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This article has been accepted for publication in a future issue of this journal, but has not been

fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TPEL.2015.2411754, IEEE Transactions on Power Electronics

Operating Conditions Monitoring for High Power Density and Cost-

Effective Resonant Power Converters

Héctor Sarnago, Member, IEEE, Óscar Lucía, Senior Member, IEEE,


Denis Navarro, and José. M. Burdío, Senior Member, IEEE.

Department of Electronic Engineering and Communications,


University of Zaragoza, Spain

E-Mail: hsarnago@unizar.es, olucia@unizar.es, denis@unizar.es, burdio@unizar.es

Corresponding author: Óscar Lucía


E-mail: olucia@unizar.es
Phone: +34–876 555319
Fax: +34–976 762111.
Postal address: María de Luna, 1. 50018 Zaragoza. Spain.

Keywords: Resonant power conversion, measurement, induction heating.

Abstract.-Resonant power conversion is a key enabling technology for many high

performance and high efficiency systems. Induction heating is an example of such

systems which outperforms conventional heating technologies, leading to a wide

spectrum of industrial, domestic, and medical applications. In order to ensure the proper

operation of the resonant converter, accurate converter operation monitoring techniques

are required. This paper proposes an effective monitoring technique based on the

measurement of the resonant capacitor voltage. The proposed monitoring system provides

essential information regarding the output power, soft-switching conditions, and input

voltage, while featuring a cost-effective implementation. The proposed technique is

validated through an FPGA-controlled resonant power converter applied to induction

heating, proving the feasibility of this proposal.

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10.1109/TPEL.2015.2411754, IEEE Transactions on Power Electronics

I. INTRODUCTION

Resonant power converters [1] are essential in many applications due to their high

efficiency and the inherent high power density achieved [2]. As a result of this, these

converters are widespread in a number of applications from industrial [3], to aerospace

[4], domestic [5], and medical [6] areas. Nowadays, aerospace, lighting, and contactless

energy transfer systems, including induction heating, are a relevant example of

applications taking advantage of resonant power conversion.

One common design challenge is the need of using a robust measurement and control

architecture in order to ensure the optimum operating conditions of the converter, usually

involving soft-switching and accurate output voltage/power control. This becomes

essential to accurately control resonant converters in applications such as wireless power

transfer [7] or advanced induction heating systems [2, 8-11]. This paper proposes and

analyzes an output power measurement technique to provide an effective measurement

and high power density implementation for digitally controlled systems.

In order to measure the operating conditions and the output power of the power

converters, several techniques have been presented in the literature. Firstly, the most

immediate implementation consist on measuring magnitudes at the input of the power

converter [12, 13] (Fig. 1(a)). This requires low-frequency techniques and gives an

accurate measurement of the input power, but provides nearly no information about the

converter operation, its efficiency, and the power distribution in the case of multi-phase

or multi-coil systems.

The second, most commonly adopted, technique consist on measuring magnitudes at

the output of the power converter [14] (Fig. 1(b)). This entails using high-sampling-rate

high-precision ADCs, as proposed in [15] and [16]. In [15] two high-precision digital

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voltmeters are used and in [16] an oscilloscope is used. The main disadvantage of these

systems is the high cost of the measurement system. In [17, 18], the output voltage is

estimated from the bus voltage and the gating signals of the switching devices. The bus

voltage is considered constant in [17] and measured through a low-cost ΣΔ ADC in [18].

Nevertheless, the delay of the switching devices commutation has to be estimated, which

decreases the measurement accuracy. In [19], the first-harmonic approximation is

proposed. This method approximates the output power as the power supplied by the 1st-

harmonic component. However, the approximation taken into account increases the

system uncertainty. Finally, in [20] the power measurement is performed by using an

analog circuit. The main disadvantage of this method is the sensitivity of the measurement

with temperature and aging of the analog components.

(a) (b)

Fig. 1. Power measurement alternative schemes: low-frequency input (a) and high-
frequency output (b).

In order to provide an accurate measurement of the output power, bus voltage and

soft-switching conditions, while providing a high power density and cost-effective

implementation, this paper proposes a measurement technique based on the resonant

capacitor charge analysis. Unlike previous proposals [21, 22], the proposed technique

only requires measuring the resonant capacitor voltage with reduced sampling rate,

improving significantly currently adopted solutions.

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The remainder of this paper is organized as follows. Section II details the proposed

power measurement technique and its fundamentals. Section III details the resonant

power converter under study and the FPGA-based monitoring technique implementation.

Section IV summarizes the main experimental results, including accuracy for the dc-link

voltage and output power estimation, as well as the soft-switching conditions. Finally, the

main conclusions of this paper are drawn in Section V.

II. PROPOSED MONITORING TECHNIQUE

In order to analyze the proposed technique, the resonant converter under study is

presented and deeply analyzed, and the main expressions required are derived.

A. RESONANT CONVERTER ANALYSIS

The resonant inverter under study is shown in Fig. 2 (a). It is composed of two

bidirectional and unipolar switches, SH and SL, which are implemented typically using

IGBTs with antiparallel diodes. The equivalent induction heating load is composed of a

series resistance, RL, and inductance, Lr [23], and the resonant capacitor, Cr. Usually,

operation above the resonant frequency is preferred in order to ensure a ZVS soft-

switching behavior [24]. Additionally, lossless snubber capacitors, Cs, are placed in

parallel with the switching devices in order to reduce the switching losses during the turn-

off transition. The main steady-state waveforms, including the load current, io, and the

resonant capacitor voltage, vc, are shown in Fig. 2 (b).

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+
SH
Cs
IH-load
VS io
+ RL Lr + Rd
SL vo vc
Cs Cr
- - - Rm ADC

(a)
Tsw
DTsw

Vg_H
Vg_L

Vc,D
Vc,C
Vc,A Vc,A
vc Vc,B Vc,B

vo
io
I II III IV I

ts,H ts,L
dtH dtL

(b)
Fig. 2. Schematic of the half-bridge series resonant converter (a) and main waveforms
(b).

Four different equivalent states can be established, I to IV, depending on the

equivalent resonant circuit (Fig. 2(b) and Fig. 3). During State I, i.e.0≤t<ts,H, the snubber

capacitors are charged by the load current, leading to a reduced dv/dt transition in the

devices. The applied output voltage, vo,I, results

1
2Cs t
vo,I (t )  io ( )d , (1)

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io/2 io
+ +
SH SH
Cs Cs
IH-load IH-load
VS io VS io
+ RL Lr + + RL Lr +
SL vo vc SL vo vc
Cs Cr Cs Cr
- - - - - -
I II
io/2
+
+ SH
SH Cs
Cs
IH-load
IH-load VS io
VS io + +
RL Lr
+ RL Lr + SL vo vc
SL vo vc Cs Cr
Cs Cr - - -
- - -
III IV
Fig. 3. Electrical states of the series resonant converter.

During State II (ts,H ≤t<DTsw), the dc-link voltage, Vs, is applied to the load, i.e.

vo,II=Vs, and thus the load current, io, flows through SH. Considering the operation above

the resonant frequency, a negative load current is expected at the beginning of this state

flowing through the antiparallel diodes. Consequently, ZVS turn-on transition is achieved

in SH if a proper dead-time between activation signals is applied dtH≥ts,H.

State III (DTsw≤t<DTsw+ts,L) begins when SH is turned off, yielding to the

charge/discharge of the snubber capacitors, Cs, through the load current, io, forcing a

reduced dv/dt in the transistors, and thus, reducing switching losses during the turn-off

transition of SH. The applied output voltage, can be obtained by integrating the load

current, yielding vo,III (t)= vo,I (t).

Finally, State IV (DTsw+ts,L≤t<Tsw) begins when the snubber capacitors are

completely charged/discharged, turning on the antiparallel diode of SL. By applying a

proper dead time, dtL≥ts,L, a ZVS turn-on transition is achieved. During this state, the

applied output voltage results vo,IV=0.

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B. PROPOSED MEASUREMENT TECHNIQUE FOR MONITORING THE DC-LINK VOLTAGE

By using the proposed measurement technique, the dc-link voltage, Vs, can be

monitored by means of the resonant capacitor voltage, vc. Considering the series RLC

resonant tank, the applied output voltage, vo, can be expressed as

vo  t   RLio  t   vl  t   vc  t  . (2)

In steady-state, both the average resonant capacitor current, Io, and the equivalent

inductance average voltage, Vl, are zero, yielding to Vo=Vc. Finally, the average output

voltage results, Vo=DVs, where D is the duty cycle, and therefore, the dc-link voltage can

be measured by means of the average capacitor voltage (Fig. 4(a)),

Vc  DVs . (3)

Additionally, considering D=0.5, i.e. assuming a square wave (SW) modulation

which is commonly applied in most WPT and IH systems, the average resonant capacitor

voltage can be simplified [25] to:

Vc , D  0.5 
V c,A  V c ,C 
, (4)
2

where Vc,A and Vc,C are the values of the resonant capacitor voltage when the switching

devices are turned off, as shown in Fig. 2(b). This leads to the simplified equation (5) that

requires only measuring two points per switching period for monitoring the dc-link

voltage (Fig. 4(b)), significantly reducing the sampling frequency requirements.

Vs,D0.5  Vc, A  Vc,C . (5)

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Tsw Tsw

Vg_H Vg_H
Vg_L Vg_L

Vc,C
vc vc Vc,A Vc,A

(a) (b)
Fig. 4. Classical measurement method for an arbitrary duty cycle (a) and proposed
method for D=0.5 (b).

C. PROPOSED MEASUREMENT TECHNIQUE FOR THE OUTPUT POWER

In order to demonstrate proposed measurement technique, the analytical model of the

converter output power will be analyzed. The average output power delivered to the load,

Po, can be obtained by computing the following expression

1
Tsw Tsw
Po  voiodt, (6)

where Tsw=1/fsw is the switching period. As it has been aforementioned the applied output

voltage is

 1
 2C  io ( )d , 0  t  t  s ,H
 s t
VS , t  t  DTsw 
vo  t   
s ,H
. (7)
 1 io ( )d ,  DT  t  DTsw  ts ,L 
 2Cs t sw


0,  DT sw  ts ,L  t  Tsw 

In order to compute the average output power, it is important to consider that the

average output power delivered during the snubber intervals (States I, III) is zero,

therefore, the output power results

VS DTsw VS DTsw  ts , L
Po 
Tsw 
ts , H
io (t )dt 
Tsw  0
io ( t )dt , (8)

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where D is the duty cycle. It is important to remark that classical high-frequency

measurement methods are based on equations (6) and (8), therefore, two magnitudes are

required to be continuously sampled, i.e. the load current, io, and the inverter output

voltage, vo, or the dc-link voltage, VS, respectively. However, the proposed technique will

rely on measuring only the resonant capacitor voltage (Fig. 2(a)). The instantaneous

resonant capacitor voltage, vc, can be obtained as a function of the load current,

1
Cr t
vc (t )  Vc,0  io ( )d , (9)

where Vc,0 is the resonant capacitor voltage at the beginning of the integration period.

Therefore, by replacing (9) in (8), the average output power is simplified as follows

 
 DTsw DTsw  ts , L 
VS 
io (t )dt   io (t )dt  .
Tsw  0
Po  (10)
DTsw

 C      
 r vc  DTsws vc  0 Qs 

By denoting Vc,A=vc(0), Vc,B=vc(dtH), Vc,C=vc(DTsw), Vc,D=vc(DTsw+dtL), according to Fig.

2(b), and simplifying the snubber charge, Qs=2VsCs, results

VS
Po  Cr Vc ,C  Vc , A   2VS Cs  . (11)
Tsw 

As a conclusion of (10), the average output power can be obtained as function of the

dc-link voltage, VS, and a two instantaneous values of the resonant capacitor voltage (Vc,A,

Vc,C). Additionally, in the case of D=0.5, the measurement of the instantaneous value of

the resonant capacitor voltage at the switching points (4) enables computing the output

voltage as follows.

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Po , D  0.5 
V c,A  V c ,C 
 C r Vc ,C  Vc , A   2 Vc , A  Vc ,C  C s  . (12)
Tsw

It is important to note that this implementation significantly decreases the sampling

frequency requirements, leading to a simple and cost-effective implementation.

D. PROPOSED MEASUREMENT TECHNIQUE FOR THE SOFT-SWITCHING CONDITIONS

Following the proposed methodology, it is also possible to ensure the proper ZVS

soft-switching conditions by evaluating the resonant capacitor voltage during transitions.

As it has been aforementioned, the snubber capacitors are charged/discharged by the load

current, requiring a charge, Qs=2CsVS. The available charge during each transition, Qo,H,

Qo,L, for SL and SH turn off, respectively, can be computed by

Qo , H   i (t )dt  C V
dt H
o r c,A  Vc , B  , (13)

Qo , L   i (t )dt  C V
dt L
o r c ,D  Vc ,C  . (14)

Therefore, soft-switching conditions can be ensured by fulfilling the conditions Qo,H,

Qo,L≥Qs, which means that the snubber capacitors are completely charged, and the current

has not changed sign. As it is shown in Fig. 5 for the SH turn-off transition, four different

scenarios are possible: if Qo,L<Qs (Fig. 5(a)), the snubber capacitors are not completely

charged/discharged when SL is activated and, therefore, additional losses in the form of

Cs vo2
are expected, where vo denotes the remainder snubber capacitor voltage when
2

SL is turned on.

A correct turn-off transition is performed if Qo,L=Qs, (Fig. 5(b)) or Qo,L>Qs, (Fig.

5(c)), being preferable Qo,L=Qs if a synchronous rectification is desired in the case of

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MOSFET devices. Finally, if the dead-time applied is too high (Fig. 5(d)), a load current

zero crossing may occur, yielding to additional losses.

At this point it is important to note that monitoring the output power and bus vultage

require measuring at 2 points, whereas monitoring soft-switching conditions require

measuring at 4 points. The final implementation must be carefully analyzed for each

converter considering both cost and performance considerations. However, due to the

important implications of soft-switching in terms of efficiency, performance, EMC and

long-term reliability, and the current availability of inexpensive ADC in the resonant

converter switching frequency range, usually soft-switching condition monitoring can be

recommended.

Vg_H Vg_H
Vg_L Vg_L
vo vo
Vc,D
Vc,C Vc,D Vc,C

vc vc
∆vo
io io
t t

(a) (b)
Vg_H Vg_H
Vg_L Vg_L
vo vo
Vc,D
Vc,D
Vc,C Vc,C

vc vc

io io
t t

(c) (d)
Fig. 5. Turn-off transition for different dead-times: dtL<ts,L (a),
dtL=ts,L (b), dtL>ts,L (c), and dtL>>ts,L (d).

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III. CONVERTER AND MONITORING TECHNIQUE IMPLEMENTATION

In order to prove the feasibility of the proposed monitoring technique and asses its

accuracy, an experimental test-bench has been designed and implemented. It is composed

of a 3.3-kW half-bridge series resonant inverter for induction heating applications (Fig.

6). The power converter features state-of-the-art 600-V IGBTs and the resonant tank is

composed of the induction load, modeled as a RL, Lr, equivalent, and the resonant

capacitor Cr. Table I summarizes the values of the induction loads used in the

experimental measurements.

It is important to note that the proposed technique relies on the knowledge of the

resonant capacitor value. Since usually MKP technology is used, it does not suffer from

significant ageing effects, and tolerance value is the main design issue. This can be

addressed by performing calibration during the production process and by controlling

component batches.

+
SH
Cs
IH-load
VS io
+ RL Lr + Rd
SL vo vc
Cs Cr Rm
- - -
ADC

DIGITAL PWM Vs monitoring


ZVS so-switching USB
UART
FPGA
∑ Po measurement

(a)

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(b)
Fig. 6. Experimental test-bench schematic (a) and prototype (b).

TABLE I. INDUCTION HEATING LOADS


IH Load #1 #2 #3
RL 2,9 Ω 2,1 Ω 2,0 Ω
Lr 27 µH 18 µH 21 µH
Cr 1440 nF

The proposed monitoring scheme is intended to be implemented within a digital

control architecture. It has been implemented using an FPGA for a final ASIC

implementation for consumer appliances.

Fig. 6 (a) shows the digital control architecture block diagram [26, 27]. A Xilinx

Spartan 6 FPGA is used to generate the driving signals for the resonant power converter

as well as to measure the resonant capacitor voltage. Low-cost ADCS7476 analog-to-

digital converters have been selected to obtain accurate monitoring while obtaining a cost-

effective implementation taking advantage of the proposed monitoring scheme.

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Fig. 7 shows the measurement timing diagram for the proposed monitoring scheme.

It is important to note that the proposed technique requires only measuring the resonant

capacitor voltage at 4 points, denoted as A, B, C, D in the figure. Following this approach,

the sampling frequency of the ADC, f s , is required to be only twice the switching

frequency fs  2 fsw , obtaining a throughput of 1 data/cycle for the output power and bus

voltage estimation, and 0.5 data/cycle for the complete soft-switching conditions

estimation. The latency for all measurements is mainly determined by the sampling time,

being approximately 1 fs . Besides, the delay between the control signals and the

sampling point is taking into account through the  ADC parameter.

Vg_H
Vg_L
Vc,D
Vc,C

vc
Vc,A

Vc,B
φADC φADC φADC φADC

ADC
DATA Vc,A Vc,C Vc,B Vc,D

Fig. 7. Measurement timing diagram.

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IV. EXPERIMENTAL RESULTS

This section summarizes the experimental measurements carried out in order to

assess the accuracy and validate the proposed monitoring technique for the dc-link

voltage and output power measurement, and the soft-switching conditions estimation.

A. DC-LINK VOLTAGE MEASUREMENT

As it has been previously explained, the proposed monitoring scheme enables the

estimation of the bus voltage. This is especially critical for domestic induction heating

systems located at remote locations with bad quality mains, or heavy industry systems.

Fig. 8 shows the bus voltage accuracy results for different induction heating loads and

different possible bus voltage values according to the current EU regulations for 230 V

mains. These results proves the accuracy in the bus voltage estimation, enabling a more

robust resonant converter operation taking into account possible changes in the input bus

voltage.

4
IH-LOAD #1
IH-LOAD #2
2 IH-LOAD #3
Error (%)

-2

-4
-10 -5 0 5 10
Dc-link voltage variation (%)
Fig. 8. Bus voltage measurement accuracy for different output powers. Yokogaya
PZ4000 power analyzer considered as reference.

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B. OUTPUT POWER MEASUREMENT

Fig. 9 shows the output power measured following the proposed technique for

different induction heating loads and operating conditions, compared with the Yokogawa

PZ4000 Power Analyzer measurements, considered as reference. In this figure, it can be

seen that the proposed approach achieves accurate measurements for the wide operation

range typical of induction heating systems. As it is detailed in Fig. 9 (b), the proposed

technique obtains errors lower than 1.5% in the complete range, enabling proper output

power control while requiring an affordable implementation.

4000
IH-LOAD #1
3500 IH-LOAD #2
Measured power (W)

3000 IH-LOAD #3
2500
2000
1500
1000
500
0
20 30 40 50 60 70 80
Switching frequency (kHz)

(a)
1,32
1,24

1,25

1,24
1,18

0,98
0,94

0,91

0,90

0,60
0,69
0,69
0,61

0,68
0,60
0,45
0,38

0,39
0,35

0,31
0,28
Error (%)

-0,17

3500 3000 2500 2000 1500 1000 500


Measured power (W)
(b)
Fig. 9. Output power measurement with different induction heating loads as a function
of the switching frequency (a). Errors compared with Yokogaya PZ4000 power
analyzer considered as reference: (b).

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C. SOFT-SWITCHING MONITORING

Finally, the proposed monitoring technique allows to evaluate the soft-switching

conditions of the proposed converter, detect the correct ZVS operation, and compensate

dead-times if required. Fig. 10 shows the main resonant converter waveforms for different

switching conditions, non-ZVS because of lower (a) and higher (b) dead-times than

required, ZVS condition (c), and optimum ZVS condition (d). The values used by the

FPGA-based control architecture to evaluate the soft-switching operation are shown in

Table II, proving a proper control operation. Consequently, the proposed technique enable

ensuring soft-switching conditions, improving the converter efficiency and reliability.

(a) (b)

(c) (d)
Fig. 10. Main resonant converter waveforms during the switching transition: (a) non-ZVS
low dead-time, (b) non-ZVS high dead-time, (c) ZVS, and (d) optimum ZVS. From top to bottom:
control signals (20 V/div), output voltage (40 V/div), and resonant capacitor voltage (50 V/div).

0885-8993 (c) 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See
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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TPEL.2015.2411754, IEEE Transactions on Power Electronics

TABLE II. MEASURED SOFT-SWITCHING PARAMETERS


Dead time 0.680 µs 4.180 µs 3.460 us 0.938 µs
Image Fig 10 (a) Fig 10 (b) Fig 10 (c) Fig 10 (d)
Qo,L 16.58 µC 36.39 µC 36.00 µC 20.41 µC
Qo,L,meas 14.28 µC 37.67 µC 35.15 µC 21.03 µC
Qs 20.24 µC
ZVS NO NO YES YES

V. CONCLUSIONS

Resonant power conversion is a key enabling technology for those systems requiring

high performance, efficiency and power density. In order to obtain reliable and efficiency

implementations, accurate power converter operation monitoring is advisable. This paper

has proposed an accurate and cost-effective technique based on the low-frequency

sampling of the resonant capacitor voltage. The proposed technique enables to measure

the output power and the input voltage, and evaluate the soft-switching conditions of the

converter.

The proposed approach has been tested by means of a 3.3 kW resonant inverter for

induction heating applications. Experimental results shows a good accuracy of both the

output power and bus voltage measurements, as well as the effectiveness of the ZVS soft-

switching detection. Consequently, the proposed system provides essential information

for the resonant converter control, improving the converter reliability and performance,

while obtaining a cost-effective implementation.

ACKNOWLEDGMENT

This work was partly supported by the Spanish MINECO under Project TEC2013-

42937-R, Project CSD2009-00046, and Project RTC-2014-1847-6, by the DGA-FSE, by

the University of Zaragoza under Project JIUZ-2014-TEC-08, and by the BSH Home

Appliances Group.

0885-8993 (c) 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See
http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TPEL.2015.2411754, IEEE Transactions on Power Electronics

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