This work proposes a methodology for designing power electronic converters called “Automatic Design for Manufacturing” (ADFM). This methodology proposes creating Power Converter Arrays (PCAs) using standardized converter cells. The approach is greatly inspired by the microelectronics integrated circuit design flow, power electronics building blocks, and multicell converters. To achieve the desired voltage/current specifications, the PCA conversion stage is made from the assembly of several Conversion-Standard Cells (CSCs) in series and/or parallel. The ADFM uses data-based models to simulate the behavior of a PCA with very little computational effort. These models require a special characterization approach to maximize the amount of knowledge while minimizing the amount of data. This approach consists of establishing an experiment plan to select the relevant measurements that contain the most information about the PCA technology, building an experimental setup that is capable of acquiring data automatically and using statistical learning to train models that can yield precise predictions. This work performed over 210 h of tests in nine different PCAs in order to gather data to the statistical models. The models predict the efficiency and converter temperature of several PCAs, and the accuracy is compared with real measurements. Finally, the models are employed to compare the performance of PCAs in a specific battery charging application.

This paper introduces the implementation of a DC–AC step up isolated converter from associations of bidirectional Conversion Standard Cells (CSCs). The designed multi-cell converter is an array of standardized converter cells. It is described and then compared to a reference converter with respect to differential mode conducted electro-magnetic interference (EMI). The paper outlines the motivation for developing a generic multi-cell approach before underlining the benefits from the point of view of conducted EMI when implementing power converter arrays (PCAs). In particular, it is shown that in PCAs, the differential mode (DM) EMI filter can advantageously utilize distributed CSCs, making it possible to use very low value AC inductors to filter the AC current ripple. Experimental results are provided to validate the analysis carried out in the paper.

The paper deals with arrays of numerous power conversion cells, associated in series and/or in parallel to build larger step up or step down direct current (DC)/DC isolated converters. The work focuses on the impact of the spread and distribution of the conversion cell characteristics on the characteristics and performance of the power converter array (PCA). Based on a characterization protocol, about 130 conversion standard cells (CSC) are characterized and classified from a statistical point of view. Three families are defined and representatives are chosen and implemented in various configurations, in open and closed loop control, to analyze the impact of their spread characteristic over the global converter, the PCA. The paper is based on an extended practical set up and protocols, all described in details. Guidelines on CSCs implementation with respect to their dispersion are provided at the end on the paper.

Réseaux de convertisseurs - Méthodes et outils pour la conception automatique de convertisseurs: Ce travail présente une méthode de conception et de fabrication automatique de convertisseurs de puissance appelée « Automatic Design for manufacturing » (ADFM). La méthode consiste en concevoir des « Power Converter Arrays » (PCA) via l’assemblage de cellules standards. La technique est inspirée de l’industrie de la microélectronique, des PEBB (Power Electronic Building Blocks) et des convertisseurs multicellulaires. La partie de puissance d’un PCA est formé par plusieurs Cellules Standards de Conversion (CSC) connectées en série ou/et en parallèle en entrée comme en sortie.Afin de prédire le comportement de tous les assemblages possibles de CSC, cette démarche s’appuie sur des modèles statistiques eux-mêmes déterminés par des caractérisations électrothermiques de convertisseurs tests. Cette thèse va établir les bases de cette modélisation en trois étapes : la définition d’un plan d’expérience ; la construction d’un banc d’essais pour réaliser des mesures automatiques, et finalement, l’étude des modèles statistiques permettant de réaliser prédictions précises.9 convertisseurs ont ainsi été réalisés et caractérisés, totalisant plus de 210 heures de tests afin de réaliser toutes les étapes allant de la caractérisation aux prédictions de l’efficacité et de la température d’un convertisseur. Finalement, afin de valider cette nouvelle méthode, deux cas pratiques ont été traités. Le premier vise à comparer les résultats estimés avec ceux réellement atteints par un PCA, le second s’attache à montrer les perspectives d’une telle approche en comparant les performances estimées de plusieurs PCAs pour un profil de mission donné.