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The control unit of a single phase voltage regulator

Conference Paper · December 2010

DOI: 10.1109/IECON.2010.5675034 · Source: IEEE Xplore

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 The Control Unit of a Single Phase Voltage
Regulator
Ilknur Colak Deniz Yildirim
CERN-European Organization for Nuclear Research Istanbul Technical University
Dep. of TE/EPC, 1211 Geneva/Switzerland Dep. of Elect. Eng., 34469 Istanbul/Turkey
ilknur.colak@cern.ch deniz@ieee.org

The operation of the regulator circuit is based on high

Abstract-Supplying regulated voltage to critical loads is an frequency switching of an isolated transformer. Due to its
important topic for several years. This paper presents a single- structure, this circuit simultaneously works as an active filter.
phase electronic voltage regulator based on high frequency On the other hand, the active components make it easier to
switching of an isolated transformer where primary side voltage
is controlled by two full-bridge converters sharing a common tolerate transients in the circuit, and suppress voltage
DC bus and operating at 50Hz and 20kHz switching frequencies. deviations.
This allows 50Hz induced voltage on the primary side of the II. DESCRIPTION OF THE VOLTAGE REGULATOR
transformer, regulated by high frequency switching. Depending
on the input voltage, voltage at the secondary side of the A. Main Circuit
transformer add to (boost mode) or subtract (buck mode) from Fig. 1 shows the configuration of the power stage of the
the supply voltage, therefore, maintaining a regulated voltage
value across the load. The regulator is controlled by a digital
proposed single phase voltage regulator that consists of two
controller allowing fast dynamic response. A 5kVA single-phase full bridge converters, permitting bidirectional current flow
voltage regulator is realized to verify the operation of the and an isolated transformer connected series to the line. The
proposed algorithm. The experimental results show that switching frequencies of the first and second bridges are
regulator maintains constant voltage across the load both in 50Hz and 20kHz, respectively.
step-up (low supply voltage) and step-down (high supply
voltage) modes. Both full bridge converters are connected to the same DC
bus and contain IGBT blocks with parallel diodes – allowing
I. INTRODUCTION bidirectional current flow.
Today, as the technology advances, electrical, electronical No filter capacitor is used in the DC bus for this application
and electromechanical products also advance and their uses to obtain a sinusoidal waveform on the transformer primary
become vital for everyday life. However, the electrical winding. Using the DC bus without a filter capacitor also
transmission lines required by these devices are expensive, reduces the total cost and the size of the regulator.
and this results in an unparalleled progress of market The main frequency of the induced voltage in the
consumption and required infrastructure. This causes in compensation transformer is 50Hz, although the regulation
power shortage and ripples in voltage lines. The simultaneous frequency is 20kHz. Therefore, the transformer was designed
use of electronic devices may cause overloads and voltage to work at 50Hz operation frequency. One of the other
fluctuations, and also decrease the power quality. To protect important points about the structure is that an isolated
sensitive electronic equipments from these voltage transformer must be employed in this topology; otherwise a
fluctuations and obtain maximum efficiency, different types phase-to-ground short circuit occurs on the line voltage over
of electronic and electromechanical voltage regulators are the semiconductors and the transformer [7].
used in industry. Most conventional ones such as motorized Vtr-s
regulators or tap-changing regulators offer the advantages of Vin
Cf
lower cost and simplicity [1]-[3]. On the other hand, the Vtr-p
Vout
traditional voltage regulators used to correct the voltage
variation problems have several disadvantages like slow
response, input/output harmonics and larger filter
requirement. Some of them also use complex D1 D3 D5 D7
Q1 Q3 Q5 Cr Q7
electromechanical systems, which may result in a delay of
tens of milliseconds, therefore they are not able to regulate I. Full II. Full
Bridge Bridge
the voltage during the transitions [2], [6].
D2 D4 D6 Q9 D8
Fast dynamic response and high current capability can be Q2 Q4 Q6 Q8
achieved by the use of active and passive elements together
[4]. This leads to a common practice of using a transformer
together with a switching inverter in most of the industrial Fig. 1. Power circuit of the proposed switching voltage regulator
regulator applications [4]-[7].

978-1-4244-5226-2/10/$26.00 ©2010 IEEE 710

 The amplitude of the primary winding voltage of the TABLE II
ON/OFF STATES OF EACH SWITCH AT BUCK MODE
transformer is determined by the duty ratio of the Q5 for
Mode II - Buck
positive polarity of the input voltage (as Q8 is already turned
Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8
on during the positive polarity duration) and Q7 for the Stage
negative polarity (as Q6 is already turned on during the Positive On Off Off On Off On On Off
I
half
negative polarity duration). The system also includes a triac Stage
cycle On Off Off On Off On Off On
II
which is connected to the primary winding of the transformer
Stage
to enable bypass mode operation of the system. Negative Off On On Off On Off Off On
III
half
To minimize the filter size and the harmonic distortion of Stage
cycle Off On On Off Off On Off On
IV
the output voltage waveform of an inverter, many methods
have been proposed depending on the modulation strategies
In Fig. 2, Ts1 denotes the period of first bridge, while Ts2
as can be seen in [8]–[9].
the period of second one. The dead time durations are taken
According to the basic control strategy, switching patterns as zero for both of the bridges in the following calculations.
and operating modes of the regulator are given in Fig. 2 and Therefore the duty ratios of the first bridge (Ts1) and the
Tables I and II, respectively [8]. As mentioned above, the second bridge (Ts2) can be written as,
polarity and the voltage level of the transformer is determined
by upper switches of the second bridge. As can be seen in , . (1)
Fig. 2, the lower switches Q6 and Q8 are switched at line
frequency to determine the close loop duration at low side.
where 50Hz, 20kHz,
The operation modes and the switching strategy of the system
are explained in detail in [10].
20
. (2)
Stage IV
Stage III
Stage IV
Stage III

50μ
Stage II
Stage II

Stage I
Stage I

Output
Voltage
Input B. Output Voltage Regulation
V
Voltage Second full bridge plays an important role in the synthesis
of a sinusoidal waveform at the terminal of compensation
Transformer Voltage transformer. To minimize the harmonic distortion of the
VTR output voltage waveform, SPWM (Sinusoidal Pulse Width
Modulation) technique is generally used. Meanwhile, in this
Q1 Ton1 study the converter produces sinusoidal waveform by using a
Q2 Ton1 typical PWM (Pulse Width Modulation) technique since no
Q4
capacitor is used in the DC bus.
Q3 Ton2 Fig. 3 illustrates the voltage induced in the primary
winding of the compensation transformer changes depending
Q5
on the input voltage, switching frequency, and the duty ratio.
Q6
As the regulation frequency is equal to 20kHz, 200 cycles
Q8 occur in one half cycle of the main period (20ms).
Q7
t Vtr-p Vmax= √2.Vin
TS2 = 50µs BOOST MODE BUCK MODE TS1 = 50ms

Ts1 = 2
Fig. 2. Waveforms diagram of the power circuit d2.Ts2 Ts1 = 400.Ts2
Ts2 = /200
TABLE I
ON/OFF STATES OF EACH SWITCH AT BOOST MODE
Mode I - Boost
Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 ………………..………
α
Stage
Positive On Off Off On On Off Off On
I
half
Stage
cycle On Off Off On Off On Off On
II
Stage α /200+α π ωt
Negative Off On On Off Off On On Off .
III /200 Ts2 +α
half Ts1/2
Stage
cycle Off On On Off Off On Off On
IV
Fig. 3. The voltage induced in the primary winding of the transformer

711
 Assuming that all of the components are ideal, and the dead dynamic response. The main function of the microcontroller
time is zero, the input and output voltages relationship can be involves controlling the turn-off and turn-on of the main
obtained as, . switches and the triac by the help of the GAL16V8B
programmable logic integrated circuit depicted in Fig. 4.
. . (3) Zero crossing of the line voltage is detected with a LM393
comparator circuit where the output signal is directly applied
to input pins of GAL and microcontroller. Schematic of the
. √2. V . sin ωt . d ωt . (4) circuit can be seen in Fig. 5.
In order to obtain the required isolation between the power
. 200
√2. V . sin ωt . d ωt . (5) stage and the control stage HCNR200 IC is employed which
200 provides optic isolation between the external signal and the
microcontroller input pin as it is seen in Fig. 6. The circuit
.
operates linearly and monitors the input voltage.
.
. GAL-PIN2

GAL-PIN3
NOT GAL-PIN1
199. AND

. 200
199. √2. V . sin ωt . d ωt . (6)
GAL-PIN4
200 AND GAL-PIN1
EX-OR AND

where denotes the DC voltage induced in the primary NOT

AND
GAL-PIN1

winding of the transformer during one switching period of the GAL-PIN5

AND

NOT NOT
second full bridge. GAL-PIN1
AND

The total DC voltage induced in the primary winding of the AND

EX-OR

transformer during one half cycle of the line frequency is GAL-PIN6

NOT AND
GAL-PIN1

found as in (7).
EX-OR GAL-PIN1
AND AND

√ .V GAL-PIN7
. cos cos . . (7)
Fig. 4. Inside of the GAL16V8B programmable logic integrated circuit

The RMS value of the voltage at the secondary winding of 150K 820K

the transformer can be written as in (8), where is the turns +5V

50K 1nF
ratio of the transformer. AC-LINE2 1K MICROCONTROLLER
U2A
2

8
3 +
1
. . cos cos . . (8) GND2 2 -
LM393

AC-LINE1 GAL-PIN5
4

50K
The relationship between the input and output voltages can be 150K GND2

found as in (10).
1nF
1K
. (9)

GND2

1 . cos cos .(10)

. Fig. 5. Zero-crossing detection circuit

Using (10) the output voltage value can be obtained in (11) +12V +12V1 +12V +12V +12V2 +5V

for different values of the duty ratio (d2): 100nF 100nF

270R
2K2 +5V

0
GND1 GND2 CONTROL
Æ 3 +
LM358 BC327 10K SIGNAL
1
2 - 33pF
6K8
EX- 200K
0.5 Æ . 1 . . (11) CONTROL
SIGNAL
200K 100nF - 2
1
+ 3
33K LM358

HCNR200-B HCNR200-C
1.0 . 1
GND1
Æ
100nF 100nF
10K
-12V1 -12V2
HCNR200-A
C. Control Unit GND1 GND1 GND1 GND1 GND1 GND1 GND2 GND2 GND2 GND2

In this study, digital control hardware is developed with

PIC16F876 microcontroller to ensure the stability and fast Fig. 6. DC isolation circuit

712
 Fig. 7 shows the flowchart for the mainn algorithm of the III. EXPERIM
MENTAL RESULTS
proposed voltage regulator. Depending on the voltage The experimental results of the proposed converter were
difference between the reference and feeedback signals, the realized for a 220V, 50Hz, 5kVA single phase voltage
microcontroller decides the mode of the reggulator. regulator according to the toppology. Fig. 8 illustrates the
When the phase of the voltage is changed on the experimental layout of the systeem; the apparent power of the
transformer`s terminal, an instantaneous high current may compensation transformer was specified
s as 1.6kVA.
flow over the transformer. To proteect the switching
components, the edges of the transformerr should be short-
circuited to nullify the magnetization current. After that, the Transformer
phase of the voltage can be changed safely.. By the help of the
closed loop formed by sub-switches, the magnetization
current of the transformer can be decreasedd to zero. With this Cr
method, it is not required to wait for zero crossing of current
to change the transformer phase, as it is performed
p in other
regulators. This also improves the system response
significantly.

Start On/off switch

Turnn on triac
Shut down
d PWM
No Switch Yes
ON?
Turnn off triac

Yes No Switching
Calculate VD Swiitch
ON
N? components
Yes
VD = 0

No
No Yes Set VC = 1 Snubber
Set VC = 0 VD > 0
circuit

Increase PWM Increase PWM

No No
Fig. 8. Layout of thhe power module.
VD = 0 VD = 0

Yes Yes The power value of the transfformer was defined depending
No Switch Switch No on the minimum input voltagee (170Vac) and the maximum
ON? ON? transformer current (32.4Aac) values as in the following
Yes Yes equations:
PWM = const. PW
WM = const.
Maximum apparent power in the output:

Calculate VD Caalculate VD Sout_max = 1.1 x 5kVA

No No
Yes No Yes
VD < 0
No
VD > 0 VD < 0 VD > 0 Compensation voltage value:
ON? ON?
Yes
Yes Vcomp = ±50Vac
a
Decrease PWM Decreease PWM

Yes
Yes Minimum allowable input volltage:
VD = 0 VD = 0
ON?
No
Vin_min = 170V
Vac
No

D= 0 D= 0
No ON? Yes Yes No Maximum current over the traansformer:

Fig. 7. Flowchart of the main routtine .

Imax = _
= 32.4Α (12)
_
VD: Voltage difference between reference voltage andd feedback voltage
Apparent power of transformeer:
VC: Logic control signal for phase shift (HIGH Æ 0º phase shift (boost
mode), LOW Æ180º phase shift (buck mode))
. 32.4x50 = 1.6kVA (13)

713
 The operational conditions and the experimental results of
the regulator can be found in Table III. The system was tested D6 voltage
for both 110Vac (60Hz) and 220Vac (50Hz) AC voltages waveform D8 voltage
which can be arranged by a switch in case of requirement in waveform
the application.
TABLE III
EXPERIMENTAL PARAMETERS OF THE VOLTAGE REGULATOR
Electrical Specifications
Input Voltage 110Vac / 220Vac
Input Frequency 50Hz / 60Hz ±5%
Voltage Regulation -20% - +20% for 220Vac
-40% - +40% for 110Vac
Power Factor Lag or Lead 0.96 - 0.98
Turn Ratio and Apparent Np : Ns = 4.4 : 1
Power of the Transformer Str = 1600VA
Output current
Switching Frequency 20kHz
Output Filter 10µF
Output Voltage 110Vac / 220Vac
Load Power 5000VA
Fig. 10. D6, D8 voltages and load current waveforms at buck mode (Vin =
Voltage THD 3% (with linear load)
235Vac), (Ch1 = 100V/div, Ch2 = 100V/div, Ch4 = 50A/div).
Overload Capability 150% - 2 minutes
Dynamic Response 5ms (maximum) The voltage waveform of low side diodes of the first bridge
Efficiency 97% for the same operation mode (the input voltage is also the
same) can be seen in Fig. 11. As it is expected from the
Figs. 9 – 12 show the experimental waveforms of voltages design of the switching strategy, a high frequency switching
and currents of the system illustrating the steady state signal can be seen over the second bridge diodes while it is in
characteristics for a resistive load. line frequency in the first bridge diodes.

D6 voltage D4 voltage
waveform waveform D2 voltage
D8 voltage waveform
waveform

Output current Output current

Fig. 9. D6, D8 voltages and load current waveforms at boost mode Fig. 11. D2, D3 voltages and load current waveforms at boost mode (Vin =
(Vin = 205Vac), (Ch1 = 100V/div, Ch2 = 100V/div, Ch4 = 50A/div).
205Vac), (Ch1 = 100V/div, Ch2 = 100V/div, Ch4 = 50A/div).

In Fig. 9, Ch1 and Ch2 show the voltage waveforms of the
low side parallel diodes` in the second bridge while the
system is working in boost mode. And in the Fig. 10 the same
diodes are seen while the system is working in buck mode.
180° phase shift of the current and the voltage waveforms
can be followed in Fig. 12 for a high input voltage operation.
Fig. 13 illustrates the common DC bus voltage and also one
of the low side IGBTs gate signal in the second bridge. It is
clear from the figure that the voltage across the DC bus is the
DC rectified waveform of the sinusoidal line voltage.

714

Transformer primary voltage
Output current
Fig. 12. Transformer primary voltage and output current (Buck mode -
Vin = 235Vac), (Ch1 = 100V/div, Ch4 = 25A/div).
DC bus voltage
Q8 switching signal
Fig. 13. DC bus voltage and low side switching signal (Boost mode - Vin =
200Vac), (Ch1 = 100V/div, Ch2 = 10V/div).
IV. CONCLUSION
In this paper, a novel single-phase voltage regulator, which
has a common DC bus between the two full bridge
bidirectional converters has been presented. In addition, a
new switching strategy using a cost effective digital controller
was also presented. The theoretical analysis of the power
stage and the general scheme of the regulator including the
control stage have been presented. Operation of the control
circuit has been described and the validity of the proposed
system was verified through a 5kVA single phase
experimental setup. The results are as follows.
715
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1) A DC bus filter capacitor was not used.
2) A highly efficient regulator was designed (η = 97%).
3) Output filter size was reduced.
4) A simple control strategy and a simple controller
was used.
5) Switching stress during turn on time of the IGBTs
was reduced.
6) A fast dynamic response for AC regulation was
achieved.
7) The input power factor and the power quality were
improved.
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