BUCK BOOST CONVERTER DESIGN WITH THE HELP OF D-SPACE - Rcciit

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BUCK BOOST CONVERTER DESIGNWITH THE HELP OF D-SPACEA Project report submitted in partial fulfilmentof the requirements for the degree of B. Tech in Electrical EngineeringByAbhishek Pal (11701614002)Soumak Dutta (11701614047)Ankur Bose (11701614009)Under the supervision ofMr. Sarbojit MukherjeeAssistant Professor, Department of Electrical Engineering, RCCIITDepartment of Electrical EngineeringRCC INSTITUTE OF INFORMATION TECHNOLOGYCANAL SOUTH ROAD, BELIAGHATA, KOLKATA – 700015, WEST BENGALMaulana Abul Kalam Azad University of Technology (MAKAUT) 2018

Department of Electrical EngineeringRCC INSTITUTE OF INFORMATION TECHNOLOGYGROUND FLOOR, NEW BUILDING,CANAL SOUTH ROAD, BELIAGHATA, KOLKATA – 700015, WEST BENGALPHONE: 033-2323-2463-154, FAX: ttp://www.rcciit.org/academic/ee.aspxCERTIFICATETo HODThis is to certify that the project work entitled “BUCK BOOST CONVERTERDESIGN WITH THE HELP OF DSPACE” is the bona fide work carried out byAbhishek Pal (11701614002), Soumak Dutta (11701614047) , Ankur Bose(11701614009) , the students of B.Tech in the Dept. of Electrical Engineering,RCC Institute of Information Technology (RCCIIT), Canal South Road,Beliaghata, Kolkata-700015, affiliated to Maulana Abul Kalam Azad Universityof Technology (MAKAUT), West Bengal, India, during the academic year 201617, in partial fulfillment of the requirements for the degree of Bachelor ofTechnology in Electrical Engineering and that this project has not submittedpreviously for the award of any other degree, diploma and fellowship.Signature of the GuideName:Designation:Signature of the External ExaminerName:Designation:Signature of the HODName:Designation:

ACKNOWLEDGEMENTIt is our great fortune that we have got opportunity to carry out this project work under thesupervision of Asst. Prof. Sarbojit Mukherjee in the Department of ElectricalEngineering, RCC Institute of Information Technology (RCCIIT) , Canal South Road ,Beliaghata, Kolkata-700015, affiliated to Maulana Abul Kalam Azad University ofTechnology (MAKAUT), West Bengal, India. We express our sincere thanks and deepest senseof gratitude to our guide for his constant support, unparalleled guidance and limitlessencouragement.We wish to convey our gratitude to Prof. (Dr.) Alok Kole, HOD, Department of ElectricalEngineering, RCCIIT and to the authority of RCCIIT for providing all kinds of infrastructuralfacility towards the research work.We would also like to convey our gratitude to all the faculty members and staffs of theDepartment of Electrical Engineering, RCCIIT for their whole hearted cooperation to make thiswork turn into reality.Signature of the StudentABHISHEK PAL (11701614002)Signature of the StudentSOUMAK DUTTA (11701614047)Signature of the StudentANKUR BOSE (11701614009)Place:Date:

: Table of Contents:List of Figures. .List of Tables.List of Acronyms.Abstract .iiiiiiiivCHAPTER 1:INTRODUCTION.1-2CHAPTER 2:THEORY3-142.1 Converter.2.1.1. DC-DC Converter.2.1.2. Buck Converter.2.1.3. Boost Converter.2.1.4. Buck-Boost Converter.3-143-44-77-1111-14CHAPTER 3:COMPONENTS3.1 Software Section.3.1.1 MATLAB.3.1.2 About Simulink.3.1.3 MicroLab box and dSPACE.15-1915-161616-193.2 Hardware Section.3.2.1 Circuit For Gate Driver.3.2.2 Power Source Circuit.3.2.4 Gate Driver IC (TLP 250H).3.2.5 Gate Driver IC (IR 2110).3.2.6 Designing of Inductor.3.2.3 MOSFET (IRF 540).3.2.7 Diode .3.2.8 Resistances.3.2.9 Capacitances.3.2.10 DC female Power Connector.3.2.11 12 V DC Power Adaptor.20- 3020202021-2223-2626-292929303030

CHAPTER 4:CIRCUIT DIAGRAMS AND THEIR OPERATION31-334.1 Power Circuit.4.2 TLP 250 Circuit Operation.4.3 IR 2110 Circuit Operation.4.5 Snubber Design.3131-3232-3333CHAPTER 5:SOFTWARE SIMULATION CIRCUITS AND ITS RESULTS5.1 Software Circuits.5.2 Software Output.34-423435CHAPTER 6:HARDWARE CIRCUITS AND ITS RESULTS5.1 Hardware Circuits.5.2 Hardware Output.43-454344CHAPTER 7:RESULT ANALYSIS.47CHAPTER 8:CONCLUSION.FUTURE SCOPE.484CHAPTER 9:REFERENCES.50Annexure.51

LIST OF FIGURESFig. 293031323334353637383940Name of the FigureOn modeOFF modeBoost Converter CircuitSwitch Status, Input Current, Diode CurrentCircuit of BUCK-BOOST CONVERTERSW 1 is OpenSW 1 and SW 2 both is OpenMicrolab boxGate Driver Circuit (Top view)Individual gate driver circuitIR2110 Block DiagramIR2110 IC ChipIR2110 Circuit as a single high-voltage high-side driverDiagram of a Circular Cross Section Toroid InductorDiagram of a Square Cross Section Toroid InductorCircuit Diagram of 12v DC AdapterTLP250 working CircuitUsing the IR2110 as a single high-voltage high-side driverCircuit Diagram for Buck-Boost ConverterPWM for creating pulse signalMATLAB circuit for DC-Dc converterMATLAB Simulation GraphCurrent through inductor for 20% dutyV across Diode for 20% dutyV across C for 20% DutyOutput voltage for 20% DutyI through Inductor for 75% DutyV across diode for 75% dutyV across C for 75% dutyOutput voltage for 75% dutyCircuit for Buck ConverterPulse Width of 20% Duty CycleOutput waveform of buck converterCircuit for Boost ConverterPulse Width of 80% Duty CycleOutput waveform of boost converterControl Circuit From d-SpaceOutput of 1kHz received from D-spaceTop view of IR2110 IC circuitMosFET IRF 540 Along with its Snubber CircuitPage 73737383839393940404041414343

414243444546474849TOP view of the complete Hard ware circuit1kHz of Input Pulse applied to the IR 2110Output Pulse received from IR 2110Output pulse received across load (80%)Output pulse received across capacitor (80%)Output pulse received across inductor showing charging Anddischarging (80%)Output pulse received across load (50%)Output pulse received across capacitor (50%)Output pulse received across inductor showing charging Anddischarging (50%)444444454545464646

List of Tables:Table NamePage no1. Comparison of Continuous And Discontinuous Mode2.Parameters of d-SPACE618List of Acronyms:AC Alternating CurrentDC Direct currentFPGA Field Programmable Gate ArrayIC Integrated CircuitIGBT Insulated Gate Bi-polar TransistorLED Light Emitting DiodeMOSFET Metal Oxide Semiconductor Field Effect TransistorPDPWM Phase Disposition Pulse Width ModulationPODPWM Phase Opposition Disposition Pulse Width ModulationPSIM Power SimPWM Pulse width ModulationRTI Real Time InterfaceSOA Safe Operating AreaSPWM Sine Pulse Width ModulationTHD Total Harmonic Distortion

ABSTRACTThis master report presents a voltage tracking of dc-dc buck-boost converter. The dc-dc Buckconverter is designed to tracking the output voltage with three mode of operation. This masterreport consists open loop control, closed loop control with the help of DSpace. The Buck-Boostconverter has some advantages compare to the others type of dc converter. However thenonlinearity of the dc-dc Buck-Boost converter characteristics, cause it is difficult to handle byusing conventional method such as open loop control system. In order to overcome this mainproblem, a close loop control system using DSpace is developed. The effectiveness of theproposed method is verified by develop simulation model in MATLAB-Simulink program. Thesimulation results show that the proposed method produce significant improvement controlperformance compare to convational converter for voltage tracking output for dc-dc Buck-Boostconverter.

1. INTRODUCTIONDC - DC converters are the most widely used circuits in power electronics. They can be found inalmost every electronic device nowadays, since all semiconductor components are powered byDC sources. They are basically used in all situations where there is the need of stabilizing agiven dc voltage to a desired value. This is generally achieved by chopping and filtering theinput voltage through an appropriate switching action, mostly implemented via a pulse widthmodulation (PWM) . In this project, we concentrate our research towards buck-boost DCconverter.The buck-boost is a popular non-isolated, inverting power stage topology, sometimes called astep-up/down power stage. Power supply designers choose the buck-boost power stage because;the output voltage is inverted from the input voltage, and the output voltage can be either higheror lower than the input voltage. The topology gets its name from producing an output voltagethat can be higher (like a boost power stage) or lower (like a buck power stage) in magnitudethan the input voltage. Buck-boost converter is an intriguing subject from the control point ofview, due to its intrinsic non-linearity.One of the design targets for electronic engineers is to improve the efficiency of powerconversion. For PWM (pulse-width modulation) converters, switching loss is an importantperformance measure. Fuzzy logic control has been applied successfully to a wide variety ofengineering problems, including dc to dc converters. Fuzzy control is an attractive controlmethod because its structure, consisting of fuzzy sets that allow partial membership and “if then” rules, resembles the way human intuitively approaches a control problem. This makes iteasy for a designer to incorporate heuristic knowledge of a system into the controller. Fuzzycontrol is obviously a great value for problems where the system is difficult to model due tocomplexity, non-linearity, and imprecision. DC-DC converters fall into this category becausethey have a time-varying structure and contain elements that are non-linear and have parasiticcomponents.The switched mode dc-dc converters are some of the simplest power electronic circuits whichconvert one level of electrical voltage into another level by switching action. These convertersPage 1 of 76

have received an increasing deal of interest in many areas. This is due to their wide applicationslike power supplies for personal computers, office equipments, appliance control,telecommunication equipments, DC motor drives, automotive, aircraft, etc.In this project, MATLAB simulink is used as a platform in designing the buck-boost converterand DSpace in order to study the dynamic behavior of dc to dc converter.Page 2 of 76

2. THEORYDC-DC CONVERTERIn many industrial applications, it is required to convert a fixed-voltage dc source into a variablevoltage dc source. A DC-DC converter converts directly from dc to dc and is simply known as aDC converter. A dc converter can be considered as dc equivalent to an AC transformer withcontinuously variable turn ratio. Like transformer, it can be used to step down or step up a dcvoltage source.DC converters widely used for traction motor in electric automobiles, trolleycars, marine hoists,and forklift trucks. They provide smooth acceleration control,high efficiency, and fast dynamicresponse. Dc converter can be used in regenerativebraking of dc motor to return energy bake intothe supply, and this feature results in energy saving for transportation system with frequent stop;and also are used, in dc voltage regulation. There are many types of DC-DC convertor which isbuck (step down) converter, boost (step-up) converter, buck-boost (step up- stepdown)convertor.DC conversion is of great importance in many applications, starting from lowpower applicationsto high power applications. The goal of any system is toemphasize and achieve the efficiency tomeet the system needs and requirements.Several topologies have been developed in this area, but all these topologies can beconsidered asapart or a combination of the basic topologies which are buck, boostand fly back.For low power levels, linear regulators can provide a very high-quality outputvoltage. For higherpower levels, switching regulators are used. Switching regulatorsuse power electronicsemiconductor switches in On and Off states.Because there is a small power loss in those states (low voltage across a switch in theon state,zero current through a switch in the off state), switching regulators canachieve high efficiencyenergy conversion.Page 3 of 76

FUNCTION OF DC-DC CONVERTERThe DC-DC converter has some functions. These are:i) Convert a DC input voltage Vs into a DC output voltage Vo.ii) Regulate the DC output voltage against load and line variations.iii) Reduce the AC voltage ripple on the DC output voltage below the requiredlevel.iv) Provide isolation between the input source and the load .1. BUCK CONVERTER:The AC/DC converter we use as an example is generally called a "buck" converter. Originally abuck converter meant a step-down converter, but the term came to be used for DC/DC convertersas well. While there are various theories, conventional standard step-down converters werediode-rectified (asynchronous) devices, and itbecame customary to refer to diode-rectifiedstep-down converters as buck converters.Regardless of the names used, there are anumber of step-down methods used in stepdown converters, and the step-down converterof this example is the previously mentioneddiode-rectified device.Operation of Buck ConvertersBelow, a model of a basic step-down converter is used to explain the circuit operation. Bygaining an understanding of the properties of current pathways and nodes from the basicoperation, standards for selection of peripheral components and matters demanding attention willbecome clear. In the diagrams, we replace the high-side transistor and low-side diode withswitches to explain operation schematically. The circuit principles are the same as those of dioderectification in a DC/DC converter, but the high voltage obtained by rectifying an AC voltage isdirectly switched to perform step-down voltage conversion, and so the transistor and diode actingas switches must withstand high voltages, for example 600 V or so.Page 4 of 76

When the high-side switch (the transistor) turns on, a current IL flows in the inductor L, andenergy is stored At this time, the low-side switch (the diode) is turned off The inductor current IL is expressed by thefollowing equation (ton: ON-time)Figure 1: On mode When the high-side switch (the transistor) turns off, the energy stored in the inductor is outputthrough the low-side switch (the diode) At this time, the high-side switch (the transistor) is OFF The inductor current IL is expressed by the following equation (toff: OFF time)Figure 2: OFF modePage 5 of 76

TABLE 1: Comparison of Continuous And Discontinuous ModePage 6 of 76

Discontinuous Mode and Continuous ModeIn switching operation, there are two modes, a discontinuous mode and a continuous mode. Theyare compared in the following table.The "operation" item for comparison is the waveform of thecurrents flowing in the primary windings and secondary windings of the transformer. Indiscontinuous mode, there is a period in which the inductor current IL is interrupted, hence thename, discontinuous mode. In contrast, in continuous mode there is no period in which theinductor current is zero.In each mode, arrows indicate the tendencies for the inductor, the rectifying diode, the switchingtransistor, and the efficiency; an upward arrow " " means an increase, and a downward arrow" " indicates a decrease.In the case of the continuous mode, when the switches are ON, a reverse current flows during thereverse recovery time (trr) of the rectifying diode, and losses occur due to this reverse current. Inlow-voltage switching DC/DC conversion, the reverse voltage of the rectifying diode is low andthe reverse current is also small, and so generally the continuous mode is used, giving priority toreducing the output ripple voltage and harmonics. However, in AC/DC conversion, the diodereverse voltage is high and a large reverse current flows, and so discontinuous mode, in which areverse current does not flow and losses are reduced, is generally used. However, the peakcurrent becomes large, and when the load is large, sometimes operation in continuous mode ispreferred.2. BOOST CONVERTER:The main working principle of boost converter is that the inductor in the input circuit resistssudden variations in input current. When switch is OFF the inductor stores energy in the form ofmagnetic energy and discharges it when switch is closed. The capacitor in the output circuit isassumed large enough that the time constant of RC circuit in the output stage is high. The largetime constant compared to switching period ensures a constant output voltage Vo(t) Vo(constant).Page 7 of 76

When the switch is in the ON position, the inductor output is connected to ground and thevoltage Vin is placed across it. The inductor current increases at a rate equal to Vin/L.When the switch is placed in the OFF position, the voltage across the inductor changes and isequal to Vout-Vin. Current that was flowing in the inductor decays at a rate equal to (VoutVin)/L.FIGURE 3 : Boost Converter CircuitReferring to the boost converter circuit diagram, the current waveforms for the different areas ofthe circuit can be seen as below.Page 8 of 76

FIGURE 4: Switch Status, Input Current, Diode CurrentIt can be seen from the waveform diagrams that the input current to the boost converter is higherthan the output current. Assuming a perfectly efficient, i.e. lossless, boost converter, the powerout must equal the power in, i.e. Vin Iin Vout Iout. From this it can be seen if the outputvoltage is higher than the input voltage, then the input current must be higher than the outputcurrent.Modes of operation of Boost converterThe boost converter can be operated in two modesa) Continuous conduction mode in which the current through inductor never goes to zero i.e.inductor partially discharges before the start of the switching cycle.Page 9 of 76

b) Discontinuous conduction mode in which the current through inductor goes to zero i.e.inductor is completely discharged at the end of switching cycle.Continuous conduction modecase-1: When switch S is ONWhen switch in ON the diode will be open circuited since the n side of diode is at higher voltagecompared to p side which is shorted to ground through the switch. During this state the inductorcharges and the inductor current increases. The current through the inductor is given ascase 2: When switch is offWhen switch in OFF the diode will be short circuited and the boost converter circuit can beredrawn as followsThe inductor now discharges through the diode and RC combination. Assume that prior to theclosing of switch the inductor current is I’’L, off. The current through the inductor is given asDiscontinuous conduction modeThe inductor in discontinuous mode drains all the current which it piled up in charging intervalof same switching cycle. The current through the inductor is given as (1/L)*area under the curve of voltage v/s time.Page 10 of 76

Applications of Boost converter They are used in regulated DC power supplies. They are used in regenerative braking of DC motors Low power boost converters are used in portable device applications As switching regulator circuit in highly efficient white LED drives Boost converters are used in battery powered applications where there is space constraintto stack more number of batteries in series to achieve higher voltages.3. Buck-Boost ConverterBuck – boost converter is “a DC to DC converter which either steps up or steps down the inputvoltage level”. The step up or step down of input voltage level depends on the duty ratio. Dutyratio or duty cycle is the ratio of output voltage to the input voltage in the circuit. Buck – bustconverter provides regulated DC output.FIGURE 5: Circuit of BUCK-BOOST CONVERTERWhen it is in buck mode, the output voltage obtained is less than input applied voltage. In thismode, the output current is more than input current. However, the output power is equal to theinput power.When it is in boost mode, the output voltage obtained is more than the input applied voltage. Inthis mode, the output current is less than input current. However, the output power is equal to theinput power.To operate the buck – boost converter, the two switches will operate simultaneously. Whenswitches are closed, inductor stores energy in a magnetic field. When switches are open, thePage 11 of 76

inductors get discharged and give the supply to the load. The inductors in the circuit do not allowsudden variations in the current. The capacitor across the load provides a regulated DC output.There are several formats that can be used for buck-boost converters: Vin, -Vout: This configuration of a buck-boost converter circuit uses the same numberof components as the simple buck or boost converters. However this buck-boost regulatoror DC-DC converter produces a negative output for a positive input. While this may berequired or can be accommodated for a limited number of applications, it is notnormallythemostconvenientformat.FIGURE 6: SW 1 is OpenWhen the switch in closed, current builds up through the inductor. When the switch otheload. Vin, Vout: The second buck-boost converter circuit allows both input and output tobe the same polarity. However to achieve this, more components are required. The circuitfor this buck boost converter is shown below.Page 12 of 76

FIGURE 7 :SW 1 &SW 2 both OpenIn this circuit, both switches act together, i.e. both are closed or open. When the switches areopen, the inductor current builds. At a suitable point, the switches are opened. The inductor thensupplies current to the load through a path incorporating both diodes, D1 and D2.Page 13 of 76

Page 14 of 76

3. COMPONENTSThis part consists of all the components we have used during this project work, it includes twoparts: one is software section and another part is hardware section.Software Section:This section consists of the all the software we used during this project. The softwares usedare1. MATLAB(Simulink)2. d-SPACEMATLAB: MATrix LABoratory is basically popular with the name MATLAB. In one sentence MATLABis the Language of Technical Computing.The MATLAB platform is optimized for solving engineering and scientific problems. The matrixbased MATLAB language is the world’s most natural way to express computational mathematics.Built-in graphics make it easy to visualize and gain insights from data. A vast libraryof prebuilt toolboxes lets us get started right away with algorithms essential to our domain. Thedesktop environment invites experimentation, exploration, and discovery. These MATLABtools and capabilities are all rigorously tested and designed to work together.Features of Matlab:Simulink: Simulink is a block diagram environment for multidomain simulationand Model-Based Design. It supports simulation, automatic code generation, and continuoustest and verification of embedded systems.Language Fundamentals: Syntax, operators, data types, array indexing and manipulationMathematics: Linear algebra, differentiation and integrals, Fourier transforms, andother mathematicsPage 15 of 76

Graphics: Two- and three-dimensional plots, images, animation, visualizationData Import and Analysis: Import and export, preprocessing, visual explorationProgramming Scripts and Functions: Program files, control flow, editing, debuggingApp Building: App development using App Designer, GUIDE, or a programmaticworkflowAdvanced Software Development: Object-oriented programming; code performance;unit testing; external interfaces to Java , C/C , .NET and other languagesDesktop Environment: Preferences and settings, platform differencesSupported Hardware: Support for third-party hardware, such as webcam, Arduino ,and Raspberry Pi hardware. Also the MicroLab box can be used to get the real timeoutput from the Simulink filesAbout Simulink:Simulink is a block diagram environment for multidomain simulation and Model-Based Design.It supports simulation, automatic code generation, and continuous test and verification ofembedded systems.Simulink provides a graphical editor, customizable block libraries, and solvers for modelingand simulating dynamic systems. It is integrated with MATLAB , enabling us to incorporateMATLAB algorithms into models and export simulation results to MATLAB for further analysis.To run the model in real time on a target computer, we made use of the Simulink RealTime for HIL simulation, rapid control prototyping, and other real-time testing applications.In this project, our Hardware and Software part both are based on Simulink. In the softwarepart the whole thing is simulated in Simulink and in the hardware part the control signal is alsogenerated using the Simulink file by getting a real time output using MicroLab Box anddSPACE softwareMicroLab Box and dSPACE:This hardware MicroLab box is a great product for the real time output using the MATLAB,and the dSPACE is the software part of this package which helps to connect the hardwarePage 16 of 76

section (MicroLab Box) with the user and interface it according to the user input.About MicroLab boxCompact all-in-one development system for laboratory purposesDual-core real-time processor at 2 GHzUser-programmable FPGAMore than 100 channels of high- performance I/ODedicated electric motor control featuresEthernet and CAN bus interfacesEasy I/O access via integrated connector panelFig. 8 : Microlab boxApplication AreasMicroLab Box is a compact development system for the laboratory that combines compact sizeand cost-effectiveness with high performance and versatility. MicroLab Box lets to set up control,test or measurement applications quickly and easily, and helps to turn new control conceptsinto reality. More than 100 I/O channels of different types make MicroLab Box a versatilesystem that can be used in mechatronic research and development areas, such as robotics, medicalengineering, electric drives control, renewable energy, vehicle engineering, or aerospace.Key BenefitsHigh computation power combined with very low I/O latencies provide great real-time performance.A programmable FPGA gives a high degree of flexibility and let’s to run even extremelyfast control loops, as required in applications such as electric motor control or activenoise and vibration cancellation. MicroLab Box is supported by a comprehensive dSPACEsoftware package (see options on p. 5), including, e.g., Real-Time Interface (RTI) for Simulink for model-based I/O integration and the experiment software Control Desk , whichprovides access to the real-time application during run time by means of graphical instruments.Page 17 of 76

Technical Details: -Table 2: Parameters of d-SPACE.For more Technical details go through the Annexure Section.Page 18 of 76

Real-Time Interface (RTI) using MicroLab box-RTI lets to concentrate fully on the actual design process and carry out fast design iterations. Itextends the C code generator Simulink C

The switched mode dc-dc converters are some of the simplest power electronic circuits which convert one level of electrical voltage into another level by switching action. These converters . MATLAB simulink is used as a platform in designing the buck-boost converter and DSpace in order to study the dynamic behavior of dc to dc converter. Page .

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