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1, JANUARY 2003
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
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ROSSETTO AND BUSO: DIGITALLY-CONTROLLED SINGLE-PHASE SINGLE-STAGE AC/DC PWM CONVERTER 327
TABLE I
CONVERTER OPERATING MODES
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.
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
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ROSSETTO AND BUSO: DIGITALLY-CONTROLLED SINGLE-PHASE SINGLE-STAGE AC/DC PWM CONVERTER 331
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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
almost proportional to the input voltage for at least 120 , as ex- [1] R. Redl, L. Balogh, and N. O. Sokal, “A new family of single-stage iso-
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sured power factor is 0.98. As can be seen, the approximations supply technique with input-current shaping and fast output-voltage reg-
made to simplify the controller implementation, as described in ulation for universal input-voltage-range applications,” in Proc. IEEE
the previous section, do not affect stability and do not cause a APEC’97 Conf., 1997, pp. 272–280.
[3] T. F. Wu, Y. J. Wu, and Y. C. Liu, “Development of converters for im-
significant error in the current waveform generation. proving efficiency and achieving both power factor correction and fast
Fig. 7 shows the low frequency harmonic spectrum measured output regulation,” in Proc. IEEE APEC’99 Conf., 1999, pp. 958–964.
in the same conditions of Fig. 6. As can be seen, the third har- [4] A. Ikriannikov and S. Cuk, “Direct AC/DC conversion without input
rectification,” in Proc. IEEE PESC’99 Conf., 1999, pp. 181–186.
monic is about 28 dB lower than the fundamental. A worse har- [5] Y. Jiang, G. C. Hua, W. Tang, and F. C. Lee, “A novel single-phase
monic content can be measured if the current control angle is power factor correction scheme,” in Proc. IEEE APEC’93 Conf., 1993,
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[6] R. Srinivasan and R. Oruganti, “Analysis and design of power factor
seen in Fig. 8(b), where the input power is almost at the nom- correction using half bridge-boost topology,” in Proc. IEEE APEC’97
inal value. In that case, we estimated a THD value slightly lower Conf., 1997, pp. 489–499.
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can be seen in Fig. 8(a), no stability problem is revealed, both in verter,” in Proc. IEEE Ind. Applicat. Soc. (IAS) Annu. Meeting, Chicago,
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transient determines a significant variation of the input current
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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