design and analysis of an lcc resonant converter for xenon...

Design and Analysis of an LCC Resonant Converter for Xenon Flash Lamp Simmer Circuit

Seung-Ho Song, Chan-Gi Cho, Su-Mi Park, Hyun-Il Park, Woo-Cheol Jeong and Hong-Je Ryoo

Chung-Ang University 84, Heukseok-ro, Dongjak-gu,

Seoul, 06974, Republic of Korea

ABSTRACT This paper presents a 2.5-kW (500 V/5 A) simmer circuit for a xenon flash lamp driver. The simmer circuit is based on an LCC resonant converter to take advantage of minimal arc energy from the current source characteristic. The output under no load condition was analyzed. The converter minimizes filter size with high switching frequency through the use of zero-voltage switching and SiC power devices. A gate driver with variable dead time to assist soft switching was designed. The design criteria of variable dead time implemented through a simple RC circuit are presented. A PSpice simulation was performed to verify the parameter design. The simmer circuit was implemented based on the designed LCC converter. The circuit was tested at a resistive load under rated conditions (500 V/5 A) and open condition (1400 V/0 A). The Xenon flash lamp driver was implemented using the developed simmer circuit and trigger circuit. The prototype was tested to maintain the lamp under various simmering current conditions. The influence of the arc energy on the reliability of the triggering operation was proven by comparing the waveform for filter capacitor values. The experimental results verify that the designed circuit can be effectively used for simmering xenon flash lamps.

Index Terms — xenon flash lamps, simmer circuit, LCC resonant converters, gate driver

1 INTRODUCTION

INTENSE pulsed pulsed light sintering (IPL) using a Xenon flash lamp has the advantages of fast processing time, low cost, and ease of processing in comparison with conventional techniques [1, 2]. Therefore, research on this topic is being actively pursued [1–10].

To drive a xenon flash lamp, a trigger circuit, simmer circuit, and main pulse circuit are required. The high voltage output of the trigger circuit is used to ionize the xenon gas inside the lamp. The simmer circuit outputs a low current to maintain the ignition of the ionized lamp to increase the efficiency and lifetime of the lamp [11–13]. The main pulse circuit drives the xenon flash lamp with high voltage and high current pulses. A schematic diagram of a xenon lamp driver is shown in Figure 1.

Insulation for the trigger voltage is achieved through a series connection. The simmer circuit should meet the insulation for the main pulse, not the insulation for the trigger voltage.

Figure 1. Schematic diagram of a xenon lamp driver.

The xenon flash lamp used for IPL requires a wide light-emitting area. Therefore, a large capacity driver is required. Although several studies have been carried out on xenon flash lamp drivers, most have focused on short-arc xenon lamps of a few hundred watts.

A simmer circuit consisting of a full-bridge rectifier and a ballast resistor was introduced in [14]. The ballast resistor not only regulates the power supplied to the lamp but also limits the arc energy. The structure is simple, but it has the disadvantage of resistance loss and output ripple of the line frequency. To overcome this disadvantage, a pseudo simmer circuit using a ballast resistor in a capacitor bank was

Manuscript received on 26 July 2018, in final form 9 January 2019, accepted 9 January 2019. Corresponding author: H-J. Ryoo.

DOI: 10.1109/TDEI.2019.007696

484 S.-H. Song et al.: Design and Analysis of an LCC Resonant Converter for Xenon Flash Lamp Simmer Circuit

introduced in [15]. This circuit is suitable for supplying low current. The output ripple is low, but the loss is large when the potential difference between the bank and the lamp is large [15]. These circuits are not appropriate for use in the simmer circuits of large-capacity xenon flash lamps because simmer circuits for IPL have to satisfy the requirements of a high triggering start voltage, a short-circuit current limit, and low-voltage low-current drive after triggering.

An LCC resonant converter is another candidate for application as a simmer circuit. This type of converter has many advantages in terms of its current source characteristic. The LCC resonant converter satisfies the requirements for a high open-circuit voltage and low-voltage low-current output, and it can reduce the arc energy. The high switching frequency drive through zero-voltage switching (ZVS) can increase the power density by reducing the size of the filter [16, 17]. One disadvantage of the LCC resonant converter is its limited light-load output. Typical considerations regarding the light-load output of the LCC resonant converter are summarized as follows. First, the low-resonance current under a light-load condition must completely discharge the snubber capacitor to prevent hard switching. Second, the gate driver and main switch must be capable of driving to a high switching frequency to output light loads. A gate driver with ZV detecting function has been proposed; however, it is not suitable for driving with a high switching frequency of several hundred kHz due to the high heat generated [18].

In this paper, based on the analysis of a previously studied LCC resonant converter, ‘no load’ analysis and the design of a simmer circuit are discussed [17]. The circuit is capable of full-load operation using a wide switching frequency range. High switching frequency operation is realized by a modified gate driver of the zero-voltage (ZV) detecting function using variable dead time. The variable dead time of the gate driver is driven by a simple RC time constant, and the design criteria are presented. A PSpice simulation was performed to verify the parameter design of the LCC resonant converter. A prototype was implemented for lamp drive experiments with a trigger circuit. The experiments were performed under resistive load, no load, and Xenon lamp load conditions. The test confirmed a rated output of 2.5 kW (500 V/5 A) as well as a no load output of 1440 V. A comparison of the triggering waveform of the lamp according to the filter capacitor value confirmed the effect of arc energy on the reliability of the triggering operation. The experimental results verify that the designed circuit can be effectively used as a simmer circuit.

2 ANLYSIS OF THE LCC RESONANT CONVERTER

Based on previous papers, the assumptions under a no load condition are summarized as follows [17]:

A1. The value of series capacitor C is considerably larger than the value of parallel capacitor C .

A2. During Mode 1 and Mode 2, the voltage variation of series capacitor owing to the resonance is negligible, and it

can be considered as a zero voltage. (During Mode 1 and 2, the voltage variations of series capacitor is quite small owing to A1.)

A3. Compared to the ampere-second area (charge, Q) of Q1 and Q2 in Figure 3, Q1’ and Q2’ are negligible in calculation of the input and output power.

Assuming no losses, the input power is also zero:

𝑃 0. (1) The input power can be expressed as:

𝑃 𝑉 𝑄 𝑄 ∙ 2𝑓 (2)

From 𝑉𝑖𝑛 0, 𝑓𝑠 0 , and Equations (1) and (2), 𝑄1 is

equal to 𝑄2 , 𝑡𝑀1 is equal to 𝑡𝑀2 , and 𝑉𝐶𝑝𝑡1 is zero.

The resonance current in Mode1 is expressed as:

𝑖 , 𝑡 𝑖 𝑡 ∙ cos 𝜔 𝑡 𝑡

𝑉 𝑉 𝑡 𝑉 𝑡

𝑍𝑠𝑖𝑛 𝜔 𝑡 𝑡 . (3)

From 𝑖𝐿𝑠 𝑡0 0 , 𝑉 𝑡 𝑉 /𝑁 and 𝐶𝑠 ≫ 𝐶𝑝 , the value of the resonance current can be calculated by:

𝑖 𝑡𝑉 𝑉 /𝑁

𝑍𝑠𝑖𝑛 𝜔 ∙ 𝑡 (4)

The resonance current in Mode 2 can be expressed as:

𝑖 , 𝑡 𝑖 𝑡 ∙ cos 𝜔 𝑡 𝑡

𝑉 𝑉 𝑡 𝑉 𝑡

𝑍𝑠𝑖𝑛 𝜔 𝑡 𝑡 . (5)

From 𝑉𝑐𝑝 𝑡1 0 and 𝐶𝑠 ≫ 𝐶𝑝 , the value of the resonance current can be calculated by:

𝑖 𝑡 𝑖 𝑡 ∙ cos 𝜔 ∙ 𝑡

𝑉𝑍

𝑠𝑖𝑛 𝜔 ∙ 𝑡 0. (6)

From Equations (4) and (6), the output voltage can be calculated by:

𝑉 𝑉 ∙ 𝑁 ∙1

𝑐𝑜𝑠 𝜋2 ∙

𝑓𝑓

1 . (7)

In the no load operation of the LCC resonant converter, the resonant current becomes a circulating current. To satisfy the ZVS condition, a switching frequency higher than the parallel resonance frequency should be used.

3 DESIGN AND IMPLEMENTATION OF THE LCC RESONANT CONVERTER

The simmer circuit must deal with two load characteristics of the xenon flash lamp. The first is the high-impedance state

IEEE Transactions on Dielectrics and Electrical Insulation Vol. 26, No. 2; April 2019 485

before the lamp is triggered. The simmer circuit should output a high voltage for reliable triggering of the lamp. The second is the negative resistance characteristic after triggering. The simmer circuit is required to maintain the ionization with low current. In particular, as soon as the lamp is turned on, the impedance is drastically reduced and an arc current flows. For stable operation, the simmer circuit should be designed to minimize the arc energy. The simmer circuit is designed with a high open-circuit voltage and current source characteristics.

Figure 2. Operation mode diagrams of the LCC resonant converter under no load condition.

3.1 FEATURES AND CONSIDERATIONS OF LCC CONVERTER FOR SIMMER

The characteristics of the simmer circuit for driving the Xenon lamp are as follows:

First, high voltage output is required for Xenon lamp with high impedance before ignition. Second, low voltage, constant current operation is required in the simmering mode. Third, fast response time at trigger point.

Special considerations for simmer circuit design are summarized as follows.

First, wide switching frequency drive for wide voltage and current range from no-load high voltage output to low voltage constant current source output. Second, variable dead time circuit design with wide switching frequency range. Third, parallel resonant frequency and resonant circuit design for light-load switching frequency limitation under high-voltage no-load output conditions.

Figure 3. Steady-state operating waveforms of LCC resonant converter under no load operation.

3.2 DESIGN OF 2.5 KW LCC RESONANT CONVERTER

Figure 4 shows a circuit diagram of the LCC resonant converter. The design process for the 2.5-kW LCC resonant converter is carried out as follows:

(1) The switching device was selected in consideration of the input voltage and the expected value of the RMS value of the resonance current according to the converter output. In this work, a CREE C2M0040120 silicon carbide power MOSFET was selected for high-frequency switching operation.

Figure 4. Circuit diagram of the LCC resonant converter.


(2) The maximum switching frequency was selected. LCC resonant converters using above the resonant frequency have the biggest switching losses in light-load operation. Therefore, the maximum switching frequency was selected in consideration of the light-load operation and the capacity according to the characteristics of the selected switching device. The maximum switching frequency of the designed LCC converter was selected as 420 kHz for no load output.

(3) The resonance parameters were selected according to the characteristics of the converter. First, the parallel resonant frequency that determines the peak value of the resonant current and the light-load output under the maximum switching frequency was selected. Although a high parallel resonance frequency reduces the circulation current, the parallel resonance frequency was selected as 208 kHz.

3.3 DESIGN OF THE GATE DRIVER

The variable dead time of the gate driver helps discharge the lossless snubber capacitors and ensures ZVS. Gate drivers with fixed dead time are not suitable for wide load operation due to the change in the discharge time of the snubber capacitor depending on the output condition. The LCC resonant converter for wide-load operation must operate with variable dead time for ZVS operation.

A gate driver suitable for high-frequency switching operation based on the previously introduced gate driver with variable dead time has been designed [18]. Figure 5 shows the gate driver with the variable dead time circuit diagram used in the LCC converter. The improved gate driver features a turn-off MOSFET (M2) and a pull-down resistor (R6). The operation principle is the same as that of the conventional gate driver, but the driver's energy dissipation is reduced. Due to reduced heat generation, the switching frequency is increased to several hundred kHz.

Figure 5. Circuit diagram of the gate driver with variable dead time.

The gate driver with variable dead time operates by delaying the turn-on of M1, which supplies power to the gate terminal of the main MOSFET. D1 conducts under the ZVS condition of the main MOSFET, and C1 charges up quickly through the small-value R3. When M1 is turned on in this process, the main MOSFET operates with the ZVS condition.

The maximum value of the dead time of the improved gate driver is determined by the time constant of R1, C1 + Cgs, and its value can be expressed as:

𝑡 𝑅 𝐶 𝐶 ∙ ln2 ∙ 𝑉

𝑉 𝑉. (8)

The dead time operation is short under rated load conditions in which the snubber capacitors discharge quickly due to high resonant current values. On the other hand, under a light-load condition with a low resonance current, it is necessary to operate long enough with the ZVS condition. Therefore, the maximum dead time was selected considering operation at the maximum switching frequency with a low output. The resonant current waveform at the maximum switching frequency has a triangular wave shape similar to that of the no load state. The dischargeable time of the snubber capacitor is half the switch-on time at the maximum switching frequency. The value becomes the maximum dead time, which can be expressed as:

𝑡1

4 ∙ 𝑓 , (9)

According to Equation (7), the maximum dead time is 595 ns or less, and the final selected parameters according to Equation (6) are shown in Table 1.

Table 1. Parameters of the designed gate driver.

Design Parameters VALUE

𝑓 420 KHZ

𝑡 _ 595 ns 𝐷 ES2MA (1000 V/2 A)

𝐷 NSR1020MW (20 V/1 A)

𝑀 , SSM3J334R

𝐶 280 pF

𝑉 1.4 V

𝑉 15 V

𝐶 470 pF

𝑅 1 kΩ

𝑅 , 10 Ω

𝑅 5 Ω

𝑅 10 Ω

𝑅 7.5 Ω

3.4 DESIGN OF THE TRANSFORMER

The transformer should be designed to avoid saturation, minimize losses, and ensure insulation between the windings with a turn ratio that can meet the output voltage value. In addition, the resonant parameters must be satisfied only by the leakage magnetic flux component of the transformer without the use of additional inductors.

Considerations for transformer design are the following. 1) The minimum switching frequency and input voltage should be considered to determine the number of primary side turns to avoid saturation of the transformer. 2) The number of turns


of the secondary winding satisfying the turn ratio must be determined. 3) The shape of the winding must be designed so that the leakage magnetic flux value of the transformer satisfies the resonance parameter. (Optional) The magnitude of the leakage magnetic flux can be adjusted by changing the number of turns. 4) The insulation distance between the primary and secondary sides must be ensured, and insulation between the winding and the transformer core must be ensured. According to the above considerations, the transformer was designed as a toroidal core with a turn number of 18:24. The insulation between the two windings was ensured by placing the primary and secondary windings at both ends of the toroidal core, respectively, with the desired leakage magnetic flux values.

Based on the above equation and design, an LCC resonant converter was designed. The parameters of the converter are shown in Table 2.

Table 2. Summary of specifications and designed parameters.

Design Parameters VALUE

Input supplying voltage 220 V 10%Maximum Power 2.5 kW (500 V/5 A) Maximum Voltage 1400 V Maximum Current 5 A Switching Frequency 130 420 kHzSnubber Capacitor 1 nF Parallel Resonant Capacitor 17.7 nH Series Resonant Capacitor 1 μF Leakage Inductance 33 μH Transformer Turns Ratio 18: 24 Output Filter Capacitor 1.65 μF Parallel Resonant Frequency 208 kHz Series Resonant Frequency 27.7 kHz Main Switch CREE, C2M0040120 Rectifier Diode CREE, C3D25170H

4 SIMULATION RESULTS In this study, a 2.5-kW (500 V/5 A) LCC converter was

designed for simmering operation of a Xenon flash lamp. A Pspice simulation was conducted to verify the parameter design and the output equation under a no load condition. The single-phase rectifier DC link capacitor of the input was modeled as a voltage source and the load as a resistor. The simulation was performed according to each load condition from open output to rated output.

Figure 6a presents the simulation waveforms of the resonant current and switching voltage under rated conditions (500 V/5 A) with a resistive load. The RMS value of the resonant current was 12 A, and the switching frequency was 135 kHz. Figure 6b shows the simulation waveforms under a no load condition (1400 V/0 A). The RMS value and the switching frequency of the resonant current were 14 A and 235 kHz, respectively. The parameter design values were verified by simulation, and a simmer circuit was implemented.

5 EXPERIMENTAL RESULTS The simmer circuit based on the LCC resonant converter

was tested. Experiments were carried out under rated

(a)

(b)

Figure 6. Simulation results of designed 2.5-kW LCC converter; (a) Simulation result under rated condition (500 V/5 A), (b) Simulation result under no load condition (1400 V/0 A).

conditions with a resistive load (100 Ω) and xenon flash lamp conditions. In addition, experiments were conducted to confirm the effect of arc energy reduction in lighting operation.

5.1 EXPERIMENTAL RESULTS WITH RESISTIVE LOAD

Figures 7 shows the waveform of the experiment performed using a resistive load (100 Ω) under the rated condition (500 V/5 A). The output of the developed converter was 500 V/5 A at the minimum switching frequency and 100 V/1 A at the maximum switching frequency. Variations of the output voltage with adjustment of the switching frequency under a 100 Ω resistive load are presented in Figures 8. The slope of the output at the minimum switching frequency is reduced because the average value of the DC link voltage decreased as the output increased. The decrease in DC link voltage can be seen from the switching voltage in Figure 8a.

5.2 EXPERIMENTAL RESULTS UNDER NO LOAD CONDITION

The LCC resonant converter with the above resonant frequency must be driven with a switching frequency higher than the parallel resonant frequency under a no load condition. The minimum switching frequency under a no load output condition must be higher than the parallel resonant frequency (208 kHz). In the no load test, 1,440 V was the output at the switching frequency of 238 kHz.

5.3 EXPERIMENTAL RESULTS WITH XENON FLASH LAMP TRIGGERING

A xenon lamp driver was implemented using the developed simmer circuit and trigger circuit. The prototype is shown in Figure 9. The trigger circuit outputs up to 13 kV through the 10-stage voltage multiplier circuit.


(a)

(b)

Figure 7. Experimental waveforms of developed LCC resonant converter. under 100-Ω resistive load; (a) Current and voltage waveforms when output voltage reference is 500 V, (b) Current and voltage waveforms when output voltage reference is 100 V.

Figure 8. Graph of switching frequency vs. output power under 100- Ω resistive load.

The impedance of the xenon flash lamp is rapidly reduced when the lamp is turned on. In this process, arc discharge occurs. The generation of the arc current rapidly changes the impedance of the lamp. The arc energy can be adjusted according to the size of the filter capacitor. The experimental results regarding the effect of arc energy on the reliability of lighting operation are shown in Figure 10. The experiment was performed with variation of the value of the output side

Figure 9. Prototype of developed Xenon lamp driver.

filter capacitor. The trigger voltage was not shown in the experimental waveform, and the output voltage and current of the simmer circuit were measured. It was confirmed that the triggering of the lamp through the oscillation of the simmer output was stable because the value of the filter capacitor was small.

(a)

(b)

(c)

Figure 10. Simmer output waveforms in triggering operation related to changes in filter capacitor value; (a) Output voltage and current waveform using 20μF filter capacitor, (b) Output voltage and current waveform using 7.5μF filter capacitor, (c) Output voltage and current waveform using 1.65μF filter capacitor.


5.4 EXPERIMENTAL RESULTS WITH XENON FLASH LAMP SIMMERING

The xenon lamp showed a negative resistance load characteristic in the simmering operation. A voltage drop of 276 V occurred at an output of 1.1 A, and the voltage and current ripple were measured at 15 V and 325 mA. The output waveform and the lamp impedance in relation to the changes in the simmering current are shown in Figures 11 and 12.

Figure 11. Output waveforms of simmer circuit in the simmering state.

Figure 12. Lamp impedance in relation to changes in the simmering current.

6 CONCLUSION This paper presented the design of a simmer circuit to

maintain the ionization of a xenon flash lamp. The simmer circuit was designed based on the current source characteristic of an LCC resonant converter. The output characteristics of the voltage source through the parallel resonance under no load condition were analyzed. The high step-up ratio under no load condition was used for the triggering operation of the xenon flash lamp. The converter was designed to operate in a full-load range using a wide range of switching frequencies. Design procedures for gate drivers with variable dead time to ensure ZVS were introduced.

The designed LCC resonant converter is implemented as a flash lamp driver together with a trigger circuit. A prototype was tested under rated conditions (500 V / 5 A) of resistance and xenon flash lamp load. The lamp was driven according to various simmering currents. Experiments were carried out with variation of the output side filter capacitor. The simmer circuit was verified to perform a smooth triggering operation as the arc energy is reduced.

The performance of the designed simmer circuit was demonstrated through analysis and experiment. Finally, it was confirmed that the developed simmer circuit is effective for driving a Xenon flash lamp.

ACKNOWLEDGMENT

This work was jointly supported by a National Research Foundation of Korea (NRF) grant funded by the Korean government (MSIP) (No.NRF-2017R1A2B3004855) and Human Resources Program in Energy Technology of the Korea Institute of Energy Technology Evaluation and Planning (KETEP), granted financial resource from the Ministry of Trade, Industry & Energy, Republic of Korea. (No. 20184030202270).

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Seung-Ho Song received the B.S. degree in electrical engineering from Kwang-Woon University, Seoul, South Korea, in 2016. He is currently pursuing the M.S. and Ph.D. degrees with the Department of Energy Engineering, Chung-Ang University, Seoul. His current research interests include soft switched resonant converter applications and high-voltage pulsed-power supply systems.

Chan-Gi Cho received the B.S. degree in information display engineering from Kyung-Hee University, Seoul, South Korea, in 2016, and the M.S. in energy system from Chung-Ang University, Seoul, South Korea, in 2018. He is currently pursuing the Ph.D. degree with the Department of Energy System Engineering, Chung-Ang University, Seoul. His current research interests include resonant converters and high-voltage pulse power systems.

Su-Mi Park received the B.S. degree in energy systems engineering from Chung-Ang University, Seoul, South Korea, in 2017, where she is currently working toward the M.S. degree with the Department of Energy Engineering. Her research interests include high-voltage dc-dc converters and solid state pulsed power modulators.

Hyeon-Il Park received the B.S. degree in electrical engineering from Dan-Kook University, Jukjeon, South Korea, in 2008. He is currently pursuing the M.S. degree with the Department of Energy Engineering, Chung-Ang University, Seoul. He is currently with Semisysco co., Seoul. His current research interests include high-voltage pulsed-power supply systems, including soft switched resonant converter applications for light sintering systems.

Woo-Cheol Jeong received the B.S. degree in energy systems engineering from Chung-Ang University, Seoul, South Korea, in 2019, where he is currently pursuing the integrated M.S. and Ph.D degrees with the Department of Energy System Engineering. His current research interests include soft-switched resonant converter applications and high-voltage pulsed-power supply systems.

Hong-Je Ryoo received the B.S., M.S., and Ph.D. degrees in electrical engineering from Sungkyunkwan University, Seoul, South Korea, in 1991, 1995, and 2001, respectively. From 2004 to 2005, he was a Visiting Scholar with WEMPEC, University of Wisconsin-Madison, Madison, WI, USA. From 1996 to 2015, he joined the Electric Propulsion Research Division as a Principal Research Engineer, the Korea Electrotechnology Research Institute, Changwon, South Korea, where he was a Leader with the Pulsed

Power World Class Laboratory, a director of Electric Propulsion Research Center. From 2005 to 2015, he was a Professor with the Department of Energy Conversion Technology, University of Science and Technology, Deajeon, South Korea. In 2015, he joined the School of Energy Systems Engineering, Chung-Ang University, Seoul, where he is currently an Associate Professor. His current research interests include pulsed-power systems and their applications, as well as high-power and high-voltage conversions. Prof. Ryoo is a member of the Korean Institute of Power Electronics, a senior member of the Korean Institute of Electrical Engineers and a vice president of the Korean Institute of Illuminations and Electrical Installation Engineers.


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