PFC Boost Calculation TI PDF
PFC Boost Calculation TI PDF
ABSTRACT
Low cost, high performance DSP controllers with integrated peripherals such as,
analog-to-digital (A/D) converters and pulse width modulator (PWM), have enabled the
power supply designers with a new tool for implementing control for their power
conversion functions. However, the power designers with mostly analog control
experience are faced with new challenges as they start to adopt this new technology
and make transition from the existing analog space to its new digital environment.
This application report identifies some of the basic differences between the two
approaches and shows a step-by-step implementation of a DSP controlled average
current mode power factor correction (PFC) converter. Different control loop par-
ameters in the analog control space are redefined prior to their digital implementation.
The loop is analyzed and the required voltage and current loop compensators are
derived. Finally, the discretization of these compensators and their implementation in
software are also presented.
Contents
1 Introduction .......................................................................................... 2
2 PFC Stage Hardware Interface to TMS320LF2407A .......................................... 3
3 PFC Stage Digital Controller Design ............................................................ 4
4 PFC Stage Digital Controller Design Example ................................................ 10
5 Experimental Results ............................................................................. 13
6 References ......................................................................................... 14
List of Figures
1 TMS320LF2407A Controlled Power Factor Correction (PFC) Stage ........................ 3
2 Control Loop Block Diagram of the DSP Controlled PFC Stage ............................. 4
3 Frequency and Average Component Calculation .............................................. 6
4 Bode Plot For Current Loop Compensation ..................................................... 9
5 Input Current and Voltage Waveforms (224Vrms) ............................................ 13
6 Input Current and Voltage Waveforms (100Vrms) ............................................ 14
Introduction
1 Introduction
Digital Signal Processors (DSPs) designed for closed loop control implementations are extensively used in
areas of motor control, uninterruptible power supplies (UPS), and motion control applications.
With the availability of low cost, high performance DSP controllers featuring high CPU bandwidth and
integrated power electronics peripherals such as, analog-to-digital (A/D) converters, pulse width modulator
(PWM) with built-in dead-time and asynchronous power stage protection, power supply designers have
started to consider this technology as a suitable option for their real-time power conversion and control
applications.
Compared to traditional analog control, DSP controllers provide many distinctive advantages:
• standard control hardware design for multiple platforms
• less susceptibility to aging and environmental variations
• better noise immunity
• ease of implementations of sophisticated control algorithms
• flexible design modifications to meet a specific customer need
• single chip solution for both control and communication functions
The use of DSPs in power supply applications brings new challenges to many analog designers in their
effort to change the design from the existing analog space to its new digital environment.
For a DSP controlled power supply, many pertinent factors in the design and implementation of its digital
control loop need to be addressed. Redefinition of the analog control blocks and the associated
parameters in digital domain are essential for the analog designers to change the control design from the
analog hardware to its digital software counterpart. This application report discusses the different
implementation aspects of a DSP based average current mode control of a power factor correction (PFC)
stage with input voltage feed-forward. Different control loop parameters in analog domain are redefined
prior to their digital implementation. The modifications in the analog feed-forward circuits and its
implementation in software are discussed in detail. For the 16-bit fixed-point DSP(TMS320LF2407A)
based implementation, the scaling and normalization needed to implement the universal input operating
range (85Vac-265Vac, 47Hz-63Hz) is explained. The loop is analyzed in s-domain and the required
voltage and current loop compensators are derived. The discretization of these compensators and their
implementation in software are also presented.
An example design is explained to illustrate the DSP implementation of the PFC converter. Finally, test
results from a laboratory prototype are presented to validate the performance of the digital implementation.
Q
EMI C
FILTER RL
Vac
GATE
DRIVE
Rs
VCC
Verr Iref
Vref + +
Gvea Gca PWM1
−
− A Iin
Vo
ADCIN0
B
ADCIN2
C Signal
Conditioning
Calc Calc
1/Vdc^2 Vdc
ADCIN1
TMS320x2407A
Figure 1 shows a power factor correction (PFC) stage interfaced to a TMS320LF2407A DSP. This is an
ac-dc boost converter stage, which converts the ac input voltage to a high voltage dc bus and maintains
sinusoidal input current at high input power factor. As indicated in Figure 1, three signals are required to
implement the control algorithm. These are, the rectified input voltage Vin, the inductor current Iin, and the
dc bus capacitor voltage Vo. The converter is controlled by two feedback loops. The average output dc
voltage is regulated by a slow response ‘outer loop’ ;whereas, the inner loop that shapes the input current
is a much faster loop.
d
PWM MOD
Ks.Iin
− Uca
Gca
Kavg
A Iref B
Unv
KmABC Gvea
C Vref
TMS320LF2407A
Figure 2. Control Loop Block Diagram of the DSP Controlled PFC Stage
Figure 2 shows the control loop block diagram of the DSP controlled PFC converter shown in Figure 1. In
this figure, the voltage and current sense/conditioning circuits are replaced by their respective gain blocks.
These blocks are indicated as Kf, Ks, and Kd. The multiplier gain Km is also added to the control block.
Km allows adjustments of the reference signal Iref based on the converter input operating voltage. The
inner loop is the current loop, which is programmed by the reference current signal Iref. The input to the
current loop power stage is the duty ratio command d and it’s output is the inductor current Iin. The current
controller Gca is designed to generate the appropriate control output Uca such that the inductor current Iin
follows the reference current Iref. The outer voltage loop is programmed by the reference voltage
command Vref. The input to the voltage loop power stage is Unv (voltage controller output) and its output
is the dc bus voltage Vo. The voltage controller Gvea is designed to generate the appropriate Unv to
Vthreshld_hi
Vin
Vac
Vthreshld_lo
t, t+T,
(nth sample) (n+T/Ts) th sample
Where, fmax is the maximum frequency of Vin and Nmin is the minimum number of samples of Vin over
one period(corresponding to it’s max frequency). The user software that calculates the frequency, uses the
value of N and first calculates an intermediate value 1/N. Then, this is multiplied by Nmin to find the pu
frequency. Now, in order to save the intermediate value 1/N with maximum accuracy without causing an
accumulator overflow, it is essential to know the value of Nmin, see Motor Speed Measurement
Considerations Using TMS320C24x DSPs (SPRA771). This means that the user should select the
maximum frequency of the signal to be measured, and based on that and the value of Ts, also determine
Nmin. Once Nmin is known, the quantity 1/N can be saved with maximum accuracy with the appropriate
fixed-point representation. For example, for a PFC converter with input operating frequency range of 47Hz
~ 63Hz, the maximum input frequency can be chosen as 70Hz. Then with fmax=140Hz (twice the input
frequency) and the value of Ts known from the sampling loop implementation, Nmin can be easily
calculated.
Vdc 1
T
Vin dt
t
where, T is the time period corresponding to the frequency f of the rectified input voltage Vin. In discrete
form the average component is expressed as,
inTTs inTTs
Vdc 1
T
Vin(i) Ts Vin(i) 1
TT S
Vin(i) N1
in in
Now, in calculating the inverse, Vinv, of Vdc1, i.e., Vinv=1/Vdc1, it is clear that Vinv is maximum when
Vdc1 is minimum and vice versa. Therefore, to achieve better accuracy in the fixed-point representation of
Vinv, it is necessary to represent this with a pu value normalized with respect to its own maximum value.
For a sine-wave input voltage, the minimum value of Vdc is 2Vmin/π, where, the minimum amplitude,
Vmin, of the rectified input voltage is selected based on the input operating voltage range of the PFC
converter. For example, to operate the PFC converter with a low line voltage of 90Vrms, the chosen value
of Vmin should be less than or equal to 127V. With the selected value of Vmin, the maximum value of
Vinv is (π/2Vmin) and the corresponding pu value of Vinv with respect to its own maximum value is:
1 1 V dc_MIN V
Vinv 1 1 min
V dc1 V dc_MAX V inv_MAX V dc1 V dc_MAX V dc1 V max
Once Vinv is calculated with the maximum accuracy, the feed-forward component C can be calculated
with the same accuracy as,
2
C V inv
1
V max
Km I ref MAX 2
V min
min f
V K UnvV inv
where, Zf represents the equivalent impedance of the parallel branch consisting of the bus capacitor C,
the PFC stage output impedance rO and the load impedance ZL, and is given by,
Zf 1
1 1
ro ZL
sC
For a constant power load Po, the load impedance ZL and the output impedance rO are related by,
VO 2
ZL ro
PO
For resistive load RL, the load impedance ZL and the output impedance rO are related by,
VO
ZL RL ro
IO
G VEA
2K f K S V max
K d K m V min
VO
Zf | f fcv
| Gid.Fm.Ks |
fci −1
0
| Gca | f
0 fz
Kp f
−1
| Ti |
−2
0
−1 f
fo fci
In discrete form, the current controller mentioned before, can be expressed as,
n
U CA(n ) K P E( n ) K IT S E( j )
jO
where, Ts is loop sampling time. This is implemented with output saturation and integral component
correction using the following three equations:
To deliver the maximum output power at the minimum input voltage, the maximum value of the input
current (neglecting the losses in the PFC converter) is, Imax=2Po/Vmin = 15A Different gain parameters
are calculated as,
Kf = 1/410, Kd = 1/410, Ks = 1/15, Km = 410/109.95 = 3.7286
K U (s)
GCA( s ) K Pi sIi i
Ei (s )
where, KPi = 0.1985 and KIi = 997.77
The discrete controller is implemented using the following equations,
Ui(n ) K0i * Ei(n ) Ii( n 1 ),
Ii(n ) Ii(n 1 ) K1i * Ei( n ) Kcorri * Epii
Epii Usi Ui(n )
where,
PFC_I_CONTROL_INIT:
;PFC current control loop initialization
LDP # K0i
SPLK #6504,K0i ;Q15
SPLK #545,K1i ;Q15
SPLK #2745,Kcorri ;Q15
RET
PFC_I_CONTROL:
;PFC current control loop using feed-forward technique
SETC SXM
SETC OVM
spm #0
LDP #Iref
LACC Iref ;Q15
SUB Ipfc ;Q15
SACL En0i ;Q15
LACC Uni,15 ;Q30,32-bit
LT En0i ;Q15
MPY K0i ;Q15*Q15
APAC ;Q30
SACH GPR0_pfc
ADDH GPR0_pfc ;Q31
SACH Upii ;Q15
SACH Usi ;Q15
UiMAX .set 7ffeh
UiMIN .set 0
LACC Upii
BCND SAT_UiMIN, LT ;
LACC Upii
SUB #UiMAX
BCND SAT_UiMAX, GEQ ;
B FWD_i
SAT_UiMIN SPLK #UiMIN,Usi
B FWD_i
SAT_UiMAX SPLK #UiMAX,Usi
FWD_i: LACC Usi ;Q15
SUB Upii ;Q15
SACL Epii ;Q15
LT Epii ;Q15
MPY Kcorri ;Q15
LTP En0i ;Q15
MPY K1i ;Q15
APAC ;Q30
ADD Uni,15
SACH GPR0_pfc
ADDH GPR0_pfc ; Q31
K Uv(s )
Gvea(s) K Pv sIv
Ev(s)
where, KPV = 4.63 and KIV = 290.91
The discrete controller is implemented using the following equations,
Uv(n ) K0v * Ev(n ) Iv( n 1 ),
Ivi(n ) Iv(n 1 ) K1v * Ev( n ) Kcorrv * Epiv
Epiv Usv Uv(n )
where,
Usv Uv max when Uv(n ) Uv max
Usv Uv min when Uv(n ) Uv min
otherwise,
Usv Uv(n )
The coefficients for the discrete voltage controller are,
K0v K Pv 4.7517 19463(Q12 )
K1v K Iv T S 0.004976 163(Q15 )
Experimental Results
5 Experimental Results
References
Figure 5 shows the input current (5A/div) and input voltage (224Vrms) waveforms of the PFC converter.
Figure 6 shows the same waveforms for the same output load, but at a different input voltage (100Vrms).
In this case, the PFC stage is used to drive a dc/dc stage, which delivers 48V output at 10A of load
current.
6 References
1. L.H. Dixon, “Average Current Mode Control of Switching Power Supplies”, Unitrode Power Supply
Design Seminar Manual SEM700, 1990
2. R.B. Ridley, “Average small-signal analysis of the boost power factor correction circuit”, Proceedings of
the Virginia Power Electronics Center Seminar (VPEC), Blacksburg, VA, Sept., 1989.
3. Motor Speed Measurement Considerations when Using TMS320C24x/24xx (SPRA771).
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