Analytical Calculation of the Residual ZVS Losses of TCM ...

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Received 22 December 2020; accepted 31 January 2021. Date of publication 9 February 2021; date of current version 21 April 2021. The review of this article was arranged by Associate Editor Francesco Iannuzzo. Digital Object Identifier 10.1109/OJPEL.2021.3058048 Analytical Calculation of the Residual ZVS Losses of TCM-Operated Single-Phase PFC Rectifiers MICHAEL HAIDER 1 , JON AZURZA ANDERSON 1 , NEHA NAIN 1 , GRAYSON ZULAUF 1 , JOHANN W. KOLAR 1 , DEHONG XU 2 , AND GERALD DEBOY 3 1 Power Electronic Systems Laboratory (PES), ETH Zurich, Switzerland 2 Electrical Engineering, Zhejiang University, China 3 Infineon Technologies Austria AG, Austria CORRESPONDING AUTHOR: MICHAEL HAIDER (e-mail: [email protected]) ABSTRACT Triangular-current-mode (TCM) modulation guarantees zero-voltage-switching across the mains cycle in AC-DC power converters, eliminating hard-switching with a minor 30% penalty in con- duction losses over the conventional continuous current mode (CCM) modulation scheme. TCM-operated converters, however, include a wide variation in both switching frequency and switched current across the mains cycle, complicating an analytical description of the key operating parameters to date. In this work, we derive an analytical description for the semiconductor bridge-leg losses in a TCM AC-DC converter, including the rms current and/or conduction losses, switching frequency, and switching losses. For SiC MOSFETs, we introduce a new loss model for switching losses under zero-voltage-switching, which we call “residual ZVS losses”. These losses include the constant C oss losses found in previous literature but must also add, we find, turn-off losses that occur at high switched currents. The existence and modeling of these turn-off losses, which are due to currents flowing through the Miller capacitance and raise the inner gate source voltage to the threshold level and accordingly limit the voltage slew rate, are validated on the IMZA65R027M1H 650V SiC MOSFET. The complete loss model – and the promise of TCM for high power density and high efficiency – is validated on a 2.2 kW hardware bridge-leg demonstrator, which achieves a peak 99.6% semiconductor efficiency at full load. The proposed, fully-analytical model predicts bridge-leg losses with only 12% deviation at the nominal load, accurately including residual ZVS losses across load, modulation index, and external gate resistance. INDEX TERMS AC-DC power converters, power MOSFET, rectifiers, silicon carbide, soft switching, wide band gap semiconductors, zero voltage switching. I. INTRODUCTION Power-dense and efficient AC-DC power conversion [1] is a fundamental building block for grid-interface converters as well as electric drives, and, ultimately, a key to the suc- cessful and widespread integration of renewable energy into the energy mix. In particular, kW-scale, single-phase AC- DC converters serve as power-factor-correction (PFC) recti- fier input stages for, e.g., data center power supply modules, on-board electric (EV) chargers, and PFC rectifier front-ends for low-power variable speed motor drive systems in heating, ventilation, and air conditioning (HVAC) and servo drives in industry automation and robotics, where nearly 90% of all drive systems worldwide are below 1 kW in rated power [2]. Conventionally, boost-type PFC rectifiers consisted of a diode bridge front-end, a boost inductor, and a transistor and freewheeling diode pair. Bridgeless – that is, without the diode bridge front-end – topologies were later introduced with 2 boost-type bridge-legs each with a superjunction (SJ) Si MOS- FET and a freewheeling SiC Schottky diode (the “dual-boost PFC rectifier” [3]), and later improved with synchronous rectification to eliminate the on-state voltage drop of the diodes. This final step resulted in the bridgeless totem-pole This work is licensed under a Creative Commons Attribution 4.0 License. For more information, see https://creativecommons.org/licenses/by/4.0/ 250 VOLUME 2, 2021

Transcript of Analytical Calculation of the Residual ZVS Losses of TCM ...

Page 1: Analytical Calculation of the Residual ZVS Losses of TCM ...

Received 22 December 2020; accepted 31 January 2021. Date of publication 9 February 2021;date of current version 21 April 2021. The review of this article was arranged by Associate Editor Francesco Iannuzzo.

Digital Object Identifier 10.1109/OJPEL.2021.3058048

Analytical Calculation of theResidual ZVS Losses of TCM-Operated

Single-Phase PFC RectifiersMICHAEL HAIDER 1, JON AZURZA ANDERSON 1, NEHA NAIN 1, GRAYSON ZULAUF 1,

JOHANN W. KOLAR 1, DEHONG XU 2, AND GERALD DEBOY3

1 Power Electronic Systems Laboratory (PES), ETH Zurich, Switzerland2 Electrical Engineering, Zhejiang University, China

3 Infineon Technologies Austria AG, Austria

CORRESPONDING AUTHOR: MICHAEL HAIDER (e-mail: [email protected])

ABSTRACT Triangular-current-mode (TCM) modulation guarantees zero-voltage-switching across themains cycle in AC-DC power converters, eliminating hard-switching with a minor ≈30% penalty in con-duction losses over the conventional continuous current mode (CCM) modulation scheme. TCM-operatedconverters, however, include a wide variation in both switching frequency and switched current across themains cycle, complicating an analytical description of the key operating parameters to date. In this work,we derive an analytical description for the semiconductor bridge-leg losses in a TCM AC-DC converter,including the rms current and/or conduction losses, switching frequency, and switching losses. For SiCMOSFETs, we introduce a new loss model for switching losses under zero-voltage-switching, which wecall “residual ZVS losses”. These losses include the constant Coss losses found in previous literature butmust also add, we find, turn-off losses that occur at high switched currents. The existence and modeling ofthese turn-off losses, which are due to currents flowing through the Miller capacitance and raise the innergate source voltage to the threshold level and accordingly limit the voltage slew rate, are validated on theIMZA65R027M1H 650V SiC MOSFET. The complete loss model – and the promise of TCM for high powerdensity and high efficiency – is validated on a 2.2 kW hardware bridge-leg demonstrator, which achieves apeak 99.6% semiconductor efficiency at full load. The proposed, fully-analytical model predicts bridge-leglosses with only 12% deviation at the nominal load, accurately including residual ZVS losses across load,modulation index, and external gate resistance.

INDEX TERMS AC-DC power converters, power MOSFET, rectifiers, silicon carbide, soft switching, wideband gap semiconductors, zero voltage switching.

I. INTRODUCTIONPower-dense and efficient AC-DC power conversion [1] isa fundamental building block for grid-interface convertersas well as electric drives, and, ultimately, a key to the suc-cessful and widespread integration of renewable energy intothe energy mix. In particular, kW-scale, single-phase AC-DC converters serve as power-factor-correction (PFC) recti-fier input stages for, e.g., data center power supply modules,on-board electric (EV) chargers, and PFC rectifier front-endsfor low-power variable speed motor drive systems in heating,ventilation, and air conditioning (HVAC) and servo drives in

industry automation and robotics, where nearly 90% of alldrive systems worldwide are below 1 kW in rated power [2].

Conventionally, boost-type PFC rectifiers consisted of adiode bridge front-end, a boost inductor, and a transistor andfreewheeling diode pair. Bridgeless – that is, without the diodebridge front-end – topologies were later introduced with 2boost-type bridge-legs each with a superjunction (SJ) Si MOS-FET and a freewheeling SiC Schottky diode (the “dual-boostPFC rectifier” [3]), and later improved with synchronousrectification to eliminate the on-state voltage drop of thediodes. This final step resulted in the bridgeless totem-pole

This work is licensed under a Creative Commons Attribution 4.0 License. For more information, see https://creativecommons.org/licenses/by/4.0/

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FIGURE 1. (a) Single-phase PFC rectifier in a totem-pole and/or full-bridge structure, where one bridge-leg operates at switching frequency, and the otheroperates at line frequency. (b) The characteristic TCM inductor current and mains current waveforms are shown for a 2.2 kW, 230 Vrms to 400 V PFCrectifier with a minimum turn-off current of IL− (within the positive mains half-cycle) and a fundamental current component of iac (with low fsw tohighlight the current waveform). (c) Characteristic waveforms for the time interval highlighted in (b), including the gate signals of Th and Tl (cf. (a)), wherett,h−l and tt,l−h represent the current-dependent transition times from the high-side switch to the low-side switch, and vice versa, respectively. uau is theswitch-node voltage.

and/or full-bridge arrangement of Fig. 1(a), the preferredtopology for single-phase AC-DC power conversion today.

This topology utilizes one high-frequency switching leg,often implemented with SiC MOSFETs or GaN high-electron-mobility transistors (HEMTs), and one line-frequency switch-ing leg as an unfolder, typically implemented with SJ SiMOSFETs designed to minimize the conduction losses. Undercontinuous conduction mode (CCM) operation, also known aspulse width modulation (PWM), the high-frequency bridge-leg operates with a constant switching frequency and the dutycycle is set to sinusoidally shape the mains current and thus,define the output power. In this mode, the inductor currentripple is relatively small and, during each half-cycle, oneturn-on transition in the high-frequency bridge-leg is hardwhile the other is soft under zero-voltage conditions (assum-ing an average output current much larger than the currentnecessary for soft-switching). In an effort to further improvethe power density of these converters and avoid hard commu-tation of early MOSFETs (and later of Si SJ MOSFETs), however,designers have proposed new modulation schemes with fullzero-voltage-switching (ZVS) [4], [5], including the widely-adopted triangular current mode (TCM) operation [6]–[9],which is shown in Fig. 1(b) and, in detail, in Fig. 1(c) withtransition times from low-side to high-side t t,l-h and high-sideto low-side tt,h-l.

TCM modulation confers significant benefits to the simul-taneous pursuit of high efficiency and high power density.Firstly, and most importantly, the voltage across the powerMOSFETs is reduced to zero before turn-on, eliminating thedominant switching loss component of the energy stored inthe parasitic output capacitor, Coss. These switching lossesare eliminated without requiring auxiliary circuits, as only thecontrol of the main power circuit is modified, and this controlcan be implemented using modern digital signal processingdevices (e.g. DSPs and FPGAs) and simple sensing circuits.When combined with novel wide-bandgap semiconductorsthat have both low on-resistance and an output capacitancethat is both small and linear (relative to Si SJ MOSFETS), the

higher rms current in TCM (≈ 15% higher than in CCM, re-sulting in ≈ 30% higher conduction losses) is easily toleratedand the switching frequency can be increased even further.

Under TCM modulation (and closely-related schemafor soft-switching, including critical conduction and quasi-square-wave), AC-DC power converters with SiC MOSFETsand 400 V or 800 V DC-links have reached switching frequen-cies as high as 650 kHz [10], [11]. With GaN power semicon-ductors, designers have pushed switching frequencies into theMHz regime [12] (as high as 3 MHz [13], [14]) and simulta-neously achieved efficiencies over 99% and power densitieswell over 100 Win−3 [15], [16]. Despite these demonstratedimprovements and the widespread adoption of TCM schemes,though, there does not exist a straightforward method to cal-culate the power semiconductor losses in a TCM operatedrectifier or inverter, eliminating the ability to optimize powersemiconductor selection, thermal design, or switching fre-quency with limited effort.

In the paper, we seek to fill this critical literature gap, de-riving an analytical power semiconductor loss calculation forTCM rectifiers even in the presence of (a) current-dependentZVS losses and (b) the wide variation in switching frequencyseen in TCM converters (Section II). The soft-switching (orCoss) losses occur during the process of resonantly chargingand discharging the parasitic output capacitor of the semicon-ductor and may be current-dependent [17]. These are com-bined with current-dependent turn-off losses in zero-voltage-switched converters, and we term this power dissipated as the“residual ZVS losses” that, with conduction losses, comprisethe power semiconductor losses in a TCM converter. Thisloss model is proposed and validated with measurements on anext-generation 650 V SiC MOSFET in Section III. Section IVintroduces the analytical expressions for the semiconductorlosses and in Section V, we validate the analytical equationsand loss model in a 2.2 kW PFC rectifier, a typical powerlevel [12]–[14] used in, for example, data center applicationsand industrial automation (see specifications in Table 1). Fi-nally, Section VI summarizes the key findings of the paper,

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HAIDER ET AL.: ANALYTICAL CALCULATION OF THE RESIDUAL ZVS LOSSES OF TCM-OPERATED SINGLE-PHASE PFC RECTIFIERS

TABLE 1. Single-Phase AC-DC Converter Specifications

including the unification of competing theories on Coss lossesin SiC MOSFETs.

II. TCM OPERATING BEHAVIORTo ascertain the power semiconductor losses in TCM, we firstmust describe the fundamental operating waveforms, prefer-ably with analytical solutions. With the sought-after resid-ual ZVS losses dependent on both frequency (soft-switchinglosses are the product of energy dissipated per cycle and fre-quency) and current (both soft-switching and turn-off lossesdepend on current), and both switching frequency ( fsw) andswitched current varying across the mains cycle, this descrip-tion is fundamental to an accurate loss prediction.

A. ANALYTICAL DESCRIPTIONWith a fundamental ac voltage of uac(t ) = uac sin(ωact ) withpeak uac and DC-link voltage Udc, the modulation index is:

M = uac

Udc= 0.4. . .0.81. (1)

The fundamental current iac is in phase with the voltage(iac(t ) = iac sin(ωact )), as is required for PFC operation. InTCM operation, an opposite-polarity current is selected toensure ZVS during each half of the mains cycle, shown inFig. 1(b-c) as IL- < 0 A for the positive half of the mainscycle. With a peak ac current of iac, the current bands duringthe positive half of the mains cycle (uac ≥ 0 V) are:

i+(t ) = |IL-| + 2iac sin (ωact ) i-(t ) = −|IL-|, (2)

and during the negative half of the mains cycle (uac < 0 V),the current bands are:

i+(t ) = |IL-| i-(t ) = −|IL-| + 2iac sin (ωact ). (3)

With these bands defined, we introduce the “ZVS currentratio” as the ratio between the current selected to achieve ZVSand the fundamental peak current, or:

γ = |IL-|iac

. (4)

The opposite polarity current, IL- < 0 A, must be selectedsuch that ZVS is guaranteed across the full mains cycle. Fromthe u − Zi diagram analysis in [8] that considers both therectifier and the inverter cases, the characteristic impedanceto guarantee ZVS is:

Z =√

L

2Coss,Q, (5)

where 2Coss,Q is the total charge-equivalent output capacitanceof the bridge-leg semiconductors (Coss,Q,Th + Coss,Q,Tl =2Coss,Q). For rectifier operation, ZVS is guaranteed (even with

IL- = 0 A) with M ≤ 0.5. At larger modulation indices, theminimum required turn-off current is required at the voltagepeak (uac = uac) as:

|IL-| ≥ Imin = Udc

Z·√

|2M − 1|. (6)

For inverter operation, similarly, ZVS is guaranteed withM ≥ 0.5. The minimum current requirement occurs at thevoltage zero-crossing (uac = 0 V) as:

|IL-| ≥ Imin = Udc

Z, (7)

which is the worst-case condition over the entire operatingspace and therefore defines the minimum required opposite-polarity current |IL-|.

Assuming the resonant transition is (a) much shorter thanthe on-time and off-time of the bridge-leg transistors and (b)the additional current from the resonant transition is small,we can make a triangular current approximation, and deriveanalytical equations for the switching frequency fsw across themains cycle and the rms current through the inductor (IL,rms)and the power devices Ih,rms and Il,rms.

First, the on- and off-time for the high-side switch Th,during the positive half-cycle, are defined with

⎧⎪⎪⎨⎪⎪⎩

ton(t ) = L�iL(t )/Udc

1 − M |sin(ωact )|

toff(t ) = L�iL(t )/Udc

M |sin(ωact )| ,(8)

with the bridge-leg inductance L, a mains angular frequencyωac, and the time-dependent peak-to-peak current ripple�iL(t ) = 2|IL-| + 2iac| sin (ωact )|. The expressions for ton andtoff have to be exchanged during the negative half-cycle due tothe operation of the unfolder bridge-leg. The switching pe-riod definition Tsw(t ) = ton(t ) + toff(t ) = 1/ fsw(t ), however,is true in both the positive and negative half-cycle and theswitching frequency for both rectifier and inverter operationis:

fsw(t ) = Udc

2Liac

M| sin (ωact )| − M2 sin2 (ωact )

γ + | sin (ωact )| (9)

and the global maximum fsw,max occurs at ζ = | sin (ωact∗)| =√γ 2 + γ

M − γ (see Fig. 2(a.i)) and is:

fsw,max = Udc

2Liac· Mζ − M2ζ 2

γ + ζ. (10)

With the triangular shape of the inductor current iL, thelocal inductor rms current i2L,rms = 1

Tsw

∫ Tsw0 i2L(t )dt over a

switching period Tsw = 1/ fsw is determined by the positiveand negative current limits as:

i2L,rms(t ) = 1

3

[i2+(t ) + i+(t )i-(t ) + i2- (t )

], (11)

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FIGURE 2. Comparison of the analytically-calculated and numerically-simulated (a.i) local switching frequency fsw and (b.i) transistor local rms currentsih,rms and il,rms over one mains cycle Tac = 1/fac for the specifications of Table 1 with Uac = 230 Vrms, an assumed Coss,Q = 370 pF of the bridge-leg powertransistor, and a constant turn-off current of IL− = −4 A. (ii) shows (a) the analytically-calculated maximum switching frequency fsw,max and (b) theanalytically-calculated global inductor rms current IL,rms over the operating area and (iii) shows the absolute error of this prediction compared to thenumerical simulation.

which can also be written as i2L,rms(t ) = i2h,rms(t ) + i2l,rms(t ),due to the triangular current approximation. The instanta-neous (local) rms current across the mains cycle is shown inFig 2(b.i).

Therefore, we can find the local high-side and low-sideswitch rms currents, ih,rms and il,rms, which determine theconduction losses. These are given as:

i2h,rms(t ) = i2L,rms(t ) · d (t ), (12)

i2l,rms(t ) = i2L,rms(t ) · [1 − d (t )] , (13)

with the instantaneous duty cycle d (t ) = uan(t )/Udc of:

d (t ) ={

M |sin(ωact )| if uac(t ) > 0 V

1 − M |sin(ωact )| if uac(t ) ≤ 0 V.(14)

These local rms values can then be used to cal-culate the global rms currents, as, for example,I2L,rms = 1

Tac

∫ Tac0 i2L,rms(t )dt for the inductor current. With

the current bands of Eqn. (2) and Eqn. (3), the global inductorrms current is:

IL,rms = iac

√1

3

(2 + 4

πγ + γ 2

). (15)

For γ = 0, the inductor rms current is IL,rms = iac

√23 , for

33% more conduction losses than in CCM (neglecting anyripple).

The unfolder operation ensures symmetrical operationin the high-frequency bridge-leg, allowing for a simple

determination of the switch global rms currents asIh,rms = Il,rms = 1√

2IL,rms.

B. SIMULATION VALIDATIONThe analytical expressions for the frequency fsw and the var-ious currents, including IL,rms, are compared to the resultsfrom GeckoCIRCUIT [18] numerical simulations in Fig. 2to validate the proposed equations. The simulations are carriedout with the specifications of Table 1 with Uac = 230Vrms,an assumed Coss,Q = 370 pF of each power transistor, and aconstant turn-off current of IL- = −4 A to ensure full ZVS (asanalyzed later, in Section V).

Firstly, the analytically calculated and simulated localswitching frequency fsw (Fig. 2(a.i)) and transistor localrms currents ih,rms and il,rms and inductor rms current iL,rms

(Fig. 2(b.i)) are compared over one mains cycle (Tac = 1/ fac)for an ac voltage of 230 Vrms and a maximal power of 2.2 kW.The agreement between the derived analytical expressions andthe numerical simulations is very good, with small deviationsthat are then further explored across the operating space.

In Fig. 2(a.ii), the analytically-calculated maximum switch-ing frequency across ac voltage (including the consideredapplication range from 120 Vrms to 230 Vrms) and outputpower is shown, varying between 100 kHz and 1100 kHz. Themaximum switching frequency occurs at no-load operation.This prediction is then compared to numerical simulationsin Fig. 2(a.iii). Because the calculation ignores the resonanttransition times, the calculated switching frequency is alwayshigher than the simulated switching frequency. Across theoperating space, though, the absolute error remains below 6%

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FIGURE 3. (a) Equivalent circuit of the high-frequency bridge-leg of Fig. 1(a) for the Tl turn-off switching transition, where the switch-node voltagechanges from the negative DC-link rail n to the positive DC-link rail p. The upper power transistor is only visualized schematically and the showndrain-source capacitance Cds considers the parasitic capacitances Cds,Tl, Coss,Th, and Cpar. The switched current Isw is taken as constant during the turn-offtransition. (b-d) Turn-off switching transitions at increasing current levels, from below Ik (b) to equal to Ik (c) to above Ik (d). At high currents above thekink current, Ikink, residual ZVS losses occur due to the significant overlap between the drain-source voltage (uds) and the channel current ich of Tl. Thetime behavior of the inner gate-source voltage (ugs,i) of Tl is based on a straight-line approximation.

for full-load operation and below 16% even at the worst-caseof zero-load operation.

Similarly, Fig. 2(b.ii) shows the calculated inductor rmscurrent over the operating area, with the minimum rms cur-rent (IL,rms,min = |IL-|/

√3 = 2.3 A) corresponding to no-load

operation, and Fig. 2(b.iii) shows the error between this cal-culation and the simulated current. Again, because the ana-lytical equations ignore the resonant transition times (whereinductor current increases), the analytical prediction is alwayssmaller than the current values obtained from simulation.However, since the resonant transitions are only a small frac-tion of the total period, the error at full load is smaller than1%. The error increases with lower power levels but neverexceeds 14%.

Overall, the proposed analytical expressions accurately de-scribe the key parameters and waveforms in TCM opera-tion, and we can confidently apply them to determine thetotal power semiconductor losses. First, though, the remainingswitching losses that occur during ZVS operation must bedetermined, and we combine the well-known soft-switching(or Coss) losses [17], [19]–[28] with turn-off losses to describethe total switching losses under ZVS, which we term “residualZVS losses.”

III. RESIDUAL ZVS LOSSESSoft-switching losses occur during the resonant charge-discharge process of the parasitic output capacitance in apower semiconductor, and are well-characterized in a breadth

of device types [19]–[28]. In SiC MOSFETs, in particular, re-cent literature has found that these soft-switching losses percycle are independent of duds/dt and are therefore constantwith switched current [17], [29]. In ZVS implementations,however - like the TCM topology here - the measured “switch-ing” losses are higher-than-expected and increase with cur-rent, necessitating the inclusion of an additional switchingloss mechanism beyond Coss losses. While comprehensiveanalytical models of switching behavior have been previouslygiven (for example, [30], [31]), we focus on a minimum-complexity equivalent circuit (and resulting equations) to as-certain the core driver of these residual ZVS losses.

Fig. 3(a) shows the equivalent circuit present during theturn-off transition of the low-side switch (Tl in Fig. 1(a)) andthe corresponding waveforms are shown in Fig. 3(b), assum-ing the inductor current is flowing during the whole switchingtransition in the indicated direction and that the dead-timeis large enough to guarantee zero-voltage turn-on of Th) forcomplete ZVS [5]. Cds represents the equivalent output capac-itance between D and S, including the drain-source capaci-tance of Tl, the output capacitance of Th (only indicated with afree-wheeling diode to which Isw commutates) and any addi-tional parasitic capacitances, i.e. Cds =Cds,Tl+Coss,Th + Cpar.While this turn-off transition is typically ignored when con-sidering the losses in unipolar power semiconductors, thereis an unmistakable remnant voltage-current overlap at en-hanced load current during this time in ZVS converters thatmay result in large and non-negligible losses [32], as shownin Fig. 3(d).

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A. TURN-OFF TRANSITION ANALYSISThis turn-off transition is now analyzed in detail to ascertainthe source, mechanisms, and dependencies of these residualZVS losses. During turn-off, the switched current Isw is takenas constant, and commutates from the channel (ich) to chargethe output capacitor (Cds with current iCds) and the Millercapacitor (Cgd with current iCgd). As the switched current Isw

increases, the switching voltage transition is expected to occurmore rapidly due to higher capacitor charging current, whichincreases the voltage slew of the transition duds/dt = Udc/tr.This indeed occurs – to a point.

As the switched current Isw increases, iCgd also increaseswith the current divider Cgd/(Cds + Cgd) between thegate-drain and equivalent drain-source capacitance. The gatecurrent is assumed to be determined by the gate drive circuitas ig = (ugs,i + |ug,n|)/Rg, with the inner gate-source voltageugs,i, the negative gate driver voltage magnitudeug,n = |ug,n| ≥ 0 V, and the total gate resistanceRg = Rg,int + Rg,ext. As long as the current through theMiller capacitance iCgd is smaller than the gate drive currentig, iCgd < ig, the gate-source capacitance is discharged andthe channel is closed before the drain-source voltage uds startsrising significantly, cf. Fig. 3(b). This case results in idealZVS with no turn-off losses beyond Coss and gating losses,and a voltage slew rate duds/dt that is proportional to Isw:

duds

dt= Isw

Cds + Cgd≈ Isw

Ceff, (16)

with Ceff = 2Coss,Q + Cpar.During this transition, the following order of operations

occurs, assuming that in the active region the relationshipbetween the gate-source voltage and the channel current islinear and defined by the transconductance g. Firstly, thegate-source capacitance is discharged to some level (with noeffect on the power circuit), and once the (inner) gate-sourcevoltage ugs,i reaches this level, ugs,i = uth + Isw · g, the chan-nel current starts decreasing, a decay that we assume to belinearly proportional to the difference of ugs,i and the thresholdvoltage uth (Fig. 3(b)). With the high-side diode still blocking,the switched current Isw that no longer flows through thechannel (ich) must flow through the capacitances Cds + Cgd,building up the drain-source voltage quadratically (for a lineardecrease in channel current). With a fast change in channelcurrent, the voltage-current overlap during this time periodcan be (and has been, in prior art) neglected. Once the channelcurrent has fully commutated to the output capacitcances, thegate-drain current is determined by the voltage slew and theMiller capacitance, and the gate-source capacitor continues todischarge. When iCgd < ig, the discharge of the gate-sourcecapacitance continues at a reduced slope, and once the voltagetransition has finished, the full gate current again dischargesthe gate-source capacitance and the slope increases until thetransition is completed.

As Isw is further increased, we first encounter the cornercase iCgd = ig with ugs,i = uth, (Fig. 3(c)), which we call the

“kink current” Ik:

Ik = (iCgd + iCds

)∣∣max = uth + ∣∣ug,n

∣∣Rg

(1 + Cds

Cgd

). (17)

In this case, the switched current Isw = Ik is again splitbetween Cds and Cgd, but the current through the Miller ca-pacitance from the voltage slew duds/dt equals the gate drivercurrent, i.e. iCgd = ig. Therefore, ugs,i remains at the thresholdvoltage uth and no charge is removed from the gate-sourcecapacitor (see Fig. 3(c)). As the gate-drain current is definedby the gate driver current, iCgd = ig ≈ (uth + |ug,n|)/Rg, theslew rate at the kink current is:

duds

dt

∣∣∣∣k

= Ik

Cds + Cgd≈ Ik

Ceff. (18)

If Isw is increased beyond the kink current Ik, the gate-source capacitance is discharged only to a voltage that remainsslightly higher than the threshold voltage uth (Fig. 3(d)), andthe channel remains turned on and conducts the switched cur-rent (to reiterate, taken as constant) that cannot flow throughthe combination of the gate-source and drain-source capaci-tances. This causes voltage-current overlap losses, which aredeemed “residual ZVS losses” here. With the gate-source volt-age above the threshold voltage, the continued channel currentslightly expedites the voltage transition, resulting in a voltageslew rate of:

duds

dt= 1

Ceff

{Isw if Isw < Ik

Ik + s · (Isw − Ik) if Isw ≥ Ik,(19)

with the slope s dependent on the MOSFET transconductance gas s = Ik

g(uth+|ug,n|) .As soon as the voltage transient is completed, the gate-

source voltage drops, the device turns off fully, the remainingchannel current commutates to the high-side device, and thetransition is completed.

B. EXPERIMENTAL VALIDATION OF TURN-OFFTRANSITION WAVEFORMSTo validate the proposed model and conceptual waveformsof Fig. 3, we measure the turn-off transition across draincurrents of a 650 V, 27 m� 4-pin SiC MOSFET from In-fineon IMZA65R027M1H operated with |ug,n| = 3 V andRg,ext = 24.3 � (a relatively large gate resistance is selectedfor better visualization) in a half-bridge setup. The waveformsof the drain-source voltage uds, the gate-source voltage ugs

(measured with the Tektronix IsoVu [33]), and the gate currentig (measured indirectly via the voltage drop of the externalgate resistor) are shown during the turn-off transition in Fig. 4and in Fig. 5. The saturation of the duds/dt is shown in Fig. 4,where the measured drain-source voltage during the turn-offtransition (solid lines) is compared to a linear-scaled versionof the 2.5 A transition (dashed lines, which correspond to anideal ZVS transition), an operating point well below the kinkcurrent of 6.4 A (calculated using the fitted model parametersof Table 2, as detailed below). The voltage slew rate clearly

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FIGURE 4. Drain-source voltage uds at turn-off for different load currents,measured for the IMZA65R027M1H operated with Rg,ext = 24.3 � and|ug,n| = 3 V (solid lines). For comparison, linearly-scaled waveforms of the2.5 A transition measurement are shown (dashed lines), which wouldcorrespond to ideal ZVS transitions without saturation effects. For currentsabove the kink current of 6.4 A, the voltage slew rate clearly saturates.

TABLE 2. Model Parameter of the IMZA65R027M1H

shows the expected saturation effect for currents above thekink current.

The internal threshold voltage uth, the quantity that deter-mines device behavior, can be translated into an externally-measurable quantity uth,ext by assuming a resistive voltagedivider in the gate path between the external Rg,ext and thedevice-internal gate resistance Rg,int, and is given as:

uth,ext = (uth + ∣∣ug,n

∣∣) Rg,ext

Rg,int + Rg,ext− ∣∣ug,n

∣∣ . (20)

For the given operating conditions, this results inuth,ext = 5.6 V, a threshold that is highlighted in Fig. 5and consistent with the level at which the behavior change ofthe MOSFET occurs. Even with the non-constant Miller regionof SiC MOSFETs [34], [35], the measurements align well withthe proposed waveforms of Fig. 3. Particularly, the increasedgate-source voltages and gate currents at higher switchedcurrents indicate the predicted presence of a channel currentduring the turn-off transition.

In examining the measurements of Fig. 4 and Fig. 5, wealso observe ringing in all measured waveforms of uds, ugs,and ig for switched currents above the kink current. This isattributed to the remnant channel current commutating to thehigh-side switch very quickly, exciting the parasitic powerloop inductance and causing the observed ringing. A smallfraction of this inductance is coupled with the gate-to-kelvin-source connection, and even this small ringing is seen in thegate-source voltage measurement of Fig. 5.

FIGURE 5. Measured drain-source voltage uds, gate-source voltage ugs,and gate current ig during turn-off of the IMZA65R027M1H operated withRg,ext = 24.3 � and |ug,n| = 3 V, across switched currents (also shown inFig. 4). Ik = 6.4 A for this operating condition. These waveforms and thehighlighted voltage level of uth,ext = 5.6 V, which corresponds to theconversion of the (internal) threshold voltage uth into an externallymeasurable quantity using Eqn. (20), match the theoretical waveforms andconsiderations of Fig. 3.

C. RESIDUAL ZVS LOSS MODELLINGBecause the total switched current is constant during the turn-off period, the current that cannot flow through Cgd (and Cds)must flow through the channel as

ich = Isw − Ik (21)

leading to an energy loss due to the voltage-current overlapfor currents Isw ≥ Ik. The total energy loss in the zero-voltage-switched power semiconductor, then, can be written as:

Esw(Isw) ={

E0 if Isw < Ik

E0 + k · (Isw − Ik) if Isw ≥ Ik,(22)

where E0 represents the constant Coss losses in SiCMOSFETs [17] plus the gating losses, and is therefore a current-independent, device-specific term. The factor k = 1

2U 2dc/

dudsdt

includes the voltage slope dudsdt , which, according to Eqn. (19),

is dependent on the switched current. Assuming s ≈ 0as an approximation, the voltage slope is constant,dudsdt = duds

dt |k = IkCeff

(for Isw ≥ Ik) and we can in-troduce a current-independent approximation of k,k = 1

2U 2dc/

dudsdt |k = 1

2U 2dcCeff/Ik.

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FIGURE 6. Measured duds/dt of the IMZA65R027M1H for a bridge-leg(Udc = 400 V) across switched currents Isw. Four external gate resistorsRg,ext = 0 � (dark blue), 3.3 � (blue), 5.1 � (light blue), 24.3 � (violet) andtwo gate driver voltages |ug,n| = 0 V (circles) and |ug,n| = 3 V (diamonds)are used to show the variation in Ik predicted by Eqn. (17). The results ofthe kink model (cf. Eqn. (17) and Eqn. (19)) are overlaid with indicatedkink currents to validate the proposed approach.

To fit and validate the model, further measurements areconducted on the previously-introduced half-bridge setup.Double-pulse experiments are conducted for three additionalgate resistors (Rg,ext = 0 �, 3.3 �, 5.1 �) and two turn-offvoltages (|ug,n| = 0 V, 3 V), with the results shown in Fig. 6.The duds/dt measurements are also shown for Rg,ext = 24.3 �

and |ug,n| = 3 V for completeness, as it verifies the kink cur-rent model even for large gate resistors. Voltage slew ratesduds/dt are evaluated between 10% and 90%.

Based only on the duds/dt measurements, the critical deviceparameters of Table 2 can be estimated – from which thekink current Ik and the coefficient k can be simply calcu-lated. The maximum voltage slew rate results in the Ceff ands parameters of Ceff = 646 pF (which corresponds to twicethe charge equivalent output capacitance between 40 V and360 V, i.e. 2 × 320 pF) and s is considered to be 0.2 forsmall gate resistors, i.e. for Rg,ext < 6 �. For larger resistancevalues (e.g. Rg,ext = 24.3 �), the value of s drops, for exampleto 0.1. The remaining parameters are derived based on es-timated kink currents and result in 1 + Cds

Cgd= 18, uth = 7 V

(which corresponds to the datasheet value of the extractedthreshold voltage from the typical transfer characteristic), andRg,int = 4 �, which is slightly larger than that specified in thedatasheet (Rg,int = 3 �).

The resulting kink currents for Rg,ext = 0 �, 3.3 �, 5.1 �,and 24.3 � according to the proposed model are, respectively,Ik = 29.3 A, 17.3 A, 14.0 A for |ug,n| = 0 V and Ik = 31.6 A,24.7 A, 20.0 A and 6.4 A for |ug,n| = 3 V, with the latter sethighlighted in Fig. 6. We note here that for the combination oflarge negative gate drive voltage magnitudes and small gateresistors, a gate drive current limit of approximately 1.7 Amust be included in the analysis due to the limited gate driverfall time (10 ns), which is similar to the corresponding voltagerise/fall time of the SiC MOSFET tR = 8 ns (at 50 Vns−1, cf.Fig. 6).

FIGURE 7. Measured soft-switching energy losses Esw of theIMZA65R027M1H for a full bridge-leg (Udc = 400 V) across switchedcurrents Isw, with adapted deadtimes to ensure complete soft-switchingtransitions. Three external gate resistors Rg,ext = 0 � (dark blue, i), 3.3 �

(blue, ii), 5.1 � (light blue, iii) are used to show the variation in Ikpredicted by Eqn. (17) considering |ug,n| = 1 V. The results of the proposedmodel (cf. Eqn. (17), Eqn. (19), and Eqn. (22)) are overlaid to validate theproposed approach.

Finally, the switching losses under ZVS are calorimetricallymeasured [36] and shown in Fig. 7. The negative gate drivervoltage magnitude is |ug,n| = 1 V during the measurements(due to a voltage drop within the gate driver circuitry thatoccurs when switching the devices between 500 kHz-1 MHz),which leads to E0 = 2.4 µJ.

The kink currents and resulting voltage slew rates (fors = 0.2) and the results of the residual ZVS loss model areshown overlaid in both Fig. 6 and Fig. 7, with the calculationsrelying on the fitted model parameters given in Table 2. Thelargest deviation between model and measurements appearsat the kink current. This occurs because the model does notinclude the non-linearity of Cdg, which is largest at uds = 0 V,and the voltage slew rate limitation occurs at lower currentsthan specified by the kink current.

Even with these approximations and simplifications – us-ing only voltage slope measurements, ignoring temperatureeffects, and neglecting the non-linearities of the respective ca-pacitances with voltage – the model and measurements agreeclosely, with the loss model predicting the current (Ik at whichthe losses start to increase beyond the constant Coss losses)for all three gate resistors. The maximum voltage slew rateand existence of an asymptote is also well-predicted by theproposed model, as shown in Fig. 6. The key results are givenin the top half of Table 3 for the measured device.

As an important aside, we note that this analysis clearlyindicates the need for high-performance gate drive solutionswith low gate resistances and large negative gate driver volt-age magnitudes, which push out the kink current. The onlydownside of an increased negative gate driver voltage is theincrease in gate drive losses, but a voltage increase from|ug,n| = 0 V to 3 V only increases the fixed gating energy lossfrom 1.13 µJ to 1.45 µJ per cycle. This energy loss increaseof 0.32 µJ is negligible compared to the constant part ofE0 = EG + 5%Eoss = 1.13 µJ + 1.11 µJ = 2.24 µJ (consider-ing a Coss-related energy loss of only 5% Eoss [17]). This

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FIGURE 8. (a) Comparison of the analytically calculated and simulated switching losses for Rg,ext = 3.3 �, modulation index M = 0.81 (Uac = 230 Vrms),and full load power (2.2 kW) over one mains cycle. (b) Switching loss across the operating area for Rg,ext = 3.3 � and (c) absolute error in switching lossbetween proposed analytical calculation and GeckoCIRCUIT simulation.

TABLE 3. Calculated and Fitted Switching Loss Coefficients for a 650 V SiCMOSFET (IMZA65R027M1H) Operated At Udc = 400 V and Under ZVS, Validfor Esw = a + bIsw + cI2

sw With Isw > 0 A for |ug,n| = 1 V

clearly motivates the selection of the highest-possible negativegate driver voltage magnitude, which is typically limited bythe maximum rating of the device.

Finally, while this derived model predicts the behavior ac-curately, the loss estimation is difficult to implement analyti-cally due to the discontinuity at Ik. The residual ZVS lossescan, instead, be approximated by a quadratic loss model [36]as (for Isw > 0 A):

Esw (Isw) = a + bIsw + cI2sw, (23)

where a, b, and c are switch-dependent switching loss coeffi-cients and Isw is the switched current. These fittings are over-laid on the measured losses in Fig. 7 with the coefficients ofTable 3. The coefficient a is selected to be equal to E0 (whichalso includes a fixed gating loss of 1.3 µJ per cycle). Unlikethe discontinuous loss model, these coefficients have no phys-ical meaning (e.g. b < 0) but still approximate the measuredlosses under ZVS accurately from 10 A to 50 A of switchedcurrent. In Appendix A, the switching characteristics of aSiC MOSFET from a different voltage class and manufacturer(1.2 kV, 16 m� 4-pin SiC MOSFET C3M0016120K from Wolf-speed) are measured, further validating the model’s predic-tions of voltage slew rate, kink current, and soft-switchinglosses.

We find, then, that the complete switching losses underZVS across current are predicted by the proposed model. Theresidual ZVS losses, further, can be accurately approximatedwith a continuous quadratic loss function, and we can use this

to analytically determine the total power semiconductor lossesin the TCM operated converter-of-interest.

IV. POWER SEMICONDUCTOR LOSSES IN TCMThe total power semiconductor losses in a TCM converter,then, comprise the conduction losses – based on the rms cur-rents derived in Section II – and the switching loss model ofthe previous section, where residual ZVS losses were deter-mined as a function of current. The local conduction lossesare:

ph,cond(t ) = Rdsi2h,rms(t ), (24)

pl,cond(t ) = Rdsi2l,rms(t ), (25)

which are mainly determined by the local rms currents ofEqn. (12) and Eqn. (13).

The local switching losses are the product of the switchingfrequency (determined in Eqn. (9) and validated in Fig. 2(a))and the energy loss, which is a function of the turn-off current:

ph,sw(t ) = fswEsw(i+(t )) (26)

pl,sw(t ) = fswEsw(i-(t )). (27)

Again, the analytical predictions are compared to the re-sults from GeckoCIRCUIT numerical simulations (with thequadratic fit loss model), this time for the switching losses.Fig. 8(a) shows the comparison of the local switching lossesover one mains cycle Tac = 1/ fac for an external gate resistorof Rg,ext = 3.3 �. Again, we find an accurate proposed modelof residual ZVS losses and, further, show the accuracy ofthe quadratic loss approximation. In Fig. 8(b), the switchinglosses are shown over the complete operating area of modula-tion index and load, and we highlight the current-dependencyof the switching losses (which would not be included in theCoss-loss-only model). Fig. 8(c) shows the relative error be-tween the calculated and predicted switching losses, wherewe find excellent matching that degrades somewhat at lightloads due to the error in switching frequency prediction (seeFig. 2(a.iii)).

With each loss component determined analytically in previ-ous sections of the paper, we can now find the total conductionand switching losses across the considered modulation range,

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FIGURE 9. Analytically-calculated (a) conduction Pcond, (b) switching Psw, and (c) total semiconductor losses Psemi = Pcond + Psw for the powersemiconductor bridge-leg under the specifications given in Table 1. Evaluated for (i) Rg,ext = 0 � and (ii) Rg,ext = 3.3 � to highlight the importance of theresidual ZVS losses in the bridge-leg performance of TCM converters.

load, and turn-off current for ZVS. The average conductionlosses are:

Pcond = Rdsi2ac

3

(2 + 4

πγ + γ 2

). (28)

The relative conduction losses with respect to the outputpower Po = MUdc iac/2, result in Pcond

Po= 2

3Rds

MUdc(2 + 4

πγ +

γ 2)iac and increase with the current level.The average switching losses of the bridge-leg are

Psw = 1Tac

∫ Tac0 ph,sw(t ) + pl,sw(t )dt leading to

Psw = MUdc

LiacEsw, (29)

with the average energy loss Esw as function of M, iac, and γ :

Esw =(

1 − 2M

π+ γ M

)a +

(2

π− M

2

)biac

+(

1 − 8M

3π+ γ 2 − γ 2 2M

π+ γ 3M

)ci2ac

+ 4γ

π

1 + γ M√γ 2 − 1

(a + γ 2ci2ac

)arctan

(1 − γ√γ 2 − 1

).

(30)

The relative switching losses are obtained byPswPo

= Esw(M,iac,γ )EL,pk

with EL,pk = Li2ac/2. Finally, the total

semiconductor losses are Psemi = Pcond + Psw.These analytical switching and conduction loss expres-

sions are evaluated across modulation index M and outputpower in Fig. 9 for a TCM converter of Table 1 using theIMZA65R027M1H SiC MOSFET with two different values ofexternal gate resistors, (i) 0 � and (ii) 3.3 �. Conductionlosses are shown in Fig. 9(a), which, as expected, do not

change between the gate resistance values. Switching losses(Fig. 9(b)) – even under ZVS, we must recall – signifi-cantly increase at the higher gate resistance, as Ik is loweredand the residual ZVS losses climb rapidly with current. TheRg,ext = 3.3 �, case, however, sees the maximum duds/dtreduced from 50 Vns−1 to 35 Vns−1, cf. Fig. 6, which maybe beneficial for EMI performance.

In the next section, the total loss predictions of Fig. 9(c) –and, therefore, the proposed model and analytical expressions– are validated in a hardware prototype.

V. EXPERIMENTAL VERIFICATIONThe constructed hardware prototype to validate the theoreticalresults is shown in Fig. 10, with the filter implemented exter-nally for flexibility. The 2.2 kW hardware prototype includesboth a high-frequency (IMZA65R027M1H SiC MOSFETs) andan unfolder bridge-leg (UF3SC065007K4S SiC MOSFETs),DC-link capacitors, and the required sensor suite for controland monitoring, including a zero-crossing detection (ZCD)circuit [1] that obviates the need for a high-bandwidth currentsensor.

The gate loop inductance is minimized through optimalplacement and routing to support operation with a 0 � ex-ternal gate resistor. A high-performance gate driver, TI’sUCC27531, ensures the lowest possible residual ZVS lossesthrough high-current-sink capabilities of up to 5 A and fastrise/fall times in the range of 10 ns, and we operate the gatedrive at the maximum recommended positive gate voltage(+18 V) to minimize on-resistance and close to the absolutemaximum of the negative gate voltage (−2 V), although dur-ing operation the negative drive voltage is measured at −1 Vand this value is used for the following loss predictions.

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FIGURE 10. 2.2 kW hardware demonstrator (referenced to Fig. 1(a)), tovalidate the proposed analytical model of bridge-leg losses, switchingfrequency, and rms currents in a TCM converter. The hardwaredemonstrator includes both a high-frequency (realized withIMZA65R027M1H SiC MOSFETs) and an unfolder bridge-leg that can berealized with e.g., UF3SC065007K4S SiC MOSFETs. A zero-crossing detection(ZCD) circuit and the ZYNQ System-on-Chip are used for sensing and toensure the inductor current is controlled to the calculated limits. The filteris implemented externally for extensibility and reconfiguration in testing.

With a charge-equivalent output capacitance ofCoss,Q,Th = Coss,Q,Tl = 370 pF at Uds = 400 V for theIMZA65R027M1H SiC MOSFETs, the worst-case turn-offcurrent requirements are 2.6 A at 230 Vrms for rectifieroperation (given by Eqn. (6)) and 3.2 A at zero outputvoltage for inverter operation (given by Eqn. (7)). The ZCD,further, requires a small opposite-direction current for correctoperation, resulting in 3.96 A minimum current when the140 ns circuit delay (including the 20 ns switch turn-on time)is considered. To achieve ZVS under all conditions and ensurecorrect operation of the ZCD circuit, then, a turn-off currentof |IL-| = 4 A is selected.

Because it is only switched twice per line cycle, the un-folder bridge-leg only incurs conduction losses, and the lowestRds devices with a sufficient voltage rating can be selected,i.e., the UF3SC065007K4S SiC cascode MOSFET from UnitedSiC (11.7 m� at 125 °C). At the worst-case operating point(full power at 120 Vrms), the inductor rms current is 23 A andthe unfolder bridge-leg losses are 6.2 W.

Fig. 11 shows the measured oscilloscope waveforms of thehardware prototype of phase voltage (uac), phase current (iac),and inductor current (iL). For all measured waveforms, an11.5 µH air-core inductor is used for the filter inductor, witha 3 µF filter capacitor used for the 230 Vrms measurement(Fig. 11(a)) and an 11 µF filter capacitor used for the 120 Vrms

one (Fig. 11(b)). These waveforms confirm correct operationof the hardware prototype under TCM modulation and wemove to validate the proposed loss models.

Semiconductor bridge-leg losses are calculated and mea-sured for 230 Vrms and 120 Vrms with 0 � and 3.3 � ex-ternal gate resistors. The dead time is adjusted to minimizethe diode conduction time. As Fig. 12 shows, the proposedfully-analytical model accurately predicts the measured semi-conductor losses for the TCM hardware prototype. For all

FIGURE 11. Measured oscilloscope waveforms in the hardwaredemonstrator of Fig. 10 of phase voltage (uac), phase current (iac), andinductor current (iL) for (a) 230 Vrms at full load, and (b) 120 Vrms at fullload. The filter inductor is 11.5 μH, the turn-off current is |IL-| = 4 A, andthe external gate resistance is Rg,ext = 0 �. The voltage scale is 100 V/div,the current scale is 20 A/div, and the time scale is 4 ms/div.

operating conditions, bridge-leg losses are predicted within1 W at full load and within 0.9 W at 40% load. The max-imum prediction error never exceeds 14% and is below 3%for most of the operating space. The worst-case partial loadprediction error occurs at 40% load and Rg,ext = 0 �, withan 0.88 W underestimation (13.6%) for the 120 Vrms con-dition. At full load, the worst-case prediction error occurswith Rg,ext = 3.3 � and 230 Vrms, with an underestimation of0.99 W (11.9%). These small differences are attributed to theresonant transition times, which are neglected in the analyticalmodel, and the remaining diode conduction losses.

Further, the E0 losses (Coss-related losses plus gating losses)are indicated in Fig. 12 to separate the contributions of theselosses, which are constant with current, from the residual ZVSlosses identified in this paper. At light load, the E0 losses com-prise nearly all of the semiconductor losses, while towardsthe nominal load – the operating point that typically drivesthe design of the cooling system – the residual ZVS lossesmust be considered for an accurate loss estimation. Moretangibly, with Rg,ext = 0 � and 230 Vrms, E0 losses are 98.9%of switching losses at no load but only 48.7% at full load.Similarly, at Rg,ext = 3.3 � and 120 Vrms, E0 losses are 94.5%of switching losses at no load but only 9.3% at full load. Thehardware prototype achieves a peak semiconductor efficiencyof 99.6% at 230 Vrms at full load and 99.3% at 120 Vrms at40% load. At low power levels, we see that the semiconductor

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FIGURE 12. Calculated and measured semiconductor bridge-leg losses in the hardware prototype of Fig. 10 operating in TCM for (a.i) 230 Vrms andRg,ext = 0 �, (a.ii) 230 Vrms and Rg,ext = 3.3 �, (b.i) 120 Vrms and Rg,ext = 0 �, and (b.ii) 120 Vrms and Rg,ext = 3.3 �. The total calculated losses Psemi arebroken out into conduction losses Pcond and switching losses Psw – with the E0 losses, which comprise the majority of semiconductor losses at light load,indicated – and the measured semiconductor losses are shown as circles. The maximum error between predicted and measured losses is 1.0 W over thefull load range.

losses rise due to the higher switching frequency, an increasethat could be mitigated by increasing |IL-| (which would in-crease conduction losses but lower total losses).

The hardware prototype demonstrates the exceptional effi-ciencies achievable in AC-DC converters operating with TCMmodulation, but, more importantly, proves the validity and ef-ficacy of the proposed model to accurately predict bridge-leglosses with a fully-analytical solution.

VI. CONCLUSIONTriangular-current-mode (TCM) operation of AC-DC con-verters eliminates hard-switching losses with a rms current in-crease of only ≈ 15% (≈ 30% increase of conduction losses)over continuous current mode (CCM) modulation, unlockingpower-dense and highly-efficient inversion and rectificationfor this key power processing block. With switched currentand switching frequency variation across the mains cycle,however, an analytical description of the bridge-leg losses haseluded the field.

Literature has diverged on the current-dependence of soft-switching losses in SiC MOSFETs (compare [17] to [19]and [23]). With the introduction here of the residual losses thatoccur even under zero-voltage-switching above a thresholdcurrent (the “kink current”), this work unifies the field, findingconstant Coss-only losses at low switched currents and current-dependent soft-switching losses above the kink current. Itis interesting to note that recent work on GaN HEMTs hasfound a similar switching loss dependence – again under ZVSconditions on the negative gate-driver voltage in a differentclass of power devices [37].

In the end, the simple and accurate analytical descrip-tions of switching frequency, rms currents, and semiconductorlosses under TCM operation open the opportunity for opti-mized converters without time-consuming numerical simula-tions, a powerful and extensive tool for the next generation ofAC-DC power conversion.

ACKNOWLEDGMENTThe authors would like to thank N. Kleynhans for carryingout the experimental duds/dt analyses and switching loss mea-surements in great detail.

APPENDIX ASWITCHING LOSS MEASUREMENTS ON A 1.2 kV, 16 m�

4-PIN SIC MOSFETTo verify the model across different blocking voltage classesof SiC MOSFETs, we also measure the switching losses on the1.2 kV, 16 m� 4-pin SiC MOSFET C3M0016120K from Wolf-speed. An identical procedure to that outlined in Section III isrepeated, with duds/dt measurements using the double-pulsetest for two external gate resistors (here, (Rg,ext = 0 � andRg,ext = 5.1 �) and two turn-off voltages (here, |ug,n| = 0 Vand |ug,n| = 5 V). The results are shown in Fig. 13 and Fig. 14.

We use only the duds/dt measurements of Fig. 13 to fit themodel parameters, which are reported in Table 4. The param-eters Ceff and s result directly in Ceff = 666 pF (which corre-sponds to twice the charge equivalent output capacitance be-tween 80 V and 720 V, or 2 × 313 pF), with s taken as s = 0.2for simplicity. The remaining parameters are derived basedon the estimated kink currents, resulting in 1 + Cds

Cgd= 19.5,

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FIGURE 13. Measured duds/dt of the C3M0016120K for a bridge-leg(Udc = 800 V) across switched currents Isw. Two external gate resistorsRg,ext = 0 � (dark blue), 5.1 � (light blue) and two gate driver voltagemagnitudes ug,n = 0 V (circles) and |ug,n| = 5 V (diamonds) are used toshow the variation in Ik predicted by Eqn. (17). The results of the model(cf. Eqn. (17), Eqn. (19)), are overlaid to validate the proposed approach.

FIGURE 14. Measured soft-switching energy losses Esw of theC3M0016120K for a full bridge-leg (Udc = 800 V) across switched currentsIsw, with adapted deadtimes to ensure complete soft-switching transitions.Two external gate resistors Rg,ext = 0 � (dark blue, i), 5.1 � (light blue, ii)are used to show the variation in Ik predicted by Eqn. (17) considering themeasured |ug,n| = 4 V. The results of the model (cf. Eqn. (17), Eqn. (19), andEqn. (22)), are overlaid to validate the proposed approach.

TABLE 4. Model Parameter of the C3M0016120K

uth = 7 V (which corresponds to the datasheet value of the ex-tracted threshold voltage of 6.5 V for the given typical transfercharacteristic), and Rg,int = 7 �, which is larger than speci-fied in the datasheet (2.6 �). The resulting kink currents areIk = 19.3 A (Rg,ext = 0 �) and 11.5 A (Rg,ext = 5.1 �)for ug,n = 0 V and 33.4 A (Rg,ext = 0 �) and 19.3 A(Rg,ext = 5.1 �) for ug,n = 5 V, as shown in Fig. 13.

Switching losses are again measured calorimetrically [36]with the two external gate resistors. During the experi-ments, the negative gate driver voltage magnitude was mea-sured at |ug,n| = 4 V (due to a voltage drop within the gatedrive, which also occurs during in-situ operation), leading to

TABLE 5. Calculated and Fitted Switching Loss Coefficients for a 1.2 kV SiCMOSFET (C3M0016120K) Operated At Udc = 800 V and Under ZVS, Valid forEsw = a + bIsw + cI2

sw With Isw > 0 A

E0 = 10.5 µJ with gating losses included. The measuredswitching losses under ZVS are shown in Fig. 14, and thekey results are given in Table 5. Again, the proposed modelaccurately predicts the maximum voltage slew rate, the exis-tence of an asymptote, the current at which switching lossesincrease rapidly above E0, and, in the end, the switching lossesfor the 1.2 kV SiC MOSFET.

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MICHAEL HAIDER (Graduate Student Member,IEEE) received the M.Sc. degree in electrical engi-neering from the Swiss Federal Institute of Tech-nology, ETH Zurich, Zurich, Switzerland, in 2017.He is currently working toward the Ph.D. degreewith Power Electronic Systems Laboratory, ETH,focusing on single-to-three phase converter sys-tems, power pulsation buffer concepts, and electri-cal machines. His research interests include widebandgap semiconductor device application andtheir integration into drive systems.

JON AZURZA ANDERSON (Graduate StudentMember, IEEE) received the B.Sc. degree in indus-trial technology engineering from the TECNUNSchool of Engineering, University of Navarra,Pamplona, Spain, in 2014 and the M.Sc. degree(with distinction) in electrical engineering andthe Ph.D degree in power electronics from ETHZurich, Zurich, Switzerland, in 2016 and 2020,respectively. In 2013 and 2014, he was with Fraun-hofer IIS, Nuremberg, Germany, developing soft-ware in the RFID and Radio Systems Group. Since

November 2016, he has been with Power Electronics Systems Laboratory,ETH Zurich, as a Scientific Assistant, focusing on ultra-high efficiency three-phase multilevel PWM converters.

NEHA NAIN (Student Member, IEEE) receivedthe B.E. degree in electrical and electronics en-gineering from the P.E.S Institute of Technology,Bangalore, India, in 2015 and the M.Sc. degree inelectrical engineering and information technologyfrom the Swiss Federal Institute of Technology,ETH Zurich, Zurich, Switzerland, in 2020. FromJuly 2015 to August 2018, she was with TexasInstruments as a Systems Engineer. In November2020, she joined the Power Electronic SystemsLaboratory, ETH Zurich, as a Ph.D. Student, fo-

cusing on compact, high-efficiency dc–ac and ac–ac power converters basedon wide band-gap power semiconductors.

GRAYSON ZULAUF (Student Member, IEEE) re-ceived the B.A. degree in engineering sciences in2012 and the B.E. degree in electrical engineeringwith highest honors from the Thayer School of En-gineering, Dartmouth College, Hanover, NH, USA,in 2013, the M.S. degree in electrical engineeringfrom Stanford University, Stanford, CA, USA, in2018, and the Ph.D. degree in electrical engineer-ing from Stanford University, Stanford, CA, USA,in 2020. From 2013 to 2016, he was an Electri-cal Engineer and the Product Manager with Motiv

Power Systems. In 2019, he was an Academic Guest with Power ElectronicsSystems Laboratory, ETH Zurich, as a ThinkSwiss Research Fellow. He iscurrently an Activate or Cyclotron Road Fellow with Berkeley National Lab.

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HAIDER ET AL.: ANALYTICAL CALCULATION OF THE RESIDUAL ZVS LOSSES OF TCM-OPERATED SINGLE-PHASE PFC RECTIFIERS

JOHANN W. KOLAR (Fellow, IEEE) received theM.Sc. degree in industrial electronics and controlengineering and the Ph.D. degree in electrical engi-neering (summa cum laude/promotio sub auspiciispraesidentis rei publicae) from the Vienna Univer-sity of Technology, Vienna, Austria, in 1997 and1999, respectively. Since 1984, he has been an in-dependent Researcher and International Consultantin close collaboration with the Vienna Universityof Technology, in the fields of power electronics,industrial electronics, and high-performance drive

systems. He is currently a Full Professor and the Head with the PowerElectronic Systems Laboratory, Swiss Federal Institute of Technology, ETHZurich, Zurich, Switzerland. He has proposed numerous novel PWM con-verter topologies, modulation and control concepts, and multiobjective powerelectronics design procedures, and has supervised more than 75 Ph.D. stu-dents. He has authored or coauthored more than 900 scientific papers ininternational journals and conference proceedings, four book chapters, andhas filed more than 190 patents. His current research interests include ultra-compact and ultra-efficient SiC and GaN converter systems, ANN-basedpower electronics components and systems design, solid-state transformers,power supplies on chip, ultra-high speed and ultra-light weight drives, bear-ingless motors, and energy harvesting. He has presented more than 30 edu-cational seminars at leading international conferences, and he was the IEEEPELS Distinguished Lecturer from 2012 to 2016.He was the recipient of 36IEEE Transactions and Conference Prize Paper Awards, the 2014 IEEE PowerElectronics Society R. David Middlebrook Achievement Award, the 2016IEEE William E. Newell Power Electronics Award, the 2016 IEEE PEMCCouncil Award, and two ETH Zurich Golden Owl Awards for excellencein teaching. He has initiated and/or is the Founder of four ETH Spin-offcompanies.

DEHONG XU (Fellow, IEEE) was born in Chinain 1961. He received the B.S., M.S., and Ph.D.degrees from the Department of Electrical Engi-neering, Zhejiang University, Hangzhou, China, in1983, 1986, and 1989, respectively. Since 1996,he has been with the College of Electrical Engi-neering, Zhejiang University, Hangzhou, China, asa Full Professor. From June 1995 to May 1996,he was a Visiting Scholar with the University ofTokyo, Tokyo, Japan. From June to December2000, he was a Visiting Professor with the CPES,

Virginia Tech, Blacksburg, VA, USA. From February to April 2006, he was aVisiting Professor with ETH, Zurich, Zurich, Switzerland. He has authored orcoauthored six books and more than 200 IEEE journal or conference papers.He owns more than 30 Chinese patents and three U.S. patents. His currentresearch interests include power electronics topology and control, powerconversion for energy saving, and renewable energy. He was the recipientof four IEEE journal or conference paper awards and the IEEE PELS R.D. Middlebrook Achievement Award in 2016. Since 2013, he has been thePresident of the China Power Supply Society. From 2017 to 2019, he wasan At-Large Adcom Member of the IEEE Power Electronics Society. He isan Associate Editor for the IEEE TRANSACTIONS ON POWER ELECTRONICS.From 2015 to 2018, he was the IEEE PELS Distinguish Lecturer.

GERALD DEBOY (Senior Member, IEEE) re-ceived the M.Sc. and Ph.D. degrees in physicsfrom the Technical University Munich, Munich,Germany, in 1991 and 1996, respectively. In 1994,he joined Infineon Technologies AG, Neubiberg,Germany, and is currently heading a group lookinginto opportunities and requirements for emergingapplications. He has authored and coauthored morethan 70 papers in national and international jour-nals, including contributions to three student textbooks. He holds more than 60 granted international

patents and has more applications pending.

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