A High-Power Density DC Converter for Medium-Voltage DC Distribution Networks

A DC converter is the core equipment of voltage conversion and power distribution in a DC distribution network. Its operating characteristics have a profound impact on the flexible regulation of distributed resources in an active distribution network. It is challenging for the existing single-stage conversion topology to meet the requirements of distributed renewable energy connected to a multi-voltage level, medium-voltage grid. It is necessary to study the multistage transform power unit topology further, which can satisfy high reliability, high efficiency, and wide input range. This paper proposes a high-power density DC converter for medium-voltage DC networks with wide voltage levels. It adopts Buck-LLC integrated modular composition. The input ends of the high isolation resonant power unit are connected in series to provide high voltage endurance, and the output ends are connected in parallel to meet the high-power demand and achieve high-power transmission efficiency. The proposed series dual Buck-LLC resonant power unit topology can adjust the duty cycle of series dual buck circuits to meet the needs of different levels of medium-voltage DC power grids. The soft switching problem within the wide input range of all switching tubes is solved by introducing auxiliary inductors, thereby improving energy transmission efficiency. The auxiliary circuit and control parameters are optimized based on the research of each switching tube’s soft switching boundary conditions. Finally, an experimental prototype of a 6.25~7 kW power unit is designed and developed to prove the proposed topology’s feasibility and effectiveness. Great breakthroughs have been made both in theoretical research and engineering prototype development.