The essence of the little box challenge-part A: Key design challenges & solutions

Abstract

In order to expedite the development of power electronic systems towards higher power density and efficiency at a lower cost of implementation, Google and IEEE initiated the Google Little Box Challenge (GLBC) aiming for the worldwide smallest 2 kVA / 450 V DC / 230 V AC single-phase PV inverter with η > 95 % CEC weighted efficiency and an air-cooled case temperature of less than 60 °C by using latest power semiconductor technology and innovative topological concepts. This paper, i.e., Part A of a discussion of The Essence of the Little Box Challenge, documents all important R&D activities and engineering considerations of the authors endeavor to implement the world's most compact inverter; Part B is intended to convey the main findings and lessons learned from the participation in the GLBC. First, the key technical challenges of the GLBC are discussed and the technologies and concepts selected by the authors among different options are described in detail. Relevant design considerations, such as constant frequency pulse width modulation (PWM) or triangular current mode (TCM) operation of the bridge-legs, selection of power semiconductor technology, interleaving of bridge-legs, sizing of the power buffer capacitor, limitation of ground/leakage currents, etc., to achieve an ultra-compact implementation are discussed. Based on this overview, two promising inverter concepts to tackle the GLBC, (i) an H-bridge based inverter with DC-link referenced output filter and (ii) a DC/|AC| buck-stage with series-connected low-frequency (LF) |AC|/AC unfolder inverter, are then analyzed in detail. Based on the results of a multi-objective ηρ-Pareto optimization, a comparative evaluation of the performance in terms of efficiency (η) and power density (ρ) of the two considered inverter concepts is provided. It is shown that with the DC/|AC| buck-stage and |AC|/AC H-bridge unfolder inverter operated with 140 kHz PWM a power density of 14.7 kW/dm3 (240 W/in3) with a maximum efficiency of 98.1% at 2 kW output power can be achieved. These claims are then verified in Part B by means of experimental results obtained from prototype realizations and compared to the achievements of other GLBC finalists. The conclusions are of general importance and are providing key guidelines for the future development of ultra-compact power electronic converters.