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Flyback “transformer” is NOT COUPLED INDUCTORS

The objective of this article is to correct two fundamental mistakes most POWER ELECTRONICS ENGINEERS make with following claims:

  1. Flyback transformer is no different than transformer since after all the same symbol is used as for 60Hz line transformer!
  2. Flyback transformer is really COUPLED INDUCTORS!

I am addressing the second claim here by claiming:

Flyback transformer is NOT COUPLED INDUCTORS. Here are the reasons.

First drawing shows flyback converter with its “transformer” with common ground between primary and secondary side. As shown in blue color, the ground connection can be separated to result in galvanic isolation.

Second drawing shows the identical circuit with the magnetic coupling removed. Clearly this is NOT working circuit (see enclosed the comment below highlighted in yellow color).

Definition of the COUPLED INDUCTORS is that once the coupling is removed that converter still must operate. Phrased it differently, only a few switching converters qualify to allow coupling of their inductors, like Coupled Inductor Cuk converter, Coupled Inductor SEPIC converter, multiple outputs of forward converter, and a few others. I am afraid I should know that as I invented 40 years ago the general method I called Coupled Inductor and Integrated Magnetics Method!

Coupled Inductor equations model an AC transformer using the primary and secondary self-inductances and the mutual inductance which represents the added voltage induced on primary due to the change of the secondary current. So much for the claim: current do not force the coupling. There are no “coupled-inductors” coupled by the common magnetic flux as also claimed.

In fact, one might be tempted to claim that the common magnetic flux in flyback “transformer” is described by mutual inductance. This is clearly false, the flux in primary winding exists only during ON time of the switch and flux in secondary winding exist only during the OFF time of the main switch, hence there is no coupling between those fluxes. Hence the correct comment made below: “flyback transformer” does not exist, it is a simple inductor where all the energy to be transferred is stored in GAP.

In order to fully appreciate my analysis and explanations above, I highly recommend the reader to review my introductory comments in the thread I started and the comments received which are enclosed below. I welcome your comments to this post. However, if the comments are arguing with my viewpoints expressed here, it would be preferable to use a relevant converter circuit drawings, waveforms, etc. rather than just plain words. After all we are talking here about circuits and not debate skills.

Here is a thread I started on Power Electronics Society Group

Why flyback “transformer” is NOT a TRANSFORMER?

The flyback “transformer“ lacks the main property of the isolation transformer as invented by Michael Faraday in 1831. His transformer with sinusoidal primary side 60Hz AC voltage excitation has a key magic that it does NOT store energy since it diverts 1% or less of the input AC current as a circulating magnetizing current to generate the needed flux in the core and transfer their bulk 99% current and power to the output. It was the foundation on which Nikola Tesla has built his worldwide polyphase electric power transmission system in 1884, which is powering industry worldwide ever since! It is rather unfortunate that Power Electronics field showed the great disrespect to Faraday by using the same name for flyback “transformer“ for over 60 years. It is even more inappropriate that IEEE on standards did not elect an entirely different symbol for flyback transformer marking its key deficiency of 100% energy storage and resulting in its power and efficiency limitations! As a tribute to Faraday, I enclose the video clip of my lecture to UC Irvine Power Electronics class on Faraday’s transformer. Also available on YouTube.com/slobodancukTESLAco. Link: https://youtu.be/rltXYftORyM

First below are two comments I agree with:

  1. “Really the “flyback transformer” does not exist, it is a simple inductor where all the energy to be transferred is stored in GAP”.
  2. “Slobodan – you will be pleased to hear that the students at the University of Nottingham know this distinction well (including the energy storage vs transfer point) and use the term “double wound inductor” for the flyback component (well they do if they listened in my lectures!)”

Here are the four comments I fully disagree with:

  1. “This is why I think that the magnetic element of the flyback converter should be called “coupled inductors” – coupled- by the common magnetic flux. Currents do not force the coupling”.
  2. “If you take the flyback magnetic away from its surrounding circuitry, it is indistinguishable from a transformer. So connecting a diode one way or the other to a terminal changes what the element is? No wonder people get confused. Perhaps it would be better to say it is a transformer that is not used properly.”
  3. “Structure wise, flyback transformer is a transformer, but applied in a different condition”.
  4. “Maybe the term could be just “Flyback Inductor”, or “Flyback coupled inductor”? Design has similarities to normal inductor design and differs from normal coupled inductor due to galvanic isolation. On the other hand, PE students and engineers should learn to analyze the circuit of the topology, not focus on the terminology.”

What is a lesson to be learned from these discussions?

Misleading comments or PLAIN WRONG explanations do not advance POWER ELECTRONICS field but actually hinders it. I believe that the second is the case here! My much more ambitious goal for all Electrical engineers, not just 430,000 members of the IEEE, is to learn how the principles of the real 50Hz and 60Hz transformer used for utility lines worldwide operate and to pay tribute to its inventor Michael Faraday and his 1831 Law of Electromagnetic Induction and its corollary the invention of AC transformer driven by sinusoidal voltage.

Comments on Slobodan Cuk’s article

Manoj Modi – Head R&D at Shakti Pumps (I) Ltd.

“Agreed Mr. Cuk, my Prof. V Ramanarayanan @ IISc taught us its not a transformer and not a coupled inductor, this is what we have been taught.”

Slobodan Cuk – CEO at TESLAco

“@Manoj, I personally invite you to join my LinkedIn group POWER ELECTRONICS INSTITUTE. See invitation link below: POWER ELECTRONICS INSTITUTE invitation by Dr. Ćuk Link to join: https://www.linkedin.com/groups/7045487. Objectives: goo.gl/h1M05V goo.gl/x5FrGm. Books: amazon.com/author/slobodancuk Site: teslaco.com videos: www.youtube.com/slobodancukTESLAco

Gavin Pinto™ – Electronics Design Engineer at Automotive industry

“IIT Kharagpur has not removed the word “transformer” from the flyback magnetics. Why should I be embarrassed? As explained before a “transformer” uses coupling between coils and there is a voltage transformation. I made the concession to call it double inductor -transformer earlier. But the word “transformer” will never be removed by me . See IIT Kharagpur’s document below – Page 4. http://nptel.ac.in/courses/108105066/PDF/L-22(DP)(PE)%20((EE)NPTEL).pdf

Slobodan Cuk – CEO at TESLAco

“@Manoj, your Professor Ramnarayanan Venkataramanan (his full name) has indeed taught you very well! He was one of more than dozen of my PhD students who ended up becoming Professors of Power Electronics worldwide. We called him in our Power Electronics Group Ram for short. I understand that he had a very successful career at IIT Bombay now Mumbai in India and retired a few years back. Please give him my highest compliments for teaching you kids properly and setting you well for a successful career in this exciting field. Out of 36 PhD students I supervised over 24 years of research and teaching at Caltech, others ended up in research institutions and in industry worldwide and in either design or management position. Dr. Slobodan Ćuk (former professor at Caltech).”

Alexander Dzisko – Arbeit macht arm

“Practically any transformer can work as a fly-back one, and practically any fly-back transformer may work as an ordinary transformer. Yes, some tricky guys shift the hysteresis with permanent magnets (why do not you mention this, Mr. Cuk? Never heard? It could play at your side…), and what – because of non-linear magnetic core coils stop to be coupled inductors? By the way, had never seen a linear magnetic core in this a world…”

Clifford Emeric – Independent Researcher

“So Alexander, what you are saying is because the devices look identical physically when NOT connected in a circuit, then they must obviously be the same animal and behave the same, when placed into any arbitrary circuit! This is not true, as the device’s behavior is changed by the circuit configuration it is placed in, and the various elements making up the device are separated out (distilled as it where), and reconfigured according to the dictates of the circuit. To wit: the device takes on a new citizenship commensurate with its new home – you cannot ignore circuit configuration and its influence on the magnetic device’s behavior. Lenz’s law clarified the beauty of Faraday’s transformer by noting that any o/p current is always met with an equal and opposite primary current, such that their magnetomotiveforces or MMF (Ampere-Turns IN) on the core cancel each other out, and this is why an o/p load 1000 times larger than what is needed to completely saturate and collapse the magnetic core, is allowed to pass through the transformer, having ZERO impact on core flux (limited only by size of copper wire). Now for this to work both windings must be operational at the same time, so that there is a real time primary reflected load current that will balance the o/p load current, and thereby leave the core totally unaffected. This clarification that Lenz put forward describes the primary functionality of the transformer, where a tiny magnetization current is out of phase with both the in-phase pri and sec winding voltages. Yet pri and sec load currents which are 180 degrees out of phase with each other with pri current out of phase with pri voltage, also manages to be out of phase with magnetization current itself at the same time. So an ac transformer requires that coils are coupled in real time (Lenz’s law – 2 coils operational at the same time), and it is not enough to be simply wound on the same magnetic core. It is not just coupling to the core that matters, but also a real time coupling between the coils themselves as well. What does all this really mean in practice? It means if one coil is open circuit while the other is not, then YOU DO NOT HAVE AN AC TRANSFORMER OPERATING AT ALL. It also means the ac transformer is not an energy storage device, as it’s core energy is minuscule compared to the o/p load energy that is 1000x greater. In other words, the fake fly-back transformer (i.e. chimera-Xformer) consists of two inductors, and the two coils are NOT OPERATIONAL AT THE SAME TIME (due to circuit operation), and ipso facto there is no transformer here, as Lenz’s law is not operational in the sense of a binding of the 2 coils together. So what is happening here? First i/p coil is used to charge magnetic device’s energy storage byway of its air-gap (absent in Faraday’s gap less Xformer), while at the same time o/p coil is NOT OPERATIONAL. Only one coil is operational in the ON-time sub cycle period. Then in the OFF-period i/p coil is no longer operational (switch is off), and energy is now transfered from the core’s air-gap energy storage to the o/p coil’s circuit (i.e. square wave voltages on the coils have reversed). There is no simultaneous cooperation between the two coils. If the two coils are not simultaneously operational during either the ON or OFF periods, then the coils not being coupled in real time, it is not and does does not constitute an ac TRANSFORMER. This is why a different symbol should be used to convey this difference in behavior. So how does a flyback magnetic device where coils are never simultaneously operating at the same moment in time, manage to be classified as a transformer, which by definition requires continuous operation between the coils? Let alone the difference that one stores magnetic energy to process a 2-step energy transfer, while the other stores no significant energy at all! You need to explain this before a claim is made that a fly-back device is a transformer, and what is given above proves this claim cannot be made. Topology people! That is what decides how a magnetic device will behave in any given circuit, and there are 3 elements of behavior of a magnetic device that are juggled together depending on circuit operation. It is possible for a magnetic device to be configured as an inductor, and then later reconfigured in a different mode to be a real transformer, but that is not the case with the fake fly-back chimera-transformer. And if truth be told it is not even a good inductor device. Dr. Cuk with nearly half a century of experience behind him should know what he is talking about. It is surprising to see professionals in this field who do not understand the basics of this field, and who would be better advised to learn from that knowledge base rather than debating for debating’s sake. Trust me the inventors knows better. It really is time this subject matter should be put to rest. To appreciate the new topologies this subject matter should be mastered first. OK, end of rant! This response took a life of its own.”

 

Direct 48V to 1V, 200A uP Drive

Microprocessor Fast Load Current Changes

The microprocessors and SoC Integrated Circuits impose very demanding large and fast load current changes of 10A/usec to 50A/usec yet requiring ultra small transient voltage overshoot to settle very quickly. This is currently handled by up to 12 synchronous buck converter operating in parallel at 5MHz from 12V input resulting in poor efficiency, large size and high cost! This demand is currently met by third party vendors using the same multistage buck approach consisting of over 40 power management companies slicing the 10 billion dollar market among them by providing 12V to 2V, 100A drives. This legacy solution requires an Intermediate Bus Converter (IBC) to converter 48V bus voltage to 12V. Many companies are now attempting to eliminate such intermediate converter and provide direct 48V to 1V, 200A converter. Besides using inefficient two-stage conversion solution, all these also fail to address fast load transient requirements other than using the aforementioned multi-stage synchronous buck solution.

Direct 48V to 1V, 100A Converter with Single-stage Transient Solution

This article describes in a detail the direct 48V to 1V, 100A solution based on the new Hybrid Switching Method and its implementation in novel converter topology implementing a new magnetics structure designated Hybrid transformer. The present uP drives all use the 12V to 1V legacy solution since all other proposed 48V to 1V solutions can not handle fast transients.

Dual use for 12V to 1V, 200A uP drive solution

One additional advantage of the described solution for 48V to 1V conversion is that it could be directly utulized for the present 12V, 1V uP prices by simply adjusting the transformer turns ratio and using appropriate lower voltage rated switching devices. This will also allow a smooth transition from the present 12V to 1V to new advanced 48V to 1V uP drives needed in near future.

Introduction

Basic Operation of the Ćuk-buck 2 Converter

From the converter circuit drawing below one could make the wrong conclusion that it is just another ordinary converter operating with Pulse Width Modulation with regulation using duty ratio control at constant switching frequency. Moreover, the converter topology will be easily wrongly classified as a Tapped Inductor Buck Converter as technical articles from Google, Texas Instruments and number of technical publications published by them and a number of university research teams have copied it and incorrectly analyzed due to lack of recognition of the inherent resonance implicit in this converter. (1,2,3,4)

Hidden Resonant Circuit

Even the voltage conversion ratio can not be correctly derived without recognizing the fact that there is an invisible resonant circuit operating during OFF time period as illustrated in the converter drawing below incorporating the resonant inductor in series with primary winding. Note tat this inductor is NOT a physical inductor built externally, but is actualy representing the leakage inductance of the transformer. While in all other transformers of conventional PWM converters the leakage inductance is actually very undesirable as it stores the energy which must be dissipated each cycle resulting in large losses proportional to switching frequency and square of the peak resonant current. In this converter, the leakage indcutance is absorbed in the operation of the converter due to its resonance with the resonant capacitor Cr, Resonant current is continuous at all times and has no large current jump at switching instants as it does in Tapped Inductor buck converter. Fig b shows the equivalent circuit during OFF time interval when S2 switch and diode are conducting.

Resonant inductance Lr must satisfy flux balance during the OFF time so that flux balance on vr : vr = Vcr -Vc = 0 (1)

Vcr = Vc = V (2)

Using this result and provided that

C>> Cr (3)

the simplified equivalent resonant circut is obtained as in Fig.c the solution of which is:

vcr = V sin (wrt) (4)

icr= ip= -0.5 I cos (wrt) (5)

is = I – 0.5 I cos(wrt) (6)

Note that the diode current is the sum of the primary and secondary currents hence
id= ip + is = I (1-coswrt) (7)

Voltage Conversion Derivation

From equation 2, the flux balance on the transformer is shown in drawing below for 1:1 turns ratio of transformer. Hence

(Vg -2V) D = V 2 (1-D) (8)

and converion gain is

V=0.5 D Vg (9)

In general

V= D Vg N2 /(N1 +N2) (10)

Hence the voltage gain is the same as in PWM forward converter operating with duty ratio D and transform primary turns N1 +N2 and secondary turns N2.

Linear voltage gain with duty ratio D confirmed by measurement

Measurement of the voltage conversion ratio for n=2 is displayed below, confirming linear voltage gain characteristic with duty ratio change.

Hybrid Transformer Resonant Currents

Hybrid transformer, is a close approximation of the Faraday transformer and has inherent feature that its primary and secondary currents are sinusoidal at the resonant frequency and are scaled by the transformer turns ratio. Moreover, their peak magnitudes are directly proportional to the DC load currents and therefore automatically scale-up or down with the change of the DC load current. This directly leads to the load transient elimination in a fraction of a single switching period. Shown below are the three key sinusoidal-like waveforms for the special case of 1:1 transformer turns ratio, which were analytically derive earlier. This is made for easier understanding of the fundamental principles. The general case for N1 to N2 turns ratio can then be easily derived and equations generalized using the usual transformer current scaling law via its primary to secondary turns ratios.

Converter Simulation Model

Converter is modeled using .plecs simulation program from PLEXIM shown below:

Confirmation of Key Sinusoidal Current Waveforms by Simulation

Simulation for the 4 different DC load currents for 100A, 50A, 25 A and 10A shows extraordinary feature of the converter that all steady state current waveforms (primary, secondary and diode current) are directly scaling down proportionally to the DC load cuirrent I. This is then the reason why this converter makes possible large trasient elimination in a single switching period. Moreover, this is accomplished with a single module and does not require 12 modules of the synchronous buck converters to obtain acceptable transient response.

The diode current waveforms exhibit another extraordinary feature. The diode as a switch is turned ON at zero current and turned OFF at zero current for all load currents. Hence the diode switching losses are eliminated for any DC load currents from full load to no load due to Zero Current Switching (ZCS) . In fact, diode does not even know that it is switching, since at switching instances does not even conduct any current.

This also leads to another extraordinary feature not present in any switching converter. The instantaneous diode current is always positive. Hence the discontinuous conduction mode is eliminated for any load.

Obviously, as the delivered DC load current is reduced, so are proportionally, superimposed AC ripple current. Hence there will never be a large circulating when the diode is replaced with synchronous rectifer MOSFDET. Hence an ultra high 99% efficiency is maintained from full load to light load.

Voltage Regulation

The simulation below demonstrates that reduction of duty ratio from 0.1 to 0.05 leads to proportional reduction of output voltage from 2.4V to 1.2V.

Capacitor Power Transfer Paradox

This converter utilizes the resonant capacitor in series with the primary winding. Note that all power must be transferred from input to output by current passing through this capacitor Cr. Note that this capacitor Cr voltage rating is approximately 1V and yet it converts input voltage of 50V. Hence its voltage rating is 50 times lower than the input source voltage. In addition, the capacitor value needed is on the order of 100uF. Hence very small size capacitor is needed for this 100W, 1V 100A converter.

The key operation of the converter can be best understood when the models of the two circuit subintervals are analyzed with inclusion of the leakage inductance of the transformer Lr modeling the inevitable leakage inductance associated with any transformer as described in original drawing. Note also that this resonant inductance Lr resonates with the resonant capacitance Cr on the primary resulting in resonant period Tr given by

Tr=2PI Sqrt(LrCr) (11)

PI=3.14 (12)

Note that the large magnetizing inductance of the transformer is effectively shorted during OFF time interval leading to a purely sinusoidal AC current on the primary as illustrated in waveforms and resulting sinusoidal current on secondary. This has a crucial consequences for converter operation as described below:

Leakage losses eliminated!

When this resonant period Tr is equal to TOFF time of switch S2, avery unique optimum operating pont is achieved.

Tr =Toff (13)

Leakage inductance is essential part of the primary resonance. Since this current is continuous at both switching instances there are no losses normally associated with all other switching converters. For the first time these losses which are normally proportionally growing with the increased switching frequency in all other transformer coupled converters are completely eliminated! The bonus is that the primary current is purely sinusoidal with a zero average current. Hence there is no DC bias contribution from the transformer primary reducing energy storage in transformer dramatically. Obviously there is a strong incentive for keeping this ideal operating point for all input votage and load current conditions as described next.

Optimum Control Method

The ideal operating point given by (3) can be preserved by simply keeping OFF period constant that is

Toff = Constant (14)

Clearly, the variation of the ON-time period will then result in direct output DC voltage control. Obviously, this calls for variable switching frequency control. Nevertheless, for large step-down through duty ratio, such as D=0.1 this effectively results in near constant switching frequency with around 10% frequency variation.

Two Transformers in One

The DC voltage conversion is following the rectangular voltage excitation of the hybrid transformer as used for derivation of the c voltage conversion.

The hybrid transformer currents, however, are sinusoidal also satisfying the turns ratio of the hybrid transformer.

Zero Diode and MOSFET Switching Losses

The yellow waveform for the diode current clearly confirms that the diode is both turning ON and turning OFF at ZERO current hence no switching losses. In fact, as its voltage at both switching instances is also ZERO, the diode does not even know that it is switching! Practical consequence: no spikes and no EMI generated.

Obviously, the proper drive of active switches operating with Zero Voltage Switching ( ZVS) operation eliminate switching losses of active devices as well as spikes and EMI noise typically associated with them.

Bottom line, all switching losses and leakage losses are eliminated leaving only resisitve losses. Hence the ultra high efficiency over 99% as well as low EMI noise.

No Discontinuous Conduction Mode

Simulations demonstrated that diode current always operates in Continuous Conduction Mode (CCM) for all loads. As expected, there is also no change in the voltage conversion gain as seen in all simulation waveforms. Furthermore, the high efficiency at the full load is also maintained at very light load as there are no large circulating currents as those present in synchronous buck converter at light load.

Synchronous Rectifer Implementation with MOSFET and GaN Transistors

All MOSFET Implementation

Of the remaining conduction losses, by far the largest loss contribution for low output voltages like 1V is due to conduction losses of the rectifer CR diode. This can be mitigated by use of the MOSFET with ultra low ON resistance. It is important to note the distinction between operation of this MOSFET in Cuk-buck2 converter and the synchronous buck converter MOSFET. As described above, the converter never gopes into Discontinuous Conduction Mode (DCM) for any load. Hence the synchronous rectifier MOSFET never conducts the MOSFET transistor current as all current is always diverted through its body diode.

All GaN Transistors Implementation

Therefore, the ideal implementation of this switch would be to use Dual Gate GaN device such as recently introduce Panasonic device which emulates the diode conduction without having limitations of the body diode of MOSFETs. This in fact lands itself to a new Power Integrated Circuit (PIC) implementation.

Power Integrated Circuit with GaN devices

The GaN switching devices have a unique properety that all power devices can be built on a same die. This eliminates the very lossy and space wasting coonection for making connection between separately packaged discrete devices. Moreover, the high-side drive circuit and the direct drive for Synchronous GaN DEVICE can all be built on the same substrate making it a single Power and Drive Chip.

The bonus operating GaN devices at 100kHz switching frequency is not only that gate drive losses are practically eliminated, but also the fact that paralleling a number of devices DOES decrease conduction losses greatly without increasing gate drive losses as would be the case for MOSFET implementations.

Is feedback needed for regulation of this converter?

The short answer is no! The reason feedback was always used in conventional converters is twofold:

  1. Low efficiency in the 80% and low 90% requires the change of duty ratio to compensate for the drop of the voltage due to large differences in converter losses between ful load and say 20% load.
  2. All present converters with diode rectification result in Discontinuous Inductor Mode at no load to light load and need substantial duty ratio change to maintain voltage regulation.
  3. Change of input voltage requires also change of duty ratio to keep output voltage constant despite input voltage changes.

The last problem is easily solved using the classical feedforwad control by controlling PWM sawtooth ramp magnitude with input voltage. Hence, the voltage changes are instantly compensated quickly within a single switching cycle! The first two problems are solved by having ultra high efficiency and no DCM operation of this converter.

With efficiencies in 99% and above range no regulation using feedback control is needed! Not only it is not needed but it is also not desired due to several drawbacks caused by feedback:

  1. Oscillation and stability problems resulting in potential catastrophic failures!
  2. Grossly limiting bandwidth to 10% or so of the fundamental open loop bandwidth resulting in much diminished transient response.

The remaining issue is how to change output voltage to desired discrete levels demanded by microprocessors. This can also be handled by controlling PWM sawtooth ramp, this time using a separate reference analog voltage to control even continuously the output DC voltage and not just in discrete steps!

Videos of Two Simulations

First video simulation made at the load current of 15A is shown below confirming continuity of the primary current exhibiting no current jumps as well as diode turning-on and turning-off at zero current.

Second simulation made at 50% load of 7.5A shown below confirms no change in fundamental operation and preservation of the same sinusoidal current waveforms at light load and all the way down to practically no load.

Obviously, the converter can be scaled up in current to 100A and 240W at 2.4V as illustrated in with the same salient results provided the resistive losses are likewise reduced by use of appropriately scaled resistive losses of the components!

Zero Output Ripple Voltage With Two Identical Modules

Only two identical converters operated in parallel but shifted in time for exactly half a switching period (see schematic drawing below) are sufficient to reduced output ripple voltage to ultra low value despite using 20 times less capacitance then needed in a single synchronous buck converter.

Note the simplicity of the practical implementation of two modules in parallel. Only once converter needs to be made, as the second module is IDENTICAL converter, whose operation is shifted exactly by a half switching period. Hence the control needs to include simply a sync pin to implement this parallel connection.

Note the complexity of a multistage synchronous buck with 12 modules, requiring complex phase shifting of 12 modules!

The current waveforms below show near complete cancellation of the ripple current and drastic reduction of the filtering capacitor needed on output to achieve ultra low ripple voltage.

Output Filtering Capacitor Paradox

The current waveforms below show near complete cancellation of the ripple current and drastic reduction of the filtering capacitor needed on output to achieve ultra low ripple voltage. In the previously simulated example for 48V to 2.4V, 100A converter output power of two modules would be 540W. Yet the filtering capacitors needed would have only 2.4V rating and would use capacitors which are 0 times or more reduced in value than a filtering capacitor need for a single buck converter.

Hence both resonant capacitor Cr and the output capacitor C are would be ultra compact even at high power of 500W.

Elimination of the Large and Fast Transient in a Single Cycle

The Ćuk-buck 2 converter is the very first converter which has a unique property: The peak resonant current drawn from the source is directly proportional to the DC load current as given by equation (6). Hence the sudden change of the DC load current as experienced in microprocessors, will eliminate voltage transient in less than half the switching period. This feature is inherent to both Hybrid Switching Method in general as well as Storage-less Switching Method in which both intervals have their own defined resonances. The experimental measurements recorded for converter using Storage-less Switching Method shown below is representative of the inherent Fast Transient performance with both methods.

Experimental Verification at 100kHz switching frequency

The early breadboard prototype is shown below demonstrating small size of the magnetics even at moderate switching frequencies of 100kHz. The experimental waveforms also confirm Zero Voltage Switching (ZVS) of the two MOSFET transistors.

Small magnetic size despite 100kHz switching!

The size of magnetics is directly proportional to flux per output number of turns so for 1 turn secondary N2=1 and 100kHz , we get for 0.5V output

Voltsec/N2 = 0.5V x 10usec= 5Vusec (17)

Hence for AC flux density of 0.25T this translates into core cross section of only 20mm2.

This is in fact identical what just a separate inductor in single buck converter would need. Here there is only one additional primary winding of 1 turn. For both windings being foil windings, there is actually minimal increase of the window area to implement 1:1 turn ratio transformer.

Switching frequency overkill beyond 150kHz

There is a reason for singling 150 kHz as an upper limit! Below that frequency, there is no requirements regarding radiated EMI noise, as this is deemed too low frequency band to interfere. ZVS of ideal switches and zero current switches of the diode, eliminate spike noise and conducted noise by definition anyway, so expensive filtering measures for conducted and radiated noise mitigation can be much reduced or even entirely eliminated.

Obviously, current GaN and SiC Devices proponents would continue their hype that MHz switching frequencies are needed to reduce size of magnetics and hence justify need for high speed of their devices. Nothing is further from the truth as they would work much better at below 150kHz. In addition they have to learn that conventional topologies not only abuse them in by ten times or higher overkill in frequency but also with simultaneous 10 times or more overkill in their device voltage requirements such as for 48V to 1V direct buck with GaN Devices. Brute-force with both is not solution but huge detriment for wider use of those otherwise excellent switching devices.

Applications

One might get the wrong impression that the application of the Cuk-buck 2 is limited to microprocessor drives due to its unique property to handle large and fast load transients.This is not the case, as its ultra high efficiency, small size and low cost make it ideal choice also for all automotive applications for direct 48V to 1V conversion, Point of Load applications, FPGA power supplies and many other applications.

Conclusion

The key results are summarized here. All other present approaches have three fundamental drawbacks for 48V to 1V conversion:

  1. They use two-stage conversion approach with an Intermediate Bus Converter ( IBC) for 48V to 12V conversion and separate 12V to 1V multiphase synchronous buck converters with up to 12 stages operating at 5MHz switching frequency.
  2. They are not able to provide fast transient response naturally in a single-stage but require a number of parallel stages (8 or more) at ultra high 5 MHz switching frequency.
  3. Their size, cost and weight are order of magnitude larger than achievable by two identical Ćuk-buck 2 modules.

US patent 9,231,471 B2

First page of US patent is reproduced below confirming the following:

  1. Application date: March 28, 2011
  2. Prior publication Date: Oct. 4, 2012 document US 2012/0249102 A1
  3. Publication Date: Oct. 4 2012

From the First Masterclass POWER ELECTRONICS: 50 YEARS IN 3 DAYS!

2nd Masterclass will include expanded second part on NEW POWER ELECTRONICS covering Power System on Chip (PSoC) which is analogous to System on Chip (SoC) of the signal processing in microprocessor designs and other innovations! Here is a preview.

Buck, boost, flyback and forward converters retiring!

The time has finally arrived to recognize that inductors with magnetic cores and “miraculous” air-gaps built-in to avoid core saturation with even minute DC currents are the key reason that has stalled Power Electronics for last 50 years! These inductors showed in the drawings below of four basic converters are NOT AC inductors Faraday invented in 1831!? They are “DC inductors” which saturate magnetics cores even with minimum DC currents making them into an effective short instead of a large inductance desired! The saturation is avoided with a concoction of inserting an air-gap into magnetic cores.

Air Gap Effect on Inductance

The inserted air-gap has a dramatic effect on huge reduction of inductance for even small air-gaps! See enclosed video demonstration of effect of air-gaps on DC inductors! Hence the need for 100-fold increase of switching frequency to 5MHz from 50kHz to make up for loss of that inductance with increased DC load current.

The air-gaps in magnetic cores is not the “magic” that magnetic “experts” have led you to believe for decades but simply very effective “killers” of inductance! No fancy physics of B vs H “miracles” and “basic Physics 101” as some “experts” claim!? My first masterclass graduates already learned that on Sept 25 to 27, 2018 Masterclass in great details!

The four minute video below is the single most important reason why all present non-isolated switching DC-DC converters such as buck, boost and buck-boost must be abandoned and replaced by Power Systems on Chip (PSoC) solutions. The secret is in eliminating magnetic cores and the associated air-gaps from inductors at 50kHz and NOT 50MHz as fully explained in powerelectronics.com article enclosed below!

Powerelectronics.com article on PWM Resonant converter

The article describing the first true Power Supply on a Chip converter, PWM resonant converter is published in Power Electronics.com on-line magazine in April 2017. Here is a link: https://www.powerelectronics.com/power-management/step-down-dc-dc-converter-eliminates-ferrite-cores-50khz-enabling-power-supply-chip

References TBD

Comments on Slobodan Cuk’s article

Sam Mallicoat – CTO at Information Display Company

“Pure genius SC!”

Slobodan Cuk – CEO at TESLAco

“@Sam Mallicoat Thanks a million! I feel I just started! More is to come! Photo of my Caltech days following in Nikola Tesla’s footsteps!”

Marino Dotta – Senior Power Electronics Designer

“È talmente semplice e funzionale che sembra impossibile il non averla inventata prima.”

Slobodan Cuk – CEO at TESLAco

“@Marino Dotta You say: “It is so simple and functional that it seems impossible not to have invented it before”. Historical point. I invented Ćuk converter on April 1, 1975. My employer’s California Institute of Technology (Caltech) Patent Office refused to even conduct basic search to find out if it is patentable, as it was considered so basic as you say, ” impossible not to have been invented before”. Only when the isolated extension, or Isolated Ćuk converter, was disclosed, still with only two switches, did Caltech considered doing patent search! Well, it took me another 30 years or so before I dared to add one more switch in 2008. This, however, has required first major rethinking of topologies and inventing new Switching Methods as being even more fundamental than converter topologies!

Boris Radonic – Software Engineer

“Very old, but still the best topology.”

Slobodan Cuk – CEO at TESLAco

“@Boris Radonic Thank you very much for your compliment. Much appreciated! I will, however, take exception to topology being old. My patent US 9,231,471 B2 was filed on March 28, 2011 and was officially published by Patent Office on Oct 4, 2012. Yet, it was issued on January 5, 2016 due to patent office backlogs! By international patent regulations that US is now following, patent expires 20 years from date of application, which makes it valid until March 28, 2031, still some 13 years left! Unfortunately, this does speak volumes of the present state of the Power Electronics hung-up on new switching devices driven to unsustainable MHz switching frequencies but ignoring fundamentals: new switching methods, corresponding novel converter topologies and magnetics circuits. Yet the future of Power Electronics could not be brighter with young generation continuing in our footsteps! I am still here to guide it.”

Walter Kawai Chu – Chief Innovator at Stapes Technology

“Dr. Cuk, I am in your side. Get back your license royalties deserved!”

Slobodan Cuk – CEO at TESLAco

“Walter Kawai Chu Thank you for your support and advice. My patents, license royalties and my masterclasses allowed me to keep my independence and are helping now to generate a grass-root support for moving Power Electronics out of the limbo it has been for last 50 years. I invite all Power Electronics lovers and enthusiasts to join this movement. I guarantee you it will be very rewarding! In 1988, 30 years ago, when the enclosed photo was made, I stood up at conferences and published papers against even then hyped-up 10MHz converters! Now I have many proofs that even 100kHz is more than sufficient for ultra small, efficient and low cost switching converters! There is also more to come. Stay tuned!”

Clifford Emeric – Independent Researcher

“Really? This is not a matter of recapturing an ancient patent so lost past royalties can be recaptured, and people are getting confused thinking a 2 switch buck tapped-inductor topology is somehow the same as Professor Cuk’s new 3 switch hybrid transformer Cuk-Buck2 topology. Maybe that extra switch is a clue to the difference! The buck tapped-inductor is not a transformer because when switch is off one half winding is DISCONNECTED, so ipso facto how is it a transformer when one leg is open circuit – to wit: a transformer requires both windings to be mutually active AT THE SAME TIME. The old tapped-inductor Buck just bounces energy through one winding into the magnetic core, and then bounces it back out with the other winding, and never are two windings mutually coupled during the same time interval operating as a transformer. How does a disconnected winding end stay in play? To the contrary Cuk-Buck2 during off period uses synchronous MOSFET to keep that winding end connected. Even if a sync MOSFET is added to the old Buck it still would be different as it would lack the series resonant capacitor that resonates with primary winding. Cuk-Buck2 in ON period charges both capacitor and inductor (both halves) linearly, and in OFF period primary leakage inductance and series capacitor resonant dissipating the core’s stored energy sinusoidally (unlike old Buck with square wave operation). This is just a small part of this topology’s true inner secrets with new features, like a one cycle transient response while achieving this without the need for a output feedback control circuit (only voltage feed forward is needed). Anybody want to try that with the old Buck in open loop operation? Cuk-Buck2 as you can see is RADICALLY DIFFERENT, and there is yet more to this topology.

Here is another secret! During a load transient the o/p load current loop path through o/p capacitor, o/p winding, and diode, is reflected backwards into the primary current loop path through sync MOSFET, primary winding and diode, through the transformer’s mutual coupling in true Faraday transformer fashion. In essence due to Lenz’s law input and output magnetomotive forces on the core cancel out, and thus transient impact on the core material is insignificant. Can you see one important big difference with the tapped-inductor Buck? How could one have a backwards reflected o/p load current transient appearing on the input side of the transformer in the OFF period when that winding-end is open circuit? This disconnect in part explains why transient response of the tapped-inductor Buck is poor. Now the single cycle transient response of the Cuk-Buck2 may be better appreciated, since the input winding IS NOT OPEN CIRCUIT as in the old Buck. So do you still think the Cuk-Buck2 is old topology? No sir it is brand new with fantastic transient response.”

Slobodan Cuk – CEO at TESLAco

“@Clifford Emeric Clifford, you are one of the very few who fully understand and appreciate unique features of this converter. I provided in this latest revision more simulation data to support your analysis. Thank you.”

Muhammad M. Roomi (Dr) – Postdoctoral Research Fellow

“I am recent PhD scholar who worked on single stage energy conversion and Sir, with much respect this is one fine piece of invention.”

Slobodan Cuk – CEO at TESLAco

“@Muhammad M. Roomi (Dr) Glad to hear that you recognize the importance of the single-stage conversion and are making your own contributions! I have completely revised this article to provide further detailed derivation and explanations. I would appreciated our comments after you have reviewed this latest revision.”

 

Biggest Impact: Devices or Magnetics?

Comments on Rap Session 1 at APEC 2018

The Rap Sessions 1 last year concluded that “we have all the topologies we need” with flyback and LLC converter declared undisputed champions!? The same moderator and several returning panel members who adjudicated that last year changed this year their hats from topology to become either MAGNETICS or DEVICES experts!? With topologies declared dead on arrival, they invented an artificial contest for Rap Session 1 at this APEC 2018 entitled: BIGGEST IMPACT ON POWER CONVERSION: DEVICES OR MAGNETICS? This is like comparing Apples and Oranges! The only thing they have in common is that they are just components forced to operate at switching frequencies 100 times higher than needed!

UTILIZATION OF DEVICES AND FERRITE MATERIALS?

By doing so APEC 2018 conference managed to completely switch cause and effect in Power Electronics. Topology is a cause and components like switching devices, magnetics and capacitors are just mere consequences! They are the last one to be chosen based on the limitations imposed by switching methods and their topologies! Hence, bad topologies (most present ones!) do result mostly in bad use of all components! Now those device and magnetics “experts” wants us to believe otherwise that new devices and magnetics materials will fix any bad topology!? At APEC 2018 at Rap Session 1 they could not agree only on one thing: how high switching frequency must be, 2MHz or 20MHz! In fact, it was device manufacturers, first as power management companies for the past 50 years, and now the new kid on the block, GaN device manufacturers, who imposed 2MHz on ferrite manufacturers and now demand from them 10MHz ferrite material!? Note that the discussion in this first part is strictly referring to the use of ferrite materials for transformers and not for inductors. Inductors are covered in later Section with new Coreless Step-down Converter Topology.

Discussions at Rap Session:

  1. We have all the ferrite we need… Magnetics 2MHz experts say!?
  2. We need new ferrites for 10MHz operation…Device experts say!

Yet, both Device and Magnetics experts do not recognize each other’s fundamental flaws and how their exclusive focus on 10 MHz switching is completely misguided as further analyzed below.

HIGH FREQUENCY WARNING IN 1988

I have warned Power Electronics community 30 years ago against such “Safe at 10MHz switching speed” back in 1988. The attached cover of 1988 Power Technics magazine shows me running at speed of 500kHz with Integrated Magnetics Isolated Cuk converter topology and its prototype. What follows is another prototype based on Hybrid Switching Method and corresponding Isolated Topology operating at 50kHz (note the reduced running speed!). This is my second warning after 30 years.

While everyone went to 10 times higher switching frequencies of 5MHz I came down to 10 times lower switching frequency of 50kHz and my reduced running speed on attached revised version of the same drawing! Only 100-time difference but with bonus record 98% efficiency and still reduced size!

QUESTION TO DEVICE EXPERTS BY MAGNETICS EXPERTS

  1. Utilization of devices?Have you ever seen Magnetic expert question Device expert for its 1% device utilization at any switching frequency let alone 10MHz?What is Device’s current, voltage and power ratings in actual topologies relative to their maximum capability! Please see enclosed drawing of buck converter used for 48V to 1V, 100A having 1% power utilization of its synchronous rectifier GaN device, or an “overkill” factor of 100!
  2. Hard switching at 10MHz?Did Magnetics expert ever ask Device experts why they are using hard switching at 10MHz (full square wave current of 100 A at turn-on and turn-off of the switch) instead of soft switching used even at 50kHz in proper topologies!The device switching performance is likewise 100% dependent on topology and its ability to operate them at Zero Voltage (ZV), Zero Current (ZC) or both at both switching instances!Why do device experts ignore topologies which are turning on and turning off synchronous rectifier switch at zero voltage and zero current? Then the switch does not even “know” it is switching since at critical switching instances it “sees” only zero current and zero voltage!

QUESTIONS TO MAGNETICS EXPERTS BY DEVICE EXPERTS

  1. Ferrite material utilization?Did Device experts ever ask Magnetics experts what their ferrite material utilization is (ratio of actual transformer flux density relative to its maximum flux capability)? Why is it only 0.1% for 2MHz optimized ferrite materials, or an “overkill” factor of 1000 to 1? Please see enclosed drawing of the ferrite properties of the PC200 material from TDK.
  2. Size reduction with frequency increase?Any size reduction with 40 times increased switching frequency?Why device experts never asked magnetics experts why the size of transformer is staying the same despite the 40 times reduction of frequency from 2MHz to 50kHz?While DEVICE and MAGNETICS experts are praising each other for their advanced 2MHz switching operation, let us turn to a lowly expert on Switching Methods and Topologies.

SWITCHING METHODS AND TOPOLOGIES EXPERT OPINION!

The above answers can only come from Topology experts which were sidelined last year. A more appropriate question to ask now is:

What Comes First: Switching Methods or Topologies?

It is an absence of the appropriate new optimum Switching Methods and their resulting consequence, various converter Topologies, which has stalled Power Electronics for last 70 years! We are now for the first time able to provide simultaneously optimum utilization of switching devices and best utilization of magnetic components with new Switching Methods, Resonance Scaling Method and related novel Topologies. The best yet, we DO NOT NEED 2MHz switching for size reduction as 100kHz works just fine!

MAGNETICS FOR INDUCTORS

How about ferrite cores used for inductors in converters like buck, boost and flyback. It was projected that 50MHz switching frequency would be needed to eliminate ferrite cores (see article in powerelectronics.com) This would not even reduce the magnetics size as the same cross section of the coil winding would be needed!? Yet, with right Switching Method and Topology, the ferrite core is not only eliminated at 50kHz but even reduced to short copper traces on PCB eliminating the need for windings.

CORELESS STEP-DOWN CONVERTER ELIMINATES CORES AND WINDINGS

One such converter is shown using new Storageless Switching Method and related novel Resonance Scaling Method. This drawing compares the buck converter with Coreless step-down DC-DC topology which eliminates magnetic cores and windings even at 50kHz but operates with duty ratio control and has one cycle transient response. The link to detailed powerlectronics.com article is at goo.gl/3N7qBp

BUCK CONVERTER RETIREMENT

While buck converter is used for last 70 years, now the times has come for its well-deserved retirement! Shown below is comparison buck converter with New Coreless Step-Down DC-DC. Both are regulating output DC voltage with simple PWM duty ratio modulation but with these crucial differences:

BUCK CONVERTER

  1. Large ferrite core even at 20A DC load current.
  2. Inferior transient response due to energy storage.
  3. Eight buck modules needed in parallel to fix transient response.
  4. Used exclusively to provide 12V to 2V, 100A eight module VRD.
  5. Ten-billion-dollar industry relies exclusively on this “solution”!

CORELESS STEP-DOWN CONVERTER

  1. Single IC chip with 4 GaN devices
  2. One Cycle transient with single module.
  3. No magnetics core at 50kHz.
  4. No coil windings at 50kHz.
  5. Two short copper traces of few mm each for two inductors.
  6. Ultra-high efficiency of 99%.
  7. No heat sinks needed.
  8. First Power Supply on a Chip (PwrC) for 12V to 2V, 100A.

There are number of extensions including galvanic isolation with much reduced transformer size at 50kHz switching!

REAL ADVANTAGES OF GaN DEVICES

To dispel the notion that I am advocating to go from Transistors to Vacuum tubes, there is a great news for both GaN devices and ferrite materials when they are optimized for 50 kHz to 100kHz operation. Terrific low loss ferrite materials already exist with near 100% utilization. GaN manufacturers, however completely missed this with their ultra-high frequency direction! Yet, GaN devices true advantages are:

  1. Planar technology enabling all devices and their interconnections can be implemented on a single chip.
  2. Integrated drive circuitry on the same chip with power devices.
  3. Making power switches and drive circuitry into an Integrated Power Circuit (IPC) for power processing like Integrated Circuits (IC) did for signal processing electronics.
  4. Paralleling number of devices for much reduced conduction losses.
  5. Scaling up to higher current and power taking advantage of five-times smaller size of devices compared to MOSFETs.

It does not take much to see that these GaN advantages will NOT be realized at 10MHz switching but will be much easier realized at 100 kHz switching with much improved efficiency and reduced size to boot!

Those GaN manufacturers who recognize first the need to implement and optimize their devices with new System Technology will not only be well rewarded but will also make critical contribution to advancement of Power Electronics field.

CONCLUSION

Buck converter is bad even for a single module let alone for 8 modules in parallel! Thus, it should be abandoned in favor of modern solutions. This is just one of a number of “little box solutions!” which came owing to implementation of new Switching Methods and Resonance Scaling Method resulting in state-of-the-art novel Converter Topologies. The most important is that several solutions include also isolated converters with transformer size at 100kHz even smaller than 2 MHz present designs…Oh, and one more thing: your comments are very welcome!

In addition, those who want to collaborate on this path to Power Electronics for 22nd Century NOW feel free to contact me via email on cuk@teslaco.com.

Dr. Slobodan Cuk, formerly Professor at Caltech.

GaN EXPERT QUOTES

“Magnetics are catching up with higher frequencies possible with GaN.”

“GaN is not 10 times ahead of signal processing ICs. The problem is that silicon-based controller is not designed to operate at higher than 2-3 MHz. They could be, but the controller folks are lagging the GaN folks.”

“Yes, finally! There is also a need for higher speed digital control ICs for DC-DC conversion. GaN devices can be efficiently hard-switched at 10 MHz, but digital controller is usually limited to ~1 MHz.”

Comments on Slobodan Cuk’s article:

Michael Miller – President at Miller International Group

“As a hard magnet guy, this is a comparatively easy to follow explanation/review of a very complex issue. Is Ferrite the only magnetic material used in these devices? Or are there hybrids? Thanks Slobodan.”

Slobodan Cuk – CEO at TESLAco

“Michael, Yes, ferrite materials are the only available ferromagnetic materials with acceptable core losses per unit volume for frequencies above 20kHz. If you refer to the hybrids as alloys of various combinations of Nickel, Iron and Cobalt, there are none so far to my knowledge.

TO ALL, HERE IS A LINK TO MUCH ENLARGED AND IMPROVED VERSION NAMED DEVICES OR MAGNETICS? EXT VER https://goo.gl/nW5zrr . I added video clips, additional drawings and comments. Shown below is Excel spreadsheet derived from full TDK specifications for PC 200 material which highlights the key parameters responsible for determination of the size. It shows clearly that 30 times increase in switching frequency from 100kHz to 3MHz does NOT reduce size at all! All it does is reduce efficiency dramatically due to skin and proximity effects at high frequency and increased AC resistance of copper windings. Obviously, this results in cost increase as well opposite of claimed cost reduction due to bogus reduction of transformer size. NIKOLA TESLA was the first one who showed dramatically the skin effect at high frequency and how the high frequency currents crowd to the surface of conductors dramatically increasing AC resitance over DC resistance of windings. He connected himself in a circuit with his high frequency generators and was melting copper bars without any harm to his body. In fact, this is now one of the methods used for therapeutic purposes!

Coupled-Inductor SEPIC converter

Perfectly Coupled-Inductor SEPIC converter
Reduces to WHICH Converter?

Analysis of Equivalent Circuit Transformations
by Professor Slobodan Ćuk

Perfectly Coupled-Inductor SEPIC Converter

Abstract

For quite a while now, the various “shortcuts” were circulated on LinkedIn media, such as IEEE Power Electronics Society and various websites extolling the virtues of the PWM switch small-signal model! In particular, the claim is made that the “magic shortcuts” could reduce frequency response of a Perfectly Coupled-Inductor Nonisolated SEPIC converter (CI Converter from now on!) to that of a Boost converter as included in a prior discussion to this group!?
However, the detailed analysis bellow reveals:

  1. The PWM small-signal switch model is not even needed! The sequence of correct equivalent circuit transformations would, even without any small-signal model, reduce CI Converter to ordinary nonisolated polarity inverting buck-boost converter! The addition of small-signal model only contributes to hide transformation mistakes.
  2. It then follows, even without small-signal model that CI Converter frequency response is that of buck-boost converter and not boost with its right-half-plane zero! No magic there either!
  3. This analysis points out to the critical incorrect circuit transformations leading to this erroneous result.
  4. It also points out at other incorrect simplifying assumptions, which led to boost converter circuit!
  5. As invalid transformations and simplifications are correctly identified here the correct final result of the nonisolated flyback converter is obtained!

Checking for contradictions of final result

This analysis also points out that when one obtains “surprising” result like boost frequency response, one should thoroughly scrutinize for obvious contradictions! In this case, it is simply impossible that the final result could have small signal frequency response of the boost converter and DC conversion gain of an entirely different buck-boost converter as claimed by PWM switch model!?

Detailed Analysis of CI Sepic converter

This analysis will also introduce truly “magical shortcut”, which can be used to determine what switching converters qualify for implementation of the Coupled-Inductor and Integrated Magnetics Methods (see 1979 patent posted to this group)!

Fig. 1 Basic SEPIC converter and its AC circuit

Test to verify Coupled-Inductor applicability?

First, we establish the fact that the qualifying converters must have at least two inductors before coupling. Coupling of Inductors does not change DC voltage gain which existed before the coupling. Instead, coupling only affects the distribution of the AC ripple currents between two winding as I discussed in numerous publications and in my patent on Ćuk converter and Coupled-Inductor SEPIC converter (see thread posted before!)

What makes given switching converter converter eligible for implementation of Coupled-Inductor Method I introduced over 44 years ago!

Fig.1 has original SEPIC converter! By shorting capacitors and DC voltage source, we obtain bottom AC circuit model. This is a true magic! Note that the two inductors are connected in parallel in AC model! Note also that the two switches, ideal switch S and diode CR, will generate identical common rectangular-wave voltage drive for any duty ratio D. This then qualifies both inductors to be placed on a common core in a transformer-like configuration. Note also that there could be only one turns ratio that of 1:1. Arbitrary turns ratio is not allowed, unlike in real AC transformer. Another difference is that the DC currents of each separate inductor are added together as dictated by the dot connections!

The two parallel inductors could obviously be replaced with a single common inductor L in case of a perfectly coupled winding with no leakage, when L1=L2 = L. The trick is now to determine the correct way of implementing such coupling in original DC-DC SEPIC converter. However, we first introduce the two incorrect transformations!

Two incorrect transformations

Fig. 2 further explains that point. Common inductance can be shown in circuit model as either on primary side (top circuit) or on secondary side (bottom side) of the ideal 1:1 isolation transformer! Note that marked termination points 1 & 2 for L1 and 3 & 4 for L2 determine also correct dot connection of the isolation transformer. Hence two possible circuits could be contemplated as in Fig 2 below.

Fig. 2 Two incorrect transformations with floating transformer (no common ground)

Model in which common inductance was on a secondary side (bottom drawing) is obviously wrong, since the input voltage source is NOT connected to converter at all!) On would then think that model in Fig. 2 (top) in which common inductance is retained on primary side would be OK, since now input source is connected and one would have big sigh a relief. This is, however, also wrong! Both transformations have the same problem! Both inductors in original topology are floating inductors and cannot be directly replaced with either of two inductor circuit positions.

It is interesting to note that the converter of Fig. 2 (top) is does not have steady-state and hence it does not even exist! The capacitor Cc is charging during OFF- time of switch but lacks discharge path!?

Wrong boost equivalent circuit model?

It is interesting how a desire to further simplify the wrong model of Fig.2 (top) leads to wrong boost converter model. The dubious argument is made that capacitor Cc for some reason (!?) does not participate in power conversion (although it did in SEPIC converter!) and can be therefore eliminated by shorting it to result in boost converter or Fig. 3!?

Fig. 3 Wrong boost converter model using false assumption that capacitor Cc can be SHORTED?!

This is PWM switch has led to incorrect conclusion that the Perfectly Coupled SEPIC converter using PWM switch model will have-boost frequency response!?

Correct Transformation

However, the input inductor can be relocated to the bottom leg so that terminal 1 and terminal 4 are common forming a 3-port network with a common terminal 1 & 4. Now, both transformations discussed above have the same identical correct solution obtained by shorting terminals 2 and 4 as in Fig. 4.

Fig. 4 Relocation of the input inductor to bottom leg and shorting the other two terminals 2 and 3.

This ultimately placies voltage source across coupling capacitor Cc and results in buck-boost final equivalent circuit. Note that capacitor Cc is now placed directly across ideal voltage source. This is a real reason why coupling capacitor Cc disappears in the correct buck equivalent buck-boost converter. The fact is, that in the case of the nonideal voltage source this capacitor would remain in the model and would result in buck-boost converter with inclusion of capacitor Cc and third-order dynamic model!

Final correct buck-boost equivalent circuit model

Fig. 5 Final correct buck-boost equivalent circuit.

Conclusion

Number of incorrect transformations and incorrect simplifications like shorting capacitor Cc led to wrong boost small-signal model!? Moreover, after deriving incorrectly boost small-signal frequency response, Vorperian continues to prove correctly that the DC voltage conversion is that of buck-boost!?

This would be the very first converter ever, which has frequency response of boost converter and DC voltage gain of buck-boost converter! That alone should have given the red flag to Vorperian and Ridley that something went amiss in their “magic” shortcuts!

Note regarding PWM switch model!

PWM switch model starts, as in this example, with small-signal model first, while steady-state DC model is always an after-thought!?

Yet, it is steady-state model which defines equilibrium around which small signal perturbations are made and should be the starting point!

State-Space Averaging Model

This is the case with State-Space Averaging Method, which determines first correct general steady-state (DC) model for any PWM switching converter, for those known 50 years ago as well as those invented ever since! It does not depend on “shortcut tricks” to massage the switch into an artificial 3-terminal double pole single-throw switch!

What about isolated converters or even 3-switch converters with isolation like forward and flyback converter with voltage clamp? Note that 3-switches cannot be manipulated into a single-pole double-throw ideal switch. The isolation in flyback and forward simply makes any such PWM switch transformation impossible and/or incorrect!?

Think how you would find correct frequency response of the Coupled-Inductor Isolated Sepic converter or even Integrated Magnetic SEPIC converter. With PWM switch model it is impossible. With State-Space Averaging Method this becomes a trivial extension by describing correctly mutual coupling inductances in matrix formulation.

Myth of the Moving Time Average!

Ever since my introduction of State-Space Averaging method in 1976 PhD thesis and 1976 IEEE conference paper, many revision attempts were made to explain averaging circuit method. They all followed original justification for boost small signal model in Gene Wester PhD thesis invoking “moving time average! It was claimed ever since that this somehow eliminates the ripple currents and voltages and results in smooth ripple-free continuous waveforms.

This continues even to the present day even though it has no scientific basis whatsoever! Another related argument is that just replacing PWM switch with dynamic model circuit gives you better “circuit insight” equal lacks any scientific basis!

It appears that my advisor and mentor late Prof. David Middlebrook was the only one who correctly understood my State-Space Averaging Method! In the preface of our 1981 first 2 volume paperback edition of Power Electronics books Prof. Middlebrook lamented:

“… If the models for all such converters are the same, it should be possible to derive this unique model without having to specify in advance any particular converter. This problem was solved in a very elegant manner by Slobodan Ćuk. In his 1976 PhD thesis he introduced the analysis method of State-Space Averaging which in a single stroke eliminates the switching process from consideration and exposes the desired dynamic response. From this model came the same unique small signal equivalent circuit model, which is now called the canonical model. Again, with the clarity of insight, the form of the model becomes “obvious”. It contains the three essential properties of any DC to DC converters, namely DC conversion, low pass filter and conversion ratio adjustment by a control signal.”

Extension of SSA to Hybrid Switching Method

State-Space Averaging is naturally extended now to special kind of resonant switching I introduced and called Hybrid Switching Method! This method has all the benefits of resonance but using duty ratio PWM control. It does also have 3 switches (one transistor on primary and two diodes on secondary) which automatically disqualifies PWM switch model! In addition, the resonance is essential as it fundamentally changes DC conversion ratio! PWM switch model as its names says is limited to PWM switching converters with no resonance and with special limiting single-pole double throw switch with a common terminal!

This SSA extension is not suitable for classical true resonant and quasi-resonant switching converters and latest LLC converter topologies, in which resonance extends across both switching subintervals. This is just fine, as these resonance methods are in many ways deficient to Hybrid Switching Method which contains the resonance in only one subinterval!

Conclusion

The PWM switch model and other preferable” shortcuts” are just a myth propagated by engineers who do not want to invest time to learn and expect that SPICE model of such simplified circuit model (albeit wrong) will give them the fast and correct results. Recent 2018 article on modelling says: “Compared with State-space averaging model, the PWM switch model is simpler and circuit oriented with physical insight.” No one ever explained what those better circuit and physical insights are?!

Another myth is that State-Space Averaging Method is very complicated and should not be used. The truth is that this method will give you correct analytical results for both steady-state and dynamic model for all converters of practical interests!

Would you ever want to have perfect coupling?

The answer is no, never! The question remains to be explained why this is the case if the above analysis makes the case for simpler 2nd order dynamic model of Perfectly Coupled SEPIC converter!?

What Comes First: Devices or Topology

Topologies Comparison

Topologies Comparison

Present Power Electronics Systems are built upon and resemble an INVERTED pyramid which is by definition unsustainable and ready to collapse at any moment. Why? At its bottom it has the buck converter as its foundation which than supports the next level single ended isolated converter like flyback and forward to culminate on the third level into bridge type converter with even more switching devices. Consequence: buck converter problems lead to collapse of the whole structure irrespective what switching devices are used.

The buck converter does have huge problems: device voltage stresses much higher than output regulated DC voltage and inherent hard switching operation. Moreover, the use of the inductor for filtering output ripple currents leads to inherent problems in scaling up the power due to the requirement to pass DC load current so that even modest DC load current and resulting air-gap just a fraction of millimeter leads to complete waste of the magnetic material and ineffective filtering. The new PWM/resonant switching method results in converter topologies which eliminate output inductor with DC bias and yet offering much more effective ripple current filtering.

The new switching methods and resulting converter topologies result in much reduce device voltage stresses. In the isolated converters this translated into reduction of transformer fluxes by an order of magnitude and consequent huge size reduction and efficiency improvements. The next example demonstrates that the optimum converter topology is of the primary importance for system performance and that actual switching devices utilized have only secondary importance in system improvements.

Converter Graphic

Converter Graphic

Comparison of the two switch buck converter with the three switch Cuk-buck2 demonstrates the huge differences in device stresses for 48V to 1V step down conversion. The synchronous rectifier diode in buck converter has 100V voltage stress versus 2V voltage stress in Cuk-buck converter. Hence a 10kW rated switch must be used instead of the 200W rated switch! Moreover, the diode is turned ON and turned- OFF at full 100A current in buck converter. In Cuk-buck2 the diode is turned both ON and OFF at zero current. Therefore, it does not even know that it is switching although it transfers huge current to the load. The duty ratio in buck converter is extremely small at 0.02 in order to make a 50V to 1V step-down buck converter. The Cuk-buck2 operates at 50% duty ratio and results in reduction of magnetics size by at least 50%.

Large Voltage Graphic

Large Voltage Graphic

In addition to elimination of switching losses Cuk-buk2 also has an isolated extension which retains all the above advantages, while the isolated version of the buck converter, the forward converter, suffer from the same disadvantages as the buck converter.

Device performance depends 100% on topology and not the other way around!