Novel soft-commutation DC DC power converter with high-frequency transformer secondary side phase-sh
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Novelsoft-commutationDC–DCpowerconverterwithhigh-frequencytransformersecondarysidephase-shiftedPWMactiverectifier
S.Moisseev,K.Soshin,S.Sato,L.GamageandM.NakaokaAbstract:Thispaperpresentsanovelcircuittopologyofthevoltagesourcetypezerovoltagesoft-switching(ZVS)fullbridgeDC–DCpowerconverterwithanisolatedhigh-frequencytransformer,whichincorporateszero-currentsoft-switching(ZCS)phase-shifted(PS)–PWMactivepowerswitchesinserieswithdiodesoftwobridgearmsofafull-bridgerectifieronthehigh-frequencytransformersecondaryside.Thishigh-frequencylinkedDC–DCpowerconvertercanachieveZVSfornoncontrolledactivepowerswitchesontheprimarysideofthetransformerandZCSforPS–PWMactiveswitchesonthesecondarysideofthetransformerunderwideloadvariationsaswellasawidePS–PWMregulationrange.TheswitchingpowerlossesandconductionpowerlossesoftheactivedevicesoftheproposedDC–DCconvertercanbeconsiderablyreduced.TheproposedDC–DCconverterblockscirculatingcurrentflowingthroughthesemiconductorswitchingdevicesonthetransformerprimarysideascomparedtothelosslesssnubbingcapacitorandtransformerleakageandmagnetisinginductor-assistedsoft-switchingfull-bridgeDC–DCconverterwithZVSPS–PWMschemeonthetransformerprimaryside.Thesteady-stateoperatingprinciplesoftheproposedDC–DCconverterareevaluatedanddiscussed,basedonthesimulationandexperimentalresultsobtainedfroma2kW–40kHzbreadboardset-upusingIGBTs.
ListofsymbolsEDCsupplyvoltageQ1–Q4(S1/D1-S4/D4)mainactivepowerswitchingblocksinthetransformerpri-marysideC1–C4losslesssnubbingcapacitorsinparallelwitheachmainpowerswitchQ5,Q6twoactivepowersemiconductorswitchesinserieswithtwodiodesincludingfullbridgerectifierL0–C0chokeinputtypeDCsmoothingfilterLl–Lmleakageinductanceandmagne-tizinginductanceofthehighfrequencytransformerTD5–D8rectifierdiodesnturnsratioofthehigh-frequencytransformerRloadresistancespecifiedbytheappliedelectronicequipmenti2high-frequencytransformersec-ondarysidecurrenttjphase-shiftedintervaltimejphase-shiftedangletd1deadtimeformainswitchesineachbridgelegi1high-frequencytransformerpri-
mary-sidecurrentfinverteroperatingfrequencyv0*(v0*¼vo/vo_max)normalisedoutputaverageDC
voltageIo*(Io*¼Io/Io_max)normalisedoutputaverageDC
current
1IntroductionToimprovepowerconversionefficiency,powerdensity,andtoreduceelectromagneticradiativeandconductivenoises,voltageandcurrentpeakstressescausedbyhighdi/dtanddv/dtdynamicstressesfromthehighfrequencyoperationofthepowersemiconductorswitchingdevices,avarietyofsoft-switchingpulsemodulationDC–DCpowerconvertercircuittopologieshavebeendevelopedfortelecommunication,automotiveandnewenergydistributedpowersystems[1–4].Thepreviouslyproposededge-resonantZVSPS–PWMDC–DCpowerconvertersusingMOS-gatepowersemiconductordevices(powerMOS-FETs,theIGBTsandIEGTs)havesomeadvantage:(i)constantswitchingfrequencyPWMcontrolscheme,(ii)loweredswitchinglossesofpowersemiconductordevices,(iii)reducedEMI/RFInoises,(iv)quicktransientoutputperformances,(v)smallleakcurrentduetoareduceddv/dtcapability.However,mostofthepreviouslydevelopedhigh-frequencytransformerlinkedZVSPS–PWMDC–DCconvertershavesomedrawbacks:(i)load-dependentsoft-switchingoperation,(ii)relativelynarrowZVSPS–PWMvoltageregulationrange,(iii)insufficientpowerconversion
TheauthorsarewiththeDivisionofElectricalandElectronicSystems
Engineering,TheGraduateSchoolofScienceandEngineering,YamaguchiUniversity,Yamaguchi,Japan
rIEE,2004IEEProceedingsonlineno.20040231doi:10.1049/ip-epa:20040231Paperfirstreceived2ndJuly2003andinrevisedform14thJanuary2004.Originallypublishedonline:4thMarch2004
260IEEProc.-Electr.PowerAppl.,Vol.151,No.3,May2004
Authorized licensed use limited to: TIANJIN UNIVERSITY. Downloaded on November 13, 2009 at 23:01 from IEEE Xplore. Restrictions apply. efficiencyunderalightloadconditionbecauseofhighswitchingpowerlosses.Inreality,highdv/dtofthehard-switchingPWMoperationcausestheincreaseofhighfrequencyleakcurrenttowardstheearthlineandahighvoltagesurgeduetohighdi/dtcauseselectricalinsulationbreakdownofthetransformerandfilterinductorandreducestheactualreliabilityofthesystem.Therefore,ahard-switchingPWMoperationhastobepracticallyavoidedevenunderlowDCoutputpowerspecificationsforflexibleDC–DCpowerandenergyapplications.Toovercomethesesignificantpracticalproblemsfortheconventionalfull-bridgeZVSPS–PWMDC–DCconverter,theconceptiallynewsaturablereactor-assistedfull-bridgeZVSPS–PWMDC–DCconverteranditsextendedDC–DCconverterfamilytopologieshavebeendevelopedanddiscussedbytheauthors[5–7].Stableandefficientsoft-switchingPS–PWMtransitionofthetransformerprimarysideswitchescouldbesufficientlyachievedwiththeaidofauxiliarysaturablereactorsthatactasmagneticactiveswitches.Toimprovethesaturablereactor-switchassistedsoftswitchingPS–PWMDC–DCconverter,anovelprototypeofafull-bridgesoft-switchingDC–DCpowerconverterwiththetransformer-secondarysidesynchronousPS–PWMactivepowerswitchesinserieswithdioderectifiersisproposedforthefirsttimeinthispaper.IntheproposedsoftswitchingDC–DCconverter,thetransformersecond-arysiderectifierincludestwoactivesemiconductorswitchesindiodefull-bridgerectifierarmsinsteadofthesaturablereactormagneticswitchesmentionedabove.Theoperationprincipleoftheproposedsoft-switchingDC–DCconverterisillustrated,togetherwithexplanationofitsuniquefeatures.Thesteady-stateoperatingperformancesunderwidesoftcommutationconditionsfromnoloadtofullloadaswellasvoltagepowerregulationcharacteristicsundertheopenloopcontrolschemeaswellascircuitdesignconsiderationsareillustratedanddiscussedonthebasisofthesimulationanalysisandexperimentalresultsobtainedfrom2kW40kHzbreadboardset-upusingIGBTpowermodules.