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326 IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 18, NO.

1, JANUARY 2003

Digitally-Controlled Single-Phase Single-Stage


AC/DC PWM Converter
Leopoldo Rossetto, Member, IEEE, and Simone Buso, Member, IEEE

Abstract—The paper presents the implementation of a fully for the power converter basic components is also outlined. Then,
digital controller for a boost integrated ac/dc PWM converter. a fully digital control strategy is discussed, that is employed to
The considered converter has the following basic features: high shape the input current and simultaneously control the output
power factor, full control of the dc output voltage, high-frequency
line filter inductor and insulation transformer. Its main advantage voltage. Its implementation with the TMS320F240 digital signal
is the complete integration of a rectifier and an inverter stage, processor (DSP) is described. The proposed control strategy is
requiring only four IGBTs and six diodes. The converter is then experimentally tested on a 0.5 kVA laboratory prototype.
described in detail and the structural limitations of its operation Some of the results are presented to describe the achievable
are highlighted. The paper focuses on the converter control performance and validate the design.
strategy describing in detail the implementation, by means of the
TMS320F240 digital signal processor, of a fully digital, predictive,
input current control technique. An application specific modu- II. SYSTEM DESCRIPTION
lation strategy is also developed that allows simultaneous input
current and output voltage control. The control system is finally A. Converter Scheme and Operating Modes
tested on a 0.5 kW laboratory converter prototype. The presented
results validate the design procedure and illustrate the achievable The basic scheme of the proposed converter is shown in
converter performance. Fig. 1. As can be seen, the converter employs four IGBT
Index Terms—Digital control, PWM converters, PWM rectifiers. switches, which are in a typical full-bridge configuration,
and six diodes. The two upper diodes ( and ) are the
free-wheeling diodes required by the inductive load of the
I. INTRODUCTION inverter, while the four lower diodes ( to ) act both

T HE INDUSTRIAL interest for compact ac/dc converter


topologies, integrating an high quality rectifier and a dc/dc
or dc/ac stage, is very high. This has motivated the investigation
as free-wheeling diodes and line current rectifiers. It must be
noted that this topology also allows standard IGBT modules
(comprising the free-wheeling diodes) to be adopted, provided
of several topologies, widely described in the literature, both that the four rectifier bridge diodes are externally added. Filter
for low power applications, up to 300 W [1]–[4], and for higher capacitor ensures a constant dc voltage for the inverter
power levels [5]–[7]. The goal of such integrated converters is to operation. Generator represents the line voltage, while input
obtain both power factor correction and load voltage regulation inductor provides the necessary filtering action on the input
with the minimum number of components, reducing cost and current. Finally, the converter load, which is only schematically
size and increasing efficiency, with respect to conventional represented in Fig. 1, includes the insulation transformer, the
two-stage solutions. On the other hand, the integration of the rectifier stage and the inductive-capacitive filter needed to
two stages generally limits the achievable performance, and smooth the output voltage.
negatively affects the dynamic control either of the input current The converter operation is now explained assuming that: a
or of the output voltage. This paper proposes an integrated ac/dc stable dc voltage is maintained across capacitor all along
PWM converter that provides an high quality input current, the modulation period; the input voltage is positive and suit-
compliant with IEC 61 000-3-2 low frequency EMC standard, ably lower than ; an almost unity power factor is achieved
and guarantees a fast dynamic control of the load voltage. so that the line frequency harmonic component of the input cur-
The structure integrates a diode bridge rectifier and a full rent can be considered practically in phase with the input voltage
bridge inverter. As a consequence, it appears to be particularly . In these conditions, the line current will flow through diodes
suitable for applications in the medium power range (up to some and of the rectifier stage. When the diagonal
kWs), such as battery chargers. Employing only four IGBT’s, is turned on, a positive voltage equal to is applied to the
six diodes and high frequency input inductor and insulation load, while a negative voltage (equal to ) is applied to
transformer, the converter is potentially capable of high power the input inductor . The line current is therefore forced to
densities. The paper presents in detail the converter operation decrease. When the opposite diagonal is turned on ( ), a
and the basic design constraints. A possible design procedure negative voltage ( ) is applied to the load while a positive
voltage (equal to ) is applied to the input inductor. The input
Manuscript received January 21, 2002; revised November 1, 2002. Recom- current is now forced to increase. Because of the transformer
mended by Associate Editor S. B. Leeb. used the to isolate the load, the duration of these two phases,
The authors are with the Department of Information Engineering, Univer- that are the powering phases of the converter, must always be
sity of Padova, Padova 35131, Italy (e-mail: leopoldo.rossetto@dei.unipd.it; si-
mone.buso@dei.unipd.it). the same in any modulation period, so as to allow the magne-
Digital Object Identifier 10.1109/TPEL.2002.807162 tizing current reset. By varying the duration of the powering
0885-8993/03$17.00 © 2003 IEEE

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ROSSETTO AND BUSO: DIGITALLY-CONTROLLED SINGLE-PHASE SINGLE-STAGE AC/DC PWM CONVERTER 327

TABLE I
CONVERTER OPERATING MODES

a zero average voltage across the input inductor. Imposing this


condition, we obtain:

Fig. 1. Converter basic scheme. (2)

where represents the duty-cycle used in the input current


phases it is possible to regulate the average value of the recti- control. The independent variable is the instantaneous line
fied output voltage, in principle between 0 and (assuming a angle, equal to , being the line frequency
unity turns ratio for the transformer). Two free-wheeling phases and the time variable.
are also possible, both imposing a zero voltage across the load: Equation (2) implies that the duty-cycle , required to con-
by turning on switches and a negative voltage is applied trol the input current, has to satisfy the following conditions:
to the input inductor (equal to ) which forces the input
current to decrease, while, by turning on switches and a
positive voltage (equal to ) is applied to the input inductor, (3)
which forces the input current to increase. As a consequence,
during the free-wheeling phase of the load, control of the input
current can be simply performed, without affecting the output It is possible to see that (3) can only be satisfied in the fraction
voltage regulation, by properly switching between the two com- of the line period when
binations ( or ). Of course, similar considera-
tions are possible in the case of a negative input voltage . (4)
Table I sums up all of the considered switch combinations, high-
lighting their effects on the transformer primary side voltage where and are given by the following relations:
and input current .

B. Structural Constraints
(5)
The converter exhibits some structural constraints that limit
its capability to fully control the input current waveform. As This implies that the input current can be successfully con-
previously explained, the control of the input current only takes trolled and forced to be proportional to the input voltage only
place during the free-wheeling phases of the load. This implies during a fraction of the line period. Based on (2)–(5) Figs. 2 and
that, when the modulation index of the converter , defined as 3 have been computed. Defining the input current control angle
the ratio between the average, in the modulation as the fraction of the line half-period (in degrees) where cur-
rent control is possible, Fig. 2 shows the achievable converter
average input voltage , and clarifies that current control is
(1) possible only when can be made equal to , as stated by
(2). Fig. 3, instead, shows two key design parameters, that are
period, of the rectified output voltage , and the dc link voltage both functions of . The former is the maximum allowed con-
, as in (1), is close to unity, assuming again unity turn ratio verter modulation index , the latter is the maximum al-
for the transformer, very little time is available to control the lowed ratio between the dc link voltage ( ) and the line
input current. To better clarify this point, we now consider the voltage peak value ( ). Given the desired control angle and
average inductor voltage as a function of the sinusoidal input the line voltage peak value, using Fig. 3 it is possible to deter-
voltage and dc link voltage . Equation (2) states that, mine what are the maximum possible modulation index and
in order to control the input current, it must be possible to force dc link voltage for that control angle.

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328 IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 18, NO. 1, JANUARY 2003

TABLE II
DESIGN SPECIFICATIONS

power from the line. This means that the converter cannot op-
erate in no-load conditions because the power flow from the line
to the converter in each modulation period cannot be reduced to
zero and cannot be reversed, due to the presence of the input
diode bridge. In other words, a minimum load must always be
guaranteed to ensure the power balance. Moreover, when the
output power gets close to the minimum level, the control of the
Fig. 2. Converter’s average input voltage U and line voltage U . Current input current is lost. Anyway, we verified that, in our design,
control is possible only within an angle  of the line voltage half-period. acceptable operation is possible down to 10% of the nominal
output power.

III. POWER CONVERTER DESIGN


A. Preliminary Considerations
Given the basic specifications listed in Table II, a possible
design procedure is described in the following. First of all, a
proper value for the dc link voltage has to be chosen. A suit-
able choice is 250 V, which allows the use of 400 V switches.
From this value and the peak line voltage, (5) allows to calculate
the maximum possible modulation index, that can also be de-
termined using Fig. 3. A 0.63 value is obtained. It is important
to observe that, again from Fig. 3, a minimum current control
angle of about 120 can be expected, that is wide enough to get
a sufficiently low input current harmonic distortion.

B. Converter Design
Fig. 3. Upper trace: ratio between U and line voltage peak value U as Based on an estimated efficiency of about 80%, the average
a function of the line control angle. Lower trace: maximum modulation index input power absorbed from the grid is about 0.625 kW. There-
M as a function of the line control angle.
fore the expected input current is about 5.7 A . To limit the
peak to peak current ripple to 30% of the peak input
Fig. 3 also shows that it is not possible to simultaneously
current a suitable value for the input inductor can be selected
achieve an high modulation index and the full control of
according to
the line current. Moreover, increasing the dc link voltage also
implies a reduction of the current control angle.
When the input voltage does not satisfy (4), two situations (6)
are possible: if (2) shows that the line current
will be forced to decrease to zero and the converter will operate Equation (6) is derived using (2) and (3) and calculating the
in discontinuous conduction mode at the input side. Instead, if maximum of the input current ripple as a function of the in-
the input current amplitude will be forced to stantaneous line angle . In our design, a value of 1.8 mH was
increase, practically becoming equal to that of an uncontrolled selected.
diode rectifier with capacitive output filter. In both cases the line The value of the dc link filter capacitor can be determined
current waveform will significantly differ from the ideal sinu- imposing the peak to peak voltage ripple across it. As in any
soidal waveform, exhibiting some distortion. A careful design, power factor corrector (PFC), the dc link capacitor works as an
anyway, allows to achieve a satisfactory line side behavior, as it energy tank, supplying power to the load when the pulsating
will be shown in Section V. input power is lower than that required by the load, and accumu-
Finally, we must observe that, during each modulation period, lating energy when the load power is lower than that absorbed
one of the two load powering phases implies the absorption of from the grid. This power exchange determines a voltage ripple

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ROSSETTO AND BUSO: DIGITALLY-CONTROLLED SINGLE-PHASE SINGLE-STAGE AC/DC PWM CONVERTER 329

at twice the line frequency, whose amplitude is directly deter- In Section V instead, step variations of the modulation index
mined by the size of the filter capacitor. Considering an instan- will be discussed.
taneous power balance, the following equation can be derived
A. Input Current Predictive Control Strategy
(7) We begin our discussion with the input current control
strategy. As it was explained above, during the powering
which relates the capacitor value to the desired peak to peak phases of the load, no control of the input current is possible. It
voltage ripple. Current represents the average inverter will increase or decrease depending on which diagonal of the
current, needed to transfer the required output power and bal- bridge is turned on and on the sign of the input voltage. The
ance the losses. In our case, a voltage ripple lower than 10% of free-wheeling interval, instead, allows the control of the input
the nominal value is desired, which requires a capacitor of current. The current controller has to determine the duration of
at least 320 F. We note that the capacitor current due to the low each of the two free-wheeling states in each modulation period,
frequency ripple turns out to be about 0.9 A , which seems so as to make the current track its reference.
to be an acceptable value. A possible strategy to achieve this result, exploits the
As far as switches and diodes are concerned, it is only re- following discrete-time equation (9), which is directly derived
quired to estimate the current stress, since the voltage stress is from (2) by considering a zero-order hold discretization of the
equal to for each device (see Fig. 1). The current stress of input current dynamic equation
the upper switches is only due to the load current and is there-
fore lower than the lower switches’ stress. In the lower switches
flows the sum of the input and the load currents, determining the
required rating of the devices. To give an example, in our design,
that assumes a unity transformer turns ratio, the switches need (8)
to be rated for a maximum peak current of about 11 A.
The design of the output side of the converter is quite straight-
forward, since it is based on a conventional forward structure.
Given the desired output voltage, the transformer turns ratio can (9)
be determined. The inductive-capacitive output filter, instead,
can be designed setting the maximum allowed inductor current Equation (9) relates the duty-cycle of current control to the
and output voltage ripples. input current variation in a modulation period, from the generic
instant to the following sampling instant .
IV. CONTROL STRATEGY AND IMPLEMENTATION Equation (9) assumes that all variables are sampled at the be-
The above described converter can be effectively controlled ginning of each modulation period and that input voltage
in a fully digital way. Although analog control is also possible is positive. Of course, a similar equation can be written for the
[8], we experimentally investigated only the digital approach, negative half-period of the input voltage. A predictive control
that is described in the following. The controller we developed law [8], [9] can then be based on (9) and used to determine the
includes a suitable PWM modulator, an input current controller, value of , assuming that is given by
based on a predictive algorithm, and a dc link voltage propor- (10)
tional-integral (PI) regulator. It is worth noting that in the fol-
lowing presentation we consider in detail only the input cur- where is the equivalent input conductance of the converter.
rent control and the modulation strategy, since the control of In our implementation, as it will be explained in the following,
the output voltage and current is completely conventional, pro- this is automatically adjusted by a simple PI regulator control-
vided that filter capacitor is large enough to exchange energy ling the dc link voltage , as in any conventional PFC. It is
with the load without significant voltage variations. The output worth noting that (10) assumes that the input voltage does not
voltage control can be any kind of standard voltage mode or cur- change significantly from a modulation period to the following
rent mode control applicable to a forward converter. It is worth one, so that . This hypoth-
noting that the dynamic variations of the converter’s modulation esis is normally verified, thanks to the high ratio between the
index , defined in (1), which may be required by the output sampling (and modulation) frequency and the input voltage fre-
voltage control, may cause the input current controller’s satu- quency. The predictive control equation (11) can now be derived
ration, since this operates only during the load free-wheeling by substituting (10) into (9) computed one step forward, i.e.,
phase. This is not what happens in a conventional two stage evaluated between instants and , and
PFC, where the load side and line side controls are dynamically solving for
de-coupled. However, with our converter it is possible either to
limit the variations of , so as to preserve input current control,
or to limit the input current control in the presence of dynamic (11)
load variations, if output voltage regulation is considered more
important. Anyway, in the following presentation we will not It is important to underline that the absolute value for the
take into account the interaction between the two controllers, input voltage sample and input current sample
practically assuming the modulation index to be a constant. is introduced when the control equation for the positive half

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330 IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 18, NO. 1, JANUARY 2003

TABLE III
CONVERTER PARAMETERS

lag its reference by a two sampling period delay. It is worth


noting that, being essentially a dead-beat control, this technique
guarantees an excellent dynamic performance; provided that
all the parameters of (11) are exactly known, the controller is
capable of replicating the current reference with a two cycle
delay also in the presence of step variations or other transients.
It is finally worth noting that (11) inherently takes into ac-
Fig. 4. Operation of the digital PWM modulator. count the computation delay of the microprocessor and the A/D
conversion time. The output of the control equation refers in fact
to the modulation period following the one where calculations
are performed. This means that a complete modulation period is
the maximum allowed time to sample and convert the input vari-
ables and to compute (11). As a consequence, being the compu-
tation time not so critical, the solution is attractive also for a
medium level microcontroller implementation, especially once
the control complexity is further reduced, as explained in the
following.

B. Implementation Related Issues


Though theoretically correct, (11) is not so immediate to im-
plement in a microprocessor. First of all, it is important to notice
that its derivation is based on average quantities, i.e., the modu-
lation process is totally neglected. To make the controller work
properly, it is therefore necessary that the input variables in (11)
represent the average value in the modulation period of the cor-
responding physical quantities. While this is inherently true for
slowly varying quantities like or , particular care must be
taken for the input current . In order to eliminate the current
ripple and to sample only the average current value, synchro-
nization is required between the modulation and sampling pro-
cesses. By sampling the input current properly, filtering of the
high frequency ripple can be avoided. It is possible to verify that
with our modulation strategy, explained in the following section,
sampling the input current at the beginning of each modulation
period inherently guarantees the required filtering action, but
Fig. 5. Flow chart of the control program.
implies also a low frequency error. Anyway, this error is well
compensated by the dc link voltage control loop.
period and that for the negative one are combined to get Another problem concerning (11) is the presence of several
(11). Equation (11) is thus valid for the whole line period input quantities as fraction denominators. The implementation
and represents the actual input current control equation. Its of (11) would therefore require the execution of divisions,
physical interpretation is the following. represents which are always computational time consuming. Conse-
the duty-cycle required in the next modulation period to force quently, to avoid a division and further simplify the control
the input current tracking error to zero, i.e., to get the input algorithm, the variation of the dc link voltage has been
current to its reference at instant . Of course, neglected and its nominal value has been used in (11). This
being the current reference a time varying signal, the tracking implied no particular worsening of the control performance, as
error will never get to zero; the average input current will it will be shown in Section IV.

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ROSSETTO AND BUSO: DIGITALLY-CONTROLLED SINGLE-PHASE SINGLE-STAGE AC/DC PWM CONVERTER 331

Fig. 6. Input voltage U (40 V/div) and current i (2 A/div). Horizontal: 2


ms/div. Fig. 7. Input current i spectrum (10 dB/div). Horizontal: 125 Hz/div.

Moreover, in order to avoid another division when the algo-


In order to implement the modulator, we took advantage
rithm operates on a variable instead that on a constant value
of the flexibility of the internal PWM modulator provided
as supposed by (11), the control equation has been re-written
by the selected hardware platform. We programmed three
considering a new control variable for the input current that is
PWM compare registers, namely PWM1, PWM2 and PWM3
defined as
respectively with , and ,
(12) immediately obtaining from the PWM2 output the logic state
of inverter leg . By AND-ing the negated PWM1 output
This gave the following modified control equation: (directly provided by the modulator) and the PWM3 output
signal, we obtained also the logic state of leg . This
required only an external AND gate. It is worth noting that this
organization of the modulator allows an easy synchronization
(13)
of the input current sampling with the modulation process.
As can be seen, the substitution of with greatly sim- The interrupt generated by the period counter, associated with
plifies the control equation in the case of a variable . There- the modulator, can automatically be used to trigger the A/D
fore in our implementation, (13) has been used instead of (11). conversion, with minimum delay. Moreover, the sequence of
Clearly, the control of the converter switches has now to be powering and free-wheeling phases implied by this organization,
based on variable , which implies a proper organization of allows us to sample the current exactly at its valley, as can be
the modulator. verified with the help of Table I. This way, the high frequency
ripple is filtered, but we have an error on the average current
C. Pulse Width Modulator Implementation equal to a half of the current ripple amplitude. This is anyway
A suitable PWM modulation strategy has been devised, that well compensated by the outer voltage loop.
allows to properly operate the control of load voltage and input
current, once the modulation index and the control variable D. DC Link Voltage Control
are provided by the above described external controllers. Fig. 4 As already mentioned, in our controller the reference for the
describes the modulation process in dynamic conditions. The current control loop is derived, as in any PFC controller, by mul-
plotted variables are the logical states of the two inverter legs, tiplying the input voltage samples and the output of a suitably
from top to bottom and respectively. Fig. 4 shows the designed dc link voltage controller. The idea is to absorb a cur-
effect of a sudden change in the modulation index , as could rent from the utility grid as proportional as possible to the line
be required by the output voltage controller. As in any naturally voltage, so as to maximize the power factor. The amplitude of
sampled PWM process, we have an inherent one period delay the current reference has to be adjusted to balance the power
(worst case) in the response of the modulator. In practice, the flow through the converter. This is easily done by keeping the
modulator updates the duration of the load powering phases at dc link voltage to the desired level. A simple PI regulator, whose
the beginning of the first modulation period following the step design is straightforward, can achieve this result. The only point
variation of the reference signal. Of course the duration of the which is worth underlining is the need for a quite low regulator
two free-wheeling phases is also modified by the current con- bandwidth, well below the line frequency. This is necessary to
troller to maintain the input current close to its reference. filter the dc link voltage ripple from the feedback signal and

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332 IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 18, NO. 1, JANUARY 2003

(a) (b)

(c)
Fig. 8. (a) Transient in the M parameter from 0.5 to 0.4. Input current i (2 A/div) and M signal. Horizontal: 40 ms/div. (b) Detail of the input current i (2 A/div)
and input voltage U (40 V/div) with M = 0:5. Horizontal: 2 ms/div. (c) Detail of the input current i (2 A/div) and input voltage U (40 V/div) with M = 0.4.
Horizontal: 2 ms/div.

so to avoid input current distortion. In our implementation, the algorithm and the dc link voltage controller are implemented by
PI regulator was designed for a 10 Hz bandwidth and 60 phase an assembly program, whose flow-chart and timing are shown
margin. Given the reduced bandwidth requirement the sampling in Fig. 5. As can be seen, the control program is organized
frequency for this controller can be fairly low, allowing a con- in two interrupt service routines. The dc link voltage control
siderable reduction of the computation time. routine is performed at a reduced frequency, namely 1 kHz. It
requires 7 s, including A/D conversion. The PWM routine,
including the line current controller, is instead executed at the
V. EXPERIMENTAL MEASUREMENTS modulation frequency, i.e., 20 kHz. This requires 22 s, again
including A/D conversion. As can be seen, the execution time
The above described controller has been implemented using of the routines is much smaller than the modulation period,
a TMS320F240 digital signal processor (DSP) by Texas Instru- so that the possible implementation of the output voltage con-
ments. The device allowed us to implement the PWM modulator troller would not represent a problem.
almost directly, offering significant counter programmability Following the design procedure outlined in Section III, a con-
and a large number of independent PWM channels. In case of a verter prototype was designed, whose main parameters are given
less flexible architecture it is our opinion that an FPGA-based in Table III. As described above, the input current control angle
custom modulator could be a good solution. The current control is expected to be higher than 120 , so that a good power factor

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ROSSETTO AND BUSO: DIGITALLY-CONTROLLED SINGLE-PHASE SINGLE-STAGE AC/DC PWM CONVERTER 333

and current THD are expected. The output voltage was not reg- current and of a dedicated pulse width modulator. Experimental
ulated and a constant was set for these experimental results are described, which validate the control strategy and
tests. illustrate the achievable converter performance.
Fig. 6 shows the line side behavior of the converter, with an
output power of 300 W. As can be seen, the filtered current is REFERENCES
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waveform. Reducing the value widens the current controller
operation angle, thus making the current waveform closer to Leopoldo Rossetto (M’95) was born in Italy in
an ideal sinusoid and improving the power factor. This can be 1960. He received the M.S. degree in electronic
noted comparing Fig. 8(b) and (c), where the estimated THD engineering and the Ph.D. in electrical engineering
from the University of Padova, Italy, in 1985 and
varies from almost 35% to 25%. In addition, the output power 1991, respectively.
decrease implied by the variation, from 500 W to about 350 Since 1990, he has been a Permanent Researcher
W, calls for the consequent reduction of the current reference in the Power Electronics Laboratory (PEL), Univer-
sity of Padova, and since 1998, as an Assistant Pro-
amplitude, so as to balance the input–output power flow. This fessor in electronics. His research interests are in the
takes places according to the dynamic response of the dc link fields of analog electronics, power electronics, con-
voltage controller, that is clearly visible in Fig. 8(a). trol techniques, and digital simulation.

VI. CONCLUSION
Simone Buso (M’97) received the M.S. degree
A compact, integrated ac–dc converter is discussed. The in electronic engineering and the Ph.D. degree in
topology integrates an high-quality rectifier and a conven- industrial electronics from the University of Padova,
tional full bridge inverter in a single stage. The converter is Italy, in 1992 and 1997, respectively.
Since 1993, he has been with the Power Elec-
described in detail, the structural limitations of its operation tronics Laboratory, University of Padova, where
are highlighted and design criteria are derived. The paper he is currently a Researcher in the Department of
focuses on the converter control strategy describing in detail the Information Engineering (DEI). His main research
interests include dc/dc and ac/dc converters, smart
implementation, by means of the TMS320F240 digital signal power ICs, digital control, and robust control of
processor, of a fully digital predictive controller for the input power converters.

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