Direct AC/AC Active-Clamped Converter Inductive Coupled with

Half-Bridge Converter with Reduced Switches for Battery Charging

Applications

Saniya Nayyar

1 a

and Manish Rathi

2 b

Department of Electronics and Communication Engineering, PDA College of Engineering, Kalaburagi, India

Department of Electrical and Electronics Engineering, PDA College of Engineering, Kalaburagi, India

Keywords: Power Factor Correction, Cuk Converter, Fuzzy Logic Controller, Electric Vehicle Applications, Battery

Charging.

Abstract: In this study, a novel series-series compensated inductive coupling-based battery charging. system is

suggested. It uses an innovative direct AC/AC active-clamped converter paired with A half-bridge converter.

By removing the correction stage, the suggested converter achieves a real single stage (AC-to-AC) conversion

using fewer switching devices. Additionally, it does away with need for large, life-limited electrolytic DC-

link capacitors. The suggested converter's operating modes and control structure are briefly examined.

Additionally, a novel predictive dead-beat grid current control method and the linear mean current charging

are created for the proposed converter, allowing for the management of charging current and a unity power

factor. The simulation is to be carried out in MATLAB/Simulink software. A hardware model is designed to

validate the design of the proposed system.

1 INTRODUCTION

Inductive power transfer (IPT) technique is becoming

more widely used in a wide range of products,

including electric vehicle (EV) charging, lightweight

electronics, and biomedical implants. Facilitation,

safety, and the potential for range enhancement are all

benefits of using IPT in EV charging systems since

fully automated charging gives EVs more

opportunities to charge. In its most basic form, an IPT

charging method consists of a pair of inductive

coupling coils (Ramezani et al.,2019) compensation

structures, primary converters that provide high-

frequency supplies and a secondary rectification that

changes the AC power into DC power for charging

the battery pack (Liu et al., J.2018).

In the base assembly of IPT systems, while power

factor correction (PFC) is required during conversion

between AC primary voltage to DC voltage in order

to ensure the quality of AC input power, dual-stage

conversion (AC-DC-AC) was often used until

recently. After that, high-frequency inputs are

https://orcid.org/ 0009-0002-2453-304X

https://orcid.org/ 0009-0005-4809-3642

produced and sent to the primary coil by a high-

frequency inverter that is coupled to the PFC

rectification by a DC-link capacitor (Samanta et

al.,2019).

The fundamental benefit of IPT systems

employing dual-stage converter is that both the PFC

rectification device and the power inverter may be

independently adjusted to optimise particular

performance indices since they are isolated via the

DC-link capacitor. Still, the system's price, size, and

weight are all increased by the existence of many

converter stages and a large DC-link capacitor(Phuoc

Sang Huynh et al.,2019). The usage of matrix

conversions (MCs) to supply IPT systems has come

under more and more scrutiny in the past few

decades. MCs improve system efficiency with regard

to of power density, validity, and expenditure by

enabling the instantaneous conversion of frequencies

low AC sources (50-60 Hz) over high-frequency

outcomes (up to 85 kHz) eliminating intermediary

conversion phase (Moghaddami,2018).

Nayyar, S. and Rathi, M.

Direct AC/AC Active-Clamped Converter Inductive Coupled With Half-Bridge Converter With Reduced Switches For Battery Charging Applications.

DOI: 10.5220/0012506600003808

Paper published under CC license (CC BY-NC-ND 4.0)

In Proceedings of the 1st International Conference on Intelligent and Sustainable Power and Energy Systems (ISPES 2023), pages 59-66

ISBN: 978-989-758-689-7

The DC-link storage modules on the main side of

the single-phase matrix converter-based IPT systems

are removed in order to neutralise dual frequency

ripple, which causes it shown on the battery end.

Batteries may be supplied by dual frequency (100 or

120 Hz) power using the sine wave ripple current

(SRC) recharging approach, according to with very

negligible negative impacts on performance. As a

result, IPT systems based on matrix converters may

benefit from the sinusoidal charging approach and do

without the middle DC-link capacitor. Creating a

control strategy for regulating power and correction

of power factors is the main difficulty when utilising

MCs for IPT charging devices (Huynh et al.,2020).

A supplementary interactive full bridge

rectification is utilised in an IPT recharging device

that is supplied by a buck-derived MC. The rectifier's

output power can be modulated by modulating the

MC using a phase-shift PWM technique. For the IPT

structures, a boost-derived full-bridge MC (FBMC)

that is compatible with the main parallel-series

correction system is suggested (Yao et al.,2017).

With dual loops of control that resemble those of a

typical boost converter, the suggested converter

architecture can regulate the flow of power and form

main current. Additionally, a single-stage design

merging a full-bridge VSI and a bridgeless boost PFC

converter is suggested for IPT systems.

The main current control circuit is abolished when

the converter is used in a discontinuous conduction

(DCM). Nevertheless, with DCM, the converter has

additional stress, losses, and EMI issues. The need for

several active switches and complicated switching

algorithms are the fundamental shortcomings of the

previous single-stage converter architectures (Vu et

al.,2019).

The IPT-based charging of batteries system is

suggested to be fed by a brand-new AC/AC active-

clamped converter featuring a half bridge converter

on the back end. The suggested converter offers

single-stage energy conversion by doing away with

the front-end rectification and galvanic dc-link

capacitor, which enhances the system's functionality

in terms of effectiveness, dimensions, weight, and

price. The main side of the converters must have a

serial equalisation circuit since the converter's

outcomes is high-frequency energy (Charthad et

al.,2018). To improve the system effectiveness and

prevent the discontinuous conductance phenomena

caused by the nonlinear feature in diode-bridge

rectifier devices, a dynamic rectifier is utilised in

place of them on the battery side. It is created a dual

regulation approach that combines regular mean

current regulation with predicted deadbeat current

regulation. The use of the prediction based dead-beat

(PDB) controller for line current regulation has

certain advantages, including improved power factor,

simple setup without taking into account load and

mutual inductance fluctuations, and quick reference

monitoring. In an attempt to decrease the quantity of

switches as well as high frequency switching

distortions, simultaneously reversible switches are

substituted with a single switch connected to a

rectifier bridge.

2 SYSTEM DESCRIPTION

The block diagram of the proposed system is shown

below in Fig 1.

Fig 1: Proposed system Block diagram.

To power the battery in this, an ac supply is linked

to the suggested converter. The battery serves as the

load in this. The voltage is increased using the

Ac/Ac active clamped conversion device in

accordance with the load requirements, and the rate

of supply is changed to a high frequency so that

inductively coupled transfer of power is superior

with higher frequencies. The half bridge converter

receives the transmitted power and converts it from

ac to dc. To ensure an effortless charging process

and prevent a dual frequency fluctuation (100Hz), a

dual loop regulation is offered to adjust the mean

current at the pack's side. The addition of a dead-

beat controller enhances the system's overall

dynamic performance.

Fig 2: AC/AC Converter.

ISPES 2023 - International Conference on Intelligent and Sustainable Power and Energy Systems

The suggested AC/AC converter combines an HB

matrix converter and an AC/AC boost converter. The

AC/AC converter is set up using two switches

connected to diode bridges. The input current

rectification and recharging regulation procedures in

the suggested IPT system are accomplished by

regulating the main AC/AC converter's cycle duration

using dual loops of control. Both switches S1 and S2

function in positive as well as negative phases and are

complimentary to one another. The proportion of the

duration of the switch S1's on-time to the switching

phase is known as the duty cycle, which stands for

the AC/AC converter.

A high-frequency unipolar square wave voltage

(Vp), whose magnitude and direction fluctuate on the

clamped voltage (VCi), is the resultant voltage of an

instantaneous AC–AC active–clamped HB converter.

The SS compensating system is used because it is

straightforward, affordable, highly efficient, and

compensates for loads independently. The two main

resonant networks are set to the identical resonant

frequency, which is equivalent to the frequency of the

power electronic switch, so as to maximise the

electrical power deliver capabilities and reduce the

VA grade of the converter. The secondary component

of the network has a proactive HB rectifier, and both

switches that operate Ss1 and Ss2, function at fs with

a set duty period of 0.5.

The generated duty cycle of 0.5 at the secondary

voltage Vs. Remember that the higher switch Ss1's

on-time to switching duration is referred to as the

required period ds of the converter. Both the resonant

networks have been adjusted to the switching

frequency and the phase offset across vp and vs is

required to be held from 0 to 180 degrees in enable to

transmit energy between the grid and battery pack.

Where Lp and Ls are the self-inductances of the

primary and secondary coils, Cp and Cs are the

primary and secondary compensation capacitors, and

s = 2fs is the switching angular frequency.

The modes of operation of the proposed converter

is provided below:

Fig 3a: Proposed Converter.

Mode 1:

The switch S1 is turned ON in this mode. The L1 gets

charged by the input source. The Cp discharges and

provides energy to the inductor Lp. In secondary Ss1

is ON and the inductor Ls provides energy to the load

through Cs.

Fig 3b: Mode 1 of the Proposed Converter.

Mode 2:

The switch S1 is still turned ON in this mode and L1

gets charged by the input source along with Cp. In

secondary Ss1 is ON and the inductor Ls provides

energy to the load through Cs.

Fig 4: Mode 2 of the Proposed Converter.

Mode 3:

The switch S1 is OFF and S2 is turned ON in this

mode and L1 gets discharged and charges C1 along

with Cp. In secondary Ss1 is ON and the inductor Ls

provides energy to the load through Cs.

Fig 5: Mode 3 of the Proposed Converter.

Direct AC/AC Active-Clamped Converter Inductive Coupled With Half-Bridge Converter With Reduced Switches For Battery Charging

Applications

Mode 4:

The switch S1 is OFF and S2 is turned ON in this

mode and L1 gets disconnected as it completely

discharged and C1 starts discharging and charges the

Cp. In secondary Ss1 is ON and the inductor Ls

provides energy to the load through Cs.

Fig 6: Mode 4 of the Proposed Converter.

Mode 5:

The switch S1 is OFF and S2 is turned ON in this

mode and L1 gets disconnected as it completely

discharged and C1 starts discharging and charges the

Cp. In secondary Ss2 is ON and the inductor Ls is

getting charged from Cs.

Fig 7: Mode 5 of the Proposed Converter.

Mode 6:

The switch S1 is OFF and S2 is turned ON in this

mode and L1 gets disconnected as it completely

discharged and C1 gets charged by the Cp. In

secondary Ss1 is ON and the inductor Ls is getting

discharged through Cs.

Fig 8: Mode 6 of the Proposed Converter.

For negative half cycle, the same process is repeated.

Fig 9: Mode 7 of the Proposed Converter.

Mode 7:

The switch S1 is turned ON in this mode. The L1 gets

charged by the input source in reverse direction. The

Cp discharges and provides energy to the inductor Lp.

In secondary Ss1 is ON and the inductor Ls provides

energy to the load through Cs.

Fig 10: Mode 8 of the Proposed Converter.

Mode 8:

The switch S1 is still turned ON in this mode and L1

gets charged by the input source along with Cp in

reverse direction. In secondary Ss1 is ON and the

inductor Ls provides energy to the load through Cs.

Fig 11: Mode 9 of the Proposed Converter.

ISPES 2023 - International Conference on Intelligent and Sustainable Power and Energy Systems

Mode 9:

The switch S1 is OFF and S2 is turned ON in this

mode and L1 gets discharged along with C1 and

charges Cp. In secondary Ss1 is ON and the inductor

Ls provides energy to the load through Cs.

Fig 12: Mode 10of the Proposed Converter.

Mode 10:

The switch S1 is OFF and S2 is turned ON in this

mode and L1 gets disconnected as it completely

discharged and C1 starts discharging along with Lp

and charges the Cp. In secondary Ss2 is ON and the

inductor Ls getting charged from Cs.

Fig 13: Mode 11 of the Proposed Converter.

Mode 11:

The switch S1 is OFF and S2 is turned ON in this

mode and L1 gets disconnected as it completely

discharged and C1 starts discharging along with Lp

and charges the Cp. In secondary Ss1 is ON and the

energy in inductor Ls is discharged to load through

Cs.

Fig 14: Mode 12 of the Proposed Converter.

Mode 12:

The switch S1 is OFF and S2 is turned ON in this

mode and L1 gets disconnected as it completely

discharged and C1 starts charging along with Lp from

Cp. In secondary Ss1 is ON and the energy in inductor

Ls is discharged to load through Cs.

A duty ratio is calculated to reduce the peak value of

the capacitor clamping voltage for the peak source

voltage is provided below

The source ripple current, Im, for peak source

voltage is provided below

The M is derived for peak value of source current in

which dp = Dpm, ii = Im, and ds = 0.5.

The supply side and load side compensation

capacitors are calculated as shown below:

The clamping capacitor at the supply side, Ci, is

determined according to the permissible ripple

voltage Vc is as shown below.

DUAL CONTROL MODULATION SCHEME.

The suggested linear AC/AC converter operates by

two control loops in order to attain unity source power

factor and modulate power output within the single

conversion phase.

Direct AC/AC Active-Clamped Converter Inductive Coupled With Half-Bridge Converter With Reduced Switches For Battery Charging

Applications

Fig 15: Dual Control Modulation Scheme.

To control the mean battery current across a line

cycle, an external loop is set up. An IIR filter may be

used to determine the mean current from the battery.

The maximum current source reference Im* from the

external control circuit is increased by vi/Vm to

provide the sine wave standard current Ii* used in the

internal current circuit.

The external current regulation loop, which

regulates the mean current through the battery during

a line cycle, generates the highest possible current

source reference Im*. Considering the average power

equilibrium at both ends of the circuit and the

presumption that energy losses were ignorable, the

maximum current supply reference Im* may be

roughly calculated.

where Ib* is the mean value of reference battery

current.

In order to achieve a unity power factor for the

instantaneous AC/AC converter input, the internal

control circuit is used to adjust the current source after

the grid voltage. The PDB controller is used in this

loop to regulate the mean switched source current.

The PWM signals powering the instantaneous

AC/AC converter are produced using the dual-

edge/triangle regulation. By synchronising the

sample at the maximum or trough for the carrier

signal that is used with a particular PWM generating

approach, the mean of the current source may be

determined. The deadbeat regulator produces the

following duty cycle:

3 SIMULATION RESULTS

The simulation parameters of the proposed system are

provided in the table given below:

Table 1.

Input Voltage

120 V

Input power

1 KW

Switching Frequency

85 KHZ

Inductor

1mH

Resonant Capacitor

11.86nF

Decoupling Capacitor

3.3mH

Output Capacitor

0.7mF

Load Resistance

62.5Ω

The simulation circuit for the proposed converter

is provided below:

Fig 16: Simulation circuit for the proposed converter.

In this, the supply voltage of 120V is applied to

the proposed converter and the load voltage reference

is varied from 100V to 250 V at t=0.1s. The

simulation circuit of the controller is provided below:

Fig 17: Simulation circuit for the proposed controller.

In this the load voltage and current is provided to

the voltage control loop and current control loop

respectively. The input voltage and decoupling

capacitor voltage is provided to the dead beat control

along with the reference current and from that duty

ratio is calculated. The obtained duty ratio is provided

to the pwm pulse generation and the generated pulses

are provided to the controller.

The load voltage and current is provided is

provided below:

ISPES 2023 - International Conference on Intelligent and Sustainable Power and Energy Systems

Fig 18: Load voltage and current.

In this, the reference voltage is varied from 100V to

220V at t=0.1s and the measured voltage follows the

reference voltage along with the current. The power

factor measured is provided below:

Fig 19: Power factor of the converter.

The power factor of the proposed converter is

around 0.94. The %THD of the supply current is

provided below:

Fig 20: THD for the proposed converter.

The %THD of the supply current is around 7.23%.

A hardware prototype model of proposed

converter with input voltage of 12V, 50 Hz is

developed with 48V as output voltage with load

resistance of 100 ohm. The hardware parameters is

provided below in the following Table II.

Table 2: Hardware Parameters.

Arduino uno control is used for generating the

pulses for the proposed inverter and it is provided to

driver circuit (TLP 250) in order to drive the mosfets

IRF 250. The input voltage waveform is provided

below:

Fig 21: Input voltage for the proposed converter.

The input voltage is around 14V. The load voltage

waveforms is provided below:

Fig 23: Load voltage proposed converter.

The load voltage is around 45.2V with voltage

division as 10V/div.

4 CONCLUSION

In this paper, a AC/AC active clamped converter

based battery charging system is presented along with

operational analysis design and control structure.

Additionally, a novel predictive dead-beat grid

Direct AC/AC Active-Clamped Converter Inductive Coupled With Half-Bridge Converter With Reduced Switches For Battery Charging

Applications

current control method and the linear mean current

charging were designed for the proposed converter,

improving the power factor. The power factor is

measured as 0.94 and %thd of the supply current is

around 7.23%. A hardware prototype model is

developed to verify the operation of the proposed

converter.

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