodology of magnetizing inductance is derived for zero
voltage switching (ZVS) condition, and the design methodology of the transformer and output
capacitance is derived to achieve high power density at high operating frequency. Moreover, the
structure of transformer is analyzed to obtain the proper inductance value for high switching operation.
To verify the proposed design methodology, simulation and experimental results will be presented
including temperature of passive and active components, and power conversion efficiency to evaluate
dominant power loss. In addition, the validity of magnetics design will be evaluated with operating
waveforms of the prototype converter.
Keywords: High switching frequency, LLC resonant converter, Transformer design, Power density
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Design Considerations of Resonant Network and Transformer Magnetics for High Frequency LLC Resonant Converter
implemented to experimentally verify the validity of the to the switching frequency. In this section, design con-
proposed design methodology. To obtain optimal operating siderations of the resonant network and output capacitance
points at 100 kHz and 500 kHz switching frequency, the of the LLC resonant converter for high frequency operation
magnetizing inductance is separately designed. The will be discussed.
temperature of passive and active components is measured
to find out dominant power losses at high frequency 2.1 Design for soft switching condition
operation. In addition, the validity of high-frequency
magnetics design is evaluated with mathematical analysis. To verify the validity of the proposed design methodology,
All the design considerations are verified by proper a prototype converter is implemented with an analog
simulation and experimental results with a 300 W prototype controller (ST L6599) which has a fixed dead time (0.2-0.4
LLC resonant converter operating at 100 kHz and 500 kHz μs). Comparing with the switching frequency of 500 kHz
switching frequencies. (2 μs) in the prototype converter, the dead time is longer
than 10% of the switching frequency. Fig. 3 shows
theoretical waveforms whose dead time from tc to te is
2. Design Considerations for Power Stage large enough to influence the shape of the primary current.
The primary current cannot follow the magnetizing current
The conventional medium switching frequency LLC during the dead time, and it is collapsed by the secondary
resonant converter has been designed with the relationship parasitic capacitance before the end of the dead time.
among Q-factor (Quality factor), voltage gain, and λ which From the above reasons, the conventional design method
is defined as Lr /Lm, where Lr is the leakage inductance and of the magnetizing inductance is not a proper to obtain the
Lm is the magnetizing inductance. The converter which has ZVS operation in the high switching frequency operation.
high λ needs small frequency modulation to control the Since the conventional design method is derived using the
output voltage since the higher gain variation is introduced approximation of constant primary current during the dead
by the higher λ. High λ has small conduction losses with time, it introduces considerable errors for the ZVS condition.
small circulating currents, however it has a demerit under From the conventional design method, the primary current
over-load condition because of non-monotonic gain curves. can be expressed as follows:
Small λ is convenient to control the output voltage under
over-load condition, however, it requires high frequency n(Vo + VDf )Ts
modulation to obtain enough voltage gain. Moreover, i p (tc ) = (1)
4 Lm
small λ has high conduction loss which comes from high
circulating current. The Q-factor changed by load condition
where tc is start point of dead time, ip (tc) is the constant
shows the sharpness of the voltage gain near the resonant
value of the primary current during the dead time, n is
frequency. Fig. 1 shows the scheme of the LLC resonant
the turn ratio, Vo is the output voltage, VDf is the forward
converter and Fig. 2 shows the voltage gain curve according
voltage drop of the secondary diode, and Ts is the
switching period.
S1 Cs1 D1 io
At the high switching frequency, equation (1) cannot be
ip retained during the dead time. Therefore, after tc, the
Lr
Vs Vs Co Ro Vo variation of the primary current during the dead time can
Lm
S2 Cs2 be derived as follows:
Cr im D2
VCr
Fig. 2. DC gain characteristics of the LLC resonant Fig. 3. Operational waveforms of the primary and the
converter magnetizing current during the dead time
Vb
i p (t ) = i p (tc ) cos ωr1 (t ) + sin ωr1 (t ) (2)
Z r1
Vs tdt
(Ts ,min − 2tdt ) ≥ 2CsVs (4)
8 Lm (a)
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Design Considerations of Resonant Network and Transformer Magnetics for High Frequency LLC Resonant Converter
(b)
(a) (b)
Fig. 8. Photo of the transformer for 500 kHz LLC resonant
converter: (a) EE core with an air gap to obtain the
required magnetizing inductance; (b) Implemented
transformer
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Design Considerations of Resonant Network and Transformer Magnetics for High Frequency LLC Resonant Converter
-4
4 x 10
Magnetizing inductance
Leakage inductance
69.65 uH
2
Inductance [H]
0
9.629 uH
-2
(a)
-4 5 6 7 8
10 10 10 10
Frequency [Hz]
Fig. 10. Measured results of the magnetizing and leakage
inductance designed for 500 kHz operation
(b)
Fig. 12. Experimental waveforms of 100 kHz LLC resonant
converter: (a) 3 A light load case, (b) 10A full load
case
Fig. 11. Simulation results of 100 kHz and 500 kHz LLC
resonant converter
(a)
Fig. 16. Comparison of 100 kHz and 500 kHz transformer
size
(b)
Fig. 14. Experimental waveforms of 500 kHz output ripple
voltage with 1047 μF capacitor under full load
condition: (a) output ripple voltage using 6600 μF;
(b) output ripple voltage using 1047 μF
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Design Considerations of Resonant Network and Transformer Magnetics for High Frequency LLC Resonant Converter
Table 4. Comparison of components temperature with Research Program through the National Research Found-
respect to the switching frequency ation of Korea (NRF) funded by the Ministry of Science,
Specification 100 kHz 500 kHz
ICT & Future Planning (NRF-2013R1A1A1009632).
Diode 57℃ 71℃
MOSFET 35℃ 41℃
L6599 (gate driver) 45℃ 56℃ References
Transformer 51℃ 63℃
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using the simulation and the experimental results with [11] B. C. So, K. B. Seo, D. H. Lee, H. C. Jung, S. S.
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the measured temperature and efficiency data, the of LLC Resonant Converter having Enhanced Load
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[12] H. S. Choi, “Design Consideration of Half-Bridge
Acknowledgements LLC Resonant Converter,” Journal of Power Elec-
tronics, Vol. 7, No. 1, pp. 13-20, Jan. 2007.
This research was supported by the Basic Science [13] H. De Groot, E. Janssen, R. Pagano, K. Schetters,
“Design of a 1-MHz LLC Resonant Converter Based Younggon Ryu He received B.S
on a DSP-Driven SOI Half-Bridge Power MOS degree in electrical engineering from
Module,” IEEE Trans. Power Electronics, Vol. 22, University of Ulsan, Ulsan, Korea, in
No. 6, pp.2307-2320, Nov. 2007. 2008. He is currently working toward
[14] H. S. Kim, J. W. Baek, M. H. Ryu, J. H. Kim, and J. the Ph.D. degree with the School of
H. Jung, “High Efficiency Isolated AC-DC Converter Electrical and Computer Engineering,
Using Three-Phase Interleaved LLC Resonant Con- Ulsan National Institute of Science and
verter Employing Y-Connected Rectifier,” IEEE Technology, Ulsan, Korea. His research
Trans. Power Electronics, vol. 29, no. 8, pp. 4017- interests include high frequency modeling and design for
4028, Aug. 2014. electrical machines.
[15] F. Dianbo, F. C. Lee, L. Ya, X. Ming, “Novel Multi-
Element Resonant Converter for Front-end DC/DC
Converters,” in Proc. PESC ’2008, pp. 250-256, Jun. Ki Jin Han He received the B.S.
2008. (summa cum laude) and M.S. degrees
[16] S. S. Hong, S. H. Cho, C. W. Roh, and S. K. Han, in electrical engineering from Seoul
“Precise Analysis Solution for the Peak Gain of LLC National University, Seoul, Korea, in
Resonant Converters,” Journal of Power Electronics, 1998 and 2000, respectively, and the
pp. 680-685, Nov. 2010. Ph.D. degree in electrical and com-
[17] F. Dianbo, L. Bing, F. C. Lee, “1MHz High Effi- puter engineering from the Georgia
ciency LLC Resonant Converter with Synchronous Institute of Technology, Atlanta, GA,
Rectifier,” in Proc. PESC ’2007, pp. 2404-2410, Jun. USA, in 2009. He was with the System Research and
2007 Development Laboratory, LG Precision Co., Ltd., Yongin,
[18] Z. Weimin, X. Zhuxian, Z. Zhang, F. Wang, L. M. Korea, from 2000 to 2005. From 2009 to 2011, he was with
Tolbert, B. J. Blalock, “Evaluation of 600 V Cascade the IBM Thomas J. Watson Re search Center, Yorktown
GaN HEMT in Device Characterization and all-GaN- Heights, NY, USA, from 2009 to 2011, as a Post-Doctoral
based LLC Resonant Converter,” in Proc. ECCE ’2013, Researcher. He is currently with the School of Electrical
pp. 3571-3578, Sept. 2013. and Computer Engineering, Ulsan National Institute of
[19] M. D. Seeman, S. R. Bahl, D. I. Anderson, G. A. Shah, Science and Technology, Ulsan, Korea, as an Associate
“Advantages of GaN in a High-voltage Resonant Professor. His current research interests include EMC for
LLC Converter,” in Proc. APEC ’2014, pp. 476-483, power electronics, computational electromagnetics, and
Mar. 2014. electronic packaging. Dr. Han was a recipient of the
[20] D. Huang, S. Ji, F. C. Lee, “LLC Resonant Converter Samsung Scholarship for graduate study in 2005.
with Matrix Transformer,” IEEE Trans. Power Elec-
tronics, Vol. 29, No. 8, pp. 4339-4347, Aug. 2014.
[21] H. Schmidt-Walter, http://schmidt-walter.eit.h-da.de/, Jee-Hoon Jung He was born in Suwan,
Mar. 19th 2001. Korea, in 1977. He received the B.S.,
[22] C. W. T. Mclyman, Transformer and Inductor Design M.S., and Ph.D. degree from Pohang
Handbook, 4th ed., CRC Press, 2011. University of Science and Technology
[23] Y. Ryu, S. Kim, G. Jeong, J. Park, D. Kim, J. Park, J. (POSTECH), Pohang, Korea, in 2000,
Kim and K. J. Han, “Common Mode Noise Reduc- 2002, and 2006, respectively. From
tion for an LLC Resonant Converter by Using 2006 to 2009, he was a Senior Research
Passive Noise Cancellation,” Journal of Electromag- Engineer with the Digital Printing
netic Engineering and Science, vol. 15, no. 2, pp. 89- Division, Samsung Electronics Company Ltd., Suwon,
96, Apr. 2015. Korea. From 2009 to 2010, he was a Postdoctoral Research
Associate with the Department of Electrical and Computer
Engineering, Texas A&M University of Qatar, Doha, Qatar.
From 2011 to 2012, he was a Senior Researcher with the
Hwa-Pyeong Park He received B.S Power Conversion and Control Research Center, HVDC
degree in electrical engineering from Research Division, Korea Electro technology Research
Koreatech in 2013. His research Institute, Changwon, Korea. Since 2013, he has been an
interests are high switching frequency Assistant Professor with the School of Electrical and
converter, switch mode power supply, Computer Engineering, Ulsan National Institute of Science
and digital control algorithm. and Technology, Ulsan, Korea. His research interests include
dc–dc converters, switched-mode power supplies, motor
drives and diagnosis systems, digital control and signal
processing algorithms, digitally controlled power electronics,
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Design Considerations of Resonant Network and Transformer Magnetics for High Frequency LLC Resonant Converter