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Current Sharing in Three-Phase LLC Interleaved Resonant Converter
Abstract -- In this paper, a novel approach for multi-phase However, future SMPS requirements will have to face one of
interleaved LLC resonant converter is presented. The proposed the few remaining drawbacks of LLC resonant converter
solution, based on the use of three LLC modules with star topology that is related to the output filter capacitor volume.
connection of transformer primary windings, allows a drastic Taking advantage of the interleaved approach, successfully
reduction of the output current ripple and consequently of the
applied in the past to synchronous buck solutions, in
output filter capacitor size. Differently from other multi-phase
solutions, that are greatly susceptible to resonant particular for point of load applications, the injection of
components tolerance causing current imbalance, the proposed rectified sine wave currents into the output filter capacitor
topology exhibits an inherent current sharing capability. can be adequately mitigated, thus reducing the total ripple.
Moreover, a closed-loop phase-shift control is introduced to Recently, many works have dealt with this issue and two-
additionally compensate for current mismatch and completely phase solutions, operating with 90 degrees phase-shift [4], or
balance the current supplied by each module. The benefit of even three-phase approaches, exploiting 120 degrees phase-
such solution on the reduction of output current ripple and the shift [5], have been proposed. One drawback of these
phase-shift control interaction and effect on load-step variations solutions is represented by the inherent current imbalance
are also investigated. Measurements on a prototype are added to
caused by resonant component mismatch that can lead one
simulations as validation of the assertions and proposals.
module or two modules (in the three-phase topology) to
I. INTRODUCTION reduce or even null their delivered power, requiring
mandatory workarounds to overcome the problem [6, 7]. In
During the 80s, many studies interested three-element Section II, a novel three-phase approach for LLC resonant
resonant converter topologies [1], that could possibly converter is introduced to avoid this great drawback by
overcome some limitations of two-element solutions. While means of a proper connection of the three interleaved
the LC-L resonant topology was first introduced in 1988 [2], modules. The advantages of this solution over the traditional
industry applications started to appear only in the last decade parallel topology are illustrated through Simulink
as suggested by 2002 patent [3] for the LLC topology based simulations, suggesting the inherent balancing capability of
on the topology initially presented in [2]. Indeed, resonant the proposed approach in getting rid of resonant components
converters have been confined in the last thirty years to niche tolerance effects. Section III presents an additional closed-
applications such as very high-voltage applications, airborne loop control that can be exploited to regulate modules phase-
radars or high fidelity audio systems while much effort was shift in order to increase the reduction of current imbalance
spent in research by industries and universities because of caused by component mismatch. This solution is initially
their attractive features: smooth waveforms, high efficiency tested at simulation level highlighting its benefits on output
and high power density. In recent times, the LLC resonant current ripple and current imbalance. Finally, in Section IV, a
converter, in particular in its half-bridge implementation, has laboratory prototype is introduced to validate previous
been interested by a larger diffusion since it has been widely assertions and proposals
and successfully applied to flat panel TV, 80+ ATX and
small form factor PC, where the requirements on efficiency,
power density and EMC compliance of their switching mode
power supplies (SMPS) are getting more and more stringent.
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II. THREE-PHASE LLC CONVERTER EXPLOITING STAR VIN
M UP
LR N1:N2,N2
CONNECTION FOR PRIMARY WINDINGS D1 VOUT
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derating must be taken into account during the design In ideal conditions (Fig. 4 (a)), the Y-LLC converter shows
phase, increasing the converter cost. a total output current ripple equivalent to the parallel
topology whereas the modules rectified currents are partially
In order to avoid these limitations and to allow the use of warped by Y node modulation. In Fig. 4 (b), on the contrary,
the interleaved solution in mass production applications, a the effect of resonant component mismatch is emulated (CR1
different arrangement will be presented in the following. nominal value, CR2 = CR+10%, CR3 = CR-10%) demonstrating
The proposed topology is derived from the original the inherent balancing capability. All three modules
three-phase LLC solution by removing the transformer contribute to the total output current delivery even if they
primary winding connections to ground and shorting them in exhibit a larger current deformation. Moreover, the total
a single Y node as highlighted in Fig. 2. The new output current still benefits of the interleaved approach
arrangement still allows the benefits of multi-phase highlighting a residual ripple period that is half of the
interleaved solution while exhibiting an inherent balancing converter switching period (instead of 1/6).
capability towards resonant component mismatch thanks to
the automatic modulation performed by Y node. Fig. 4 shows III. PHASE-SHIFT CONTROL FOR CURRENT BALANCING
the results of a new set of simulations on the proposed three- The simulation results presented in the previous section
phase solution with primary-side star connection (Y three- prove the high balancing capability of the Y- LLC topology
phase LLC converter or Y-LLC in the following) in the same as compared to the simple parallel topology with
operating condition as the previous simulation results for the transformers primary windings connected to ground. It has
parallel three-phase solution (VIN = 400 V; IOUT = 18 A). been demonstrated that resonant component tolerances may
cause current mismatch among modules and therefore an
35
30
increase of output current ripple.
The simulation results presented in Fig. 4 suggest the
CURRENTS
25
RECTIFIED
MODULE 1
20 MODULE 2 MODULE 3 possibility to operate on module phase shift to additionally
[A]
15
reduce the output current ripple and current mismatch
10
5 exploiting the modulation of Y node. In order to adequately
0 compensate for component tolerances, it is necessary to
35
operate on two module phase-shifts, being the sum of the
OUTPUT CURRENT
30
25
three fixed. In the following, three different approaches will
be presented based on the monitoring of three different
TOTAL
20
[A]
15 current variables.
10
5 The first approach here presented is intended to regulate the
0
2 s/div phase shifts 1-2 and 2-3, which are the phase differences
(a) between module 1 and 2 and module 2 and 3 respectively, by
means of the secondary-side current peak values, as
35
MODULE 3 illustrated in Fig. 5. The two phase-shift corrections are
30
evaluated separately by an integral regulator processing the
CURRENTS
25
RECTIFIED
30
applied to the Y-LLC converter. Simulations are performed at
25
full-load (18 A) for different input voltages (320-420 V) with
TOTAL
20
and without resonant component mismatch (mismatch
[A]
15
10 concentrated on resonant capacitors: CR1 = CR, CR2 = 1.1CR,
5 CR3 = 0.9CR). In particular, the results refer to peak-to-peak
0
2 s/div values of output current ripple with capacitor mismatch,
(b) normalized to the output current ripple using ideal condition
and without phase-control. It can be noticed that with no
Fig. 3. Simulated rectified currents and total output current waveforms phase-control the resonant capacitor mismatch can induce an
(VIN = 400 V; IOUT = 18 A) for a three-phase LLC converter using simple
increase of the output current ripple up to a factor three
parallel topology. (a) with ideal resonant components and (b) with resonant
capacitor mismatch (CR1 = CR; CR2 = 1.1CR; CR3 = 0.9CR). (+200%); on the contrary the peak-control for phase-
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controller can greatly mitigate this effect, reducing the VIN LR1
MEAN OR
PEAK
VOUT
current ripple increment down to 40%. At the same time, the 1 VALUE
10 CR3
[A]
5
Fig. 5. Three-phase LLC resonant converter exploiting secondary-side mean
or peak value phase-shift control for modules current balancing.
0
25
OUTPUT CURRENT
20
TOTAL
15
[A]
210
10
20
Y NODE
MEAN CONTROL
[V]
0 "MEAN CONTROL"
90 @ SECONDARY-SIDE
-20 @ PRIMARY-SIDE
-40 60
-60
2 s/div
30
(a) PEAK CONTROL
15 @ SECONDARY-SIDE
0
MODULE 1 MODULE 3
MODULE 2 320 340 360 380 400 420
CURRENTS
RECTIFIED
(a)
5
16
MODULE'S MEAN CURRENT MISMATCH
INCREMENT WITH CR MISMATCH [%]
0
14
25
OUTPUT CURRENT
NO PHASE CONTROL
20 12
TOTAL
15
10
[A]
10
8 "MEAN CONTROL"
5
@ PRIMARY-SIDE
0 6 MEAN CONTROL
60 @ SECONDARY-SIDE PEAK CONTROL
40 4 @ SECONDARY-SIDE
VOLTAGE
20
Y NODE
2
[V]
0
-20 0
-40 320 340 360 380 400 420
-60 DC INPUT VOLTAGE [V]
2 s/div
(b) (b)
Fig. 4. Rectified currents, total output current and floating star connection Fig. 6. Simulated output current peak-to-peak increment (a) and modules
node voltage simulated waveforms (VIN = 400 V; IOUT = 18 A) for a mean current mismatch (b), as a function of input voltage, using different
three-phase LLC converter with floating star connection at transformer phase-control approaches on a Y-LLC topology.
primary windings. (a) with ideal resonant components and (b) with resonant (IOUT = 18 A; CR1 = CR; CR2 = 1.1CR; CR3 = 0.9CR)
capacitor mismatch (CR1 = CR; CR2 = 1.1CR; CR3 = 0.9CR).
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In order to further decrease the current mismatch among the resonance inductance. The layout for the interleaved
modules induced by component tolerances a different control solution has been designed in order to allow both a simple
approach can be implemented. As depicted in Fig. 5, instead parallel connection and a floating star connection, as required
of a peak-control on secondary-side rectified currents, a for Y-LLC solution. As previously suggested by simulation
mean value control can be conveniently arranged. As can results in Section II, the inherent current balancing capability
be noticed from the simulation results plotted in Fig. 6 (b) the
of the Y-LLC and in particular the advantages of this
current mismatch at full-load is stunningly reduced to less
approach over the simple parallel topology are demonstrated
than 2%, even in the presence of a consistent resonant
capacitor mismatch. On the other hand, the peak-to-peak by experimental results on laboratory prototype. TABLE II
output current ripple is larger than using peak-control; presents the comparison of average current values measured
anyway the increment of ripple value appears to be halved under different operating conditions for the two approaches.
compared to Y-LLC converter without any phase-control The mean current delivered by each module is listed together
implemented. with the difference from nominal value, expressed as a
percentage of the nominal value. It can be noticed that, in the
Both secondary-side approaches give excellent results for
actual situation, the current mismatch measured for the
current balancing and output current ripple reduction.
simple parallel topology is up to 75%, while in the Y-LLC
However, it must be noticed that in such applications the high
output current values, in conjunction with the efficiency solution it does not exceed +5%.
requirements, may discourage the use of secondary-side The advantages of star-connection over the simple parallel
current sensing. Thus, a primary-side current sensing can be are even more evident if a larger mismatch is manually added
preferred to regulate the phase-shift between modules. Fig. 7 to the interleaved modules. Fig. 8 plots the oscilloscope
depicts the proposed mean value phase-control obtained by screenshots for primary-side currents circulating in the three
regulating the mean value of primary-side rectified currents. modules at 400 V input voltage and 8 A total output current
The new approach allows an adequate control of the current when an additional 2.7 nF capacitor is added in parallel to
balance between modules, as demonstrated by simulation CR3. Fig. 8(a), depicting the three currents in a simple parallel
results plotted in Fig. 6 (b). However, it must be noticed that topology, highlights that module 3 is not longer delivering
while the mean value control on the secondary-side rectified
power since the resonant current is only interested by the
currents allows exact regulation of the controlled variables, in
magnetizing current as suggested by the triangular waveform.
the primary-side phase-control approach the three module
output currents are regulated by means of their primary-side Meanwhile, module 1 is evidently delivering a higher current
currents. Thus, shunt inductances and so magnetizing compared to module 2. On the contrary, Fig. 8(b)
currents can introduce additional errors on balancing-control demonstrates that, even with a considerable component
due to mismatches and/or warping of monitored currents. mismatch, all the three phases are almost equally contributing
Indeed, it can be noticed that the difference between primary- to the total power delivery.
side and secondary-side mean current values increases for
lower input voltages, that is increasing discontinuous mode
operation. This phenomenon is verified even evaluating the
peak-to-peak output current ripple as demonstrated by VIN
MEAN OF
ABSOLUTE
LR1
simulation results presented in Fig. 6 (a). 1
VOUT
VALUE
LM1
+ INTEGRAL
CR1 - REGULATOR 1-2
MEAN OF
IV. EXPERIMENTAL RESULTS LR2 ABSOLUTE
2 VALUE
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TABLE II
AVERAGE CURRENTS SUPPLIED BY EACH MODULE AT DIFFERENT OPERATING CONDITIONS.
SIMPLE PARALLEL CONNECTION STAR CONNECTION
VIN =320 V VIN =320 V VIN =400 V VIN =400 V VIN =320 V VIN =320 V VIN =400 V VIN =400 V
IOUT = 6 A IOUT = 8 A IOUT = 6 A IOUT = 8 A IOUT = 6 A IOUT = 8 A IOUT = 6 A IOUT = 8 A
IOUT-1 [A] 3.5 (+75%) 4.3 (+62%) 3.5 (+75%) 4.3 (+62%) 2.1 (+5%) 2.8 (+5%) 2.1 (+5%) 2.8 (+5%)
IOUT-2 [A] 1.0 (-50%) 1.6 (-40%) 1.1 (-45%) 1.7 (-36%) 2.0 2.7 2.0 2.6 (-2.5%)
IOUT-3 [A] 1.5 (-25%) 2.1 (-22%) 1.4 (-30%) 2.0 (-26%) 1.9 (-5%) 2.5 (-5%) 1.9 (-5%) 2.6 (-2.5%)
In order to validate the phase-control approach, presented in Previous experimental results presented in TABLE II
Section III, to increase the current balancing between the highlighted a residual current imbalance of 5%. In order to
modules of a Y-LLC converter, some additional clearly evaluate the benefits of an additional phase-shift
modifications are added to the experimental prototype, as control, resonant component mismatch has been manually
illustrated in Fig. 9. In particular, three current transformers, forced in the following tests by addition of a 2.7 nF capacitor
CT1-3 in the picture, have been included in series to the in parallel to one of the three modules. The results of such
primary-side circuits to sense resonant currents. Three tests are illustrated in Fig. 10 and Fig. 11 as a function of
Schottky diode-bridges are used to rectify such currents and output current (@ VIN = 400 V). In particular, in Fig. 10 the
two pre-conditioning circuits are properly designed to maximum current mismatch for the Y-LLC prototype is
evaluate the difference between the mean currents of two evaluated with and without phase-controller. Such results
modules. Finally, a DSP by Texas-Instrument is added to the point out again the inherent balancing capability of star
prototype to perform output voltage control through connection that, even without phase-control, allows current
regulation of the converter switching frequency and to mismatch below 12%, suggesting that additional phase-shift
implement two integral regulators for the phase-control. regulation is not mandatory. The introduction of such
iP1-RECT
Module 1 Module 3 VIN S1 VOUT
MEAN-CURRENT
CT1 DIFFERENCE
+ Ki
- 1 + s
iP2-RECT
S2
MEAN-CURRENT
CT2 DIFFERENCE
+ Ki
Module 2 - 1 + s
iP3-RECT
(a)
S3
CT3
Module 1 Module 3
A/D A/D
12 23
S1
DIGITAL
Module 2 S2 PWM
S3 DSP
(b)
Fig. 8. Measured resonant currents flowing in the three modules of LLC Fig. 9. Concept scheme of the prototype for three-phase star-connected LLC
converter (400 mA/div, 2 s/div) with simple parallel connection (a) and converter with phase-shift controller.
with star connection of transformer primary windings (b) @ VIN = 400 V,
IOUT = 8 A (CR3 = CR + 2.7 nF).
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regulation however allows an additional reduction of the 7
(INTRODUCED BY CONTROLLER)
5
stated before, is partially caused by the fact that current 23
3
sensing is performed on the primary-side while current
1
mismatch is measured for dc output currents. Moreover, in
-1
the experimental set-up, also the effect of components
tolerance for the pre-conditioning circuits and current -3
20
MAXIMUM CURRNET MISMATCH [%]
18 IOUT-2_AVG
IOUT-3_AVG
16
14
12 NO PHASE CONTROL
10
IOUT-1_AVG
8
6
WITH PHASE CONTROL REGULATION
4
VOUT
2
0
2 4 6 8 10 12 14 16 18
OUTPUT CURRENT [A] (b)
Fig. 10. Measured mismatch of currents supplied by each module as a Fig. 12. Modules mean currents (1 A/div) and converters output voltage
function of output current (VIN = 400 V, CR2 = CR + 2.7 nF). (300 mV/div) measured with (b) and without (a) phase-controller for a load-
step from 0 to 18 A. (VIN = 400 V, CR1 = CR + 2.7 nF). Time axis: 2 ms/div.
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