Synchronous Rectified Soft-Switched Phase-Shift Full-Bridge Converter with Primary Energy Storage Inductor

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1 Synchrnu ecified Sf-Swiched Phae-Shif Full-Bridge Cnverer wih Primary Energy Srage Inducr Chen Zha, Xinke Wu, Wei Ya, Zhaming Qian (IEEE Senir Member Zhejiang Univeriy Ineril Crprain Jin Labrary Cllege f Elecrical Engineering, Zhejiang Univeriy Zheda ad 38#, Hangzhu China chanezha@zju.edu.cn Abrac-Thi paper preen a ynchrnu recified Sf-wiched Phae-Shif (PS Full-bridge (FB cnverer wih primary-ide energy rage inducr, which can be uilized in lw upu vlage and high upu curren applicain. Thi cnverer can be peraed in CCM, BCM and CM repecively baed n differen deign. Hwever, pimum deign cniderain indicae ha he BCM and CM perain mde are much mre uiable fr hi cnverer. Primary-ide energy rage inducr can help leading leg wiche achieve cndiin eaily. CM and BCM perain mde can make primary-ide lagging leg wiche and ecndary-ide ynchrnu recifier (S achieve ZCS cndiin. Slw di/d f riangular curren a ecndary-ide al lead lile revere recvery l f S bdy dide. The vlage re acr S can be clamped by upu vlage and he lw break-dwn vlage S are uilized reduce cnducin l. Finally, a high efficiency 300Wa 100 khz prype i buil up verify he hereical analyi and deign. I. INTUCTIN Full-bridge (FB c-c cnverer ha been inveigaed fr decade year. Cnveninal Phae-Shif (PS FB c-c cnverer ha everal apparen drawback uch a narrw range, eriu duy cycle l, large vlage pike acr he recifier, large circulaing l a primary-ide, and ec. Thu, in recen year, many auxiliary echnique have been prped and uilized vercme hee iue and mee he furher requiremen uch a high cnverin efficiency, high pwer deniy, elecrmagneic nie and perfrmance [1,,3,4]. [1] erie aurable inducr a ecndary-ide f PSFB cnverer widen he range and decreae he circulaing l a primary-ide. Bu he duy cycle l i ill eriu. Secndary-ide erie magamp cnrl i emplyed in [] bain nearly full lad range cndiin and rerain he vlage pike acr he recifier. Hwever, he neceary auxiliary cnrl circui bring in addiinal le and lead deign cmplexiy. [3] ue w clamp dide rerain vlage pike acr he recifier. Bu he addiinal primaryide erie inducr reul in mre eriu duy cycle l. Simple L-C newrk hwn in [4] can be ued achieve eaily. Bu here a rade-ff beween he range and cnducin l a primary ide. Mrever, duy-cycle l and Thi reearch wrk i uppred by ASTEC HK C.. vlage pike acr recifier ill exi. [5,6] hape he ecndary-ide curren be riangular wavefrm and clamp he revere vlage acr recifier upu by uing he energy rage inducr in erie a primary-ide and remving upu filer inducr. In hi way, he primary-ide f-wiching perain can be achieved eaily and he vlage pike acr recifier can be eliminaed. Furhermre, he prblem f duy-l can be alleviaed. [7,8] mve he energy rage inducr ecndary-ide and have imilar perain principle a prped in [5,6]. In rder fi fr lw upu vlage and high upu curren applicain, hi paper preen a ynchrnu recerified f-wiched PSFB cnverer wih primary-ide energy rage inducr. I can be peraed in CM, BCM (bundary cninue mde and CCM eparaely and primary-ide wiche can achieve he f-wiching cndiin imply. When i peraed in CM r BCM, he revere recvery curren in bdy dide f S can be reduced dramaically due lw di/d a ecndary-ide and he vlage pike acr S can be rerained by upu vlage clamping. Mrever, here n duy cycle l anymre when i peraed in hee w perain mde. Curren driven mehd prped in [9] can be uilized a ecndary-ide fr S reduce he cnducin l. The deailed perain principle f hee hree perain mde are illuraed in Secin II. Secin III analyze i eady-ae characeriic and he vlage ep acr S caued by he impac f ecndary-ide leakage inducr. Secin IV preen he imulain and experimenal reul f a 100 khz, 300Wa c-c cnverer verify he hereical analyi previuly. I high cnverin efficiency hw gd applying penial in lw upu vlage and high upu curren applicain. II. PINCIPLE F THEE IFFEENT PEATIN MES The baic plgy f hi ynchrnu recified fwiched PSFB cnverer wih primary-ide energy rage inducr i hwn in Fig.1. Q 1 ~Q 4 are he primary-ide main wiche paralleled wih c1 ~ c4 a heir bdy dide. C 1 ~C 4 are heir paraiic paralleled capacir. L i he equivalen erie inducr which cni f he added erie energy rage inducr L r and he primary-ide leakage inducr f ranfrmer L k_p. I mean ha hi cnverer can accmmdae he primary-ide leakage inducr f /08/$ IEEE 581

2 ranfrmer be a par f energy rage inducr. The L k_ i he ecndary-ide leakage inducr f ranfrmer. S 1 and S are he ynchrnu recifier a ecndary-ide paralleled wih r1 and r a heir bdy dide. C r1 and C r are heir paraiic paralleled capacir. Q4 Q 3 B c4 c3 C4 V AB C3 Q1 Q A c1 c C1 C Cr1 T r1 Lk_ S1 Lr Lk_ p Cr r Lk_ S Fig.1 he plgy f he preened PSFB cnverer uring hi perain principle analyi, all he cmpnen are upped be ideal. Leakage inducr f ranfrmer n maer a primary-ide r a ecndary-ide i negleced a all. And here n any frward vlage f dide and nreiance f MSFET. A. PEATE IN CM ME Generally, peraed in CM lead leading leg and lagging leg achieve and ZCS cndiin repecively wihu any her auxiliary circui. The revere recvery curren in S bdy dide can be reduced becaue f lw di/d a ecndary-ide. Thu, here lile revere recvery l. Addiinally, he vlage pike acr S can be rerained, which mean ha he lw break dwn vlage S can be uilized reduce he cnducin l. Hwever, cmpared wih BCM and CCM, CM uffer frm he large MS value f curren bh a primary and ecndary ide when he cnverer peraed wih ame inpu vlage and upu pwer. Fig. (a hw he ideal key wavefrm in CM. The perain prce cnain five differen ae during a half wiching perid. Sae1 ( 0 ~ 1 : uring hi acive ae, he primary-ide main wiche Q 1 and Q 3 are n. The ecndary-ide recifier S1 urn n a 0 and he pwer i ranferred frm inpu upu. V AB equal he inpu vlage V IN. The Vlage acr ranfrmer V Tran i clamped by upu vlage a nv. The vlage acr S V i clamped a V. The equivalen erie inducr L uffer frm (V IN - nv. The primary-ide curren increae wih he piive lpe and he ecndaryide curren increae wih n ime a expreed in (1. Thi mde end when Q 1 urn ff. dipri VL nv 1 diec = = = (1 d n d Where n i urn-rai f ranfrmer. Sae ( 1 ~ : Main wich Q 1 urn ff a 1, hen he paraiic paralleled capacir C 1 and C f he leading leg wiche are charged and dicharged by he primary-ide curren repecively. uring hi hr inerval, he primary-ide curren i pri can be upped a a curren urce I pri becaue f large energy red in L. T implify he analyi, C 1 and C are all upped equal C. Thu, he vlage acr he paraiic paralleled capacir C 1 and C can be expreed in ( and (3 repecively. When he vlage acr C reache zer, he bdy dide c urn n fr primaryide circulain. Then, leading leg wich Q can urn n wih C lad cndiin. bviuly, he dead ime T ead beween he driven ignal f Q 1 and Q fi fr (4 eaily. Thi inerval end when Q urn n. ( nv ( 1 0 VC1( = ( 1 ( LC ( nv ( 1 0 VC ( = ( 1 (3 LC L C Tead (4 ( nv ( 1 0 Sae3 ( ~ 3 : When Q urn n wih a, V AB equal zer. Becaue he primary-ide curren de n change direcin a hi ime, S1 cninuuly cnducin and V Tran i ill clamped a nv. Therefre, he equivalen erie inducr L uffer frm (-nv achieve vl-ecnd balance. The primary-ide curren i pri decreae wih he negaive lpe (-nv/l, which i expreed in (5. The ecndary-ide curren fall dwn wih he lpe n ime. Thi mde end when primary-ide curren i pri fall zer. ( nv ( 1 0 nv ipri ( = ( (5 Sae4 ( 3 ~ 4 : A 3, bh he primary-ide and he ecndaryide curren fall zer. Thu, bh f he lagging leg wich Q 3 and he ecndary-ide recifier S1 can urn ff wih ZCS cndiin. uring hi inerval, he ecndary-ide i eparaed frm he primary-ide. Thu, bh f V Tran and V fall zer and V fall be clamped a V. Thi inerval end when Q 3 urn ff. Sae5 ( 4 ~ 5 : Q 3 urn ff wih ZCS a 4. Befre 5, here n vlage balance curren neiher in C 3 r C 4 even Q 3 ha already urned ff. A 4, he lagging leg wich Q 4 urn n and bh f he charging curren fr C 3 and he dicharging curren fr C 4 flw hrugh i. I caue curren pike in Q 4 and reul in wiching l. Hwever, hi hard-wiching iue in he lagging leg can be remved by imply adding an auxiliary L-C f-wiching circui [4], which will be dicued in he fllwing ecin. Afer he end f mde 5, hi cnverer begin perae in anher half wiching perid. Afer he end f ae 5, he cnverer begin perae in anher half perid. There al are five perain ae which are ame a he five analyzed abve. B. PEATE IN BCM ME Fig. (b hw he ideal key wavefrm f BCM mde. Cmpared wih peraed in CM, he nly difference in BCM perain principle i he diappearance f ae 4, a paive inerval. Hence, peraed in BCM uffer frm lwer MS value f curren han ha peraed in CM when under he ame cndiin f inpu vlage and upu pwer. C. PEATE IN CCM ME Thi cnverer al can be peraed in CCM. In hi perain mde, he cnverer uffer frm he malle curren re amng hee hree perain mde. The cndiin bh fr leading leg and lagging leg wiche can be bained imply wihu any auxiliary circui. Hwever, CCM mde reul in high di/d which caue larger revere 58

3 recvery l in S bdy dide and vlage pike acr he S. Mrever, he narrw range f C gain can hardly mee he requiremen f wide inpu vlage range. Secin III will preen analyi in deail. The key wavefrm f CCM mde are hwn in Fig.4 (c. I al cnain five perain ae during a half wiching perid. Wherein, he previu w mde are ally ame a CM which i analyzed deailed abve. Here, nly he her hree differen mde are preened. Sae3 ( ~ 3 : Swich Q urn n a wih. V AB equal zer. Secndary-ide S 1 i ill n becaue primary-ide curren den change i flw direcin. uring hi paive inerval, he primary-ide erie inducr uffer revere direcin vlage V frm V Tran which equal nv. Primary-ide curren I pri decreae wih negaive lpe (-V Tran / L. Be differen CM menined abve, I pri den fall zer a he end f hi inerval 3. Thu, he lagging leg wiche can bain cndiin wihu any auxiliary circui. Vg Q 1 Q Q1 Q Q3 Q4 Q3 Vg Q1 Q Q1 Q Q3 Q4 Q3 Sae4 ( 3 ~ 4 : Swich Q 3 urn ff a 3. Then he paraiic paralleled capacir C 3 & C 4 are charged and dicharged by primary-ide curren. The required primary-ide curren fr lagging leg i given in (6. C Ipri ( 4 (6 VT in dead Sae5 ( 4 ~ 5 : Swich Q 4 will urn n a 4 wih a lng a (8 i valid. uring hi inerval, V AB equal (-V IN and S 1 mainain n. Thu, he vlage acr ranfrmer i ill clamped a nv and primary-ide erie inducr uffer frm [-(V IN nv] achieve vl-ecnd balance. Primary-ide curren decreae wih a harper negaive lpe [-(V IN nv/ L ]. I fall zer a he end f hi ae 5. Then, he cnverer begin perae in anher half perid which i he ame a befre. Vg Q1 Q Q1 Q Q 3 Q4 Q3 V AB = VAB VAB = VAB VAB = VAB Ipri Vran nv Ipri Vran nv Ipri Vran nv V1 V 1 V 1 V V V V 3 V V S = V V VS =V VS = V (a CM Mde (b BCM Mde (c CCM Mde Fig. he key wavefrm f hree differen perain mde III. ESIGN CNSIEATINS A. ANALYSIS F STEAY STATE Accrding he perain principle analyi in ecin II, i i neceary find u he relainhip beween hee hree differen perain mde f hi preened f-wiched PSFB cnverer fr pimum deign. Fr CM perain mde a hwn in Fig. (a, he C gain characeriic f hi cnverer can be derived frm he vl-ecnd balance n he energy rage inducr L and he principle f energy cnervain. I i equivalen he Buck in CM mde. Baed n (7, (8, i i eay bain he C gain in CM a hwn in (9. nv nv ( 1 0 = ( 3 1 (7 nv V ( 1 0( 3 0 = (8 TL n S V Tn 16L GainCM = = 1 1 (9 8L Tn S Wherein, T S i he whle wiching perid, i he duy cycle, ( 1 0 which can be defined a: =. TS Fr BCM perain mde a hwn in Fig. (b, he C gain can be bained eaily hru he vl-ecnd balance n L. I i hwn in (10. V Gain = BCM V = (10 IN n Fr CCM perain mde a hwn in Fig. (b, he C gain ill need be gained hru he vl-ecnd balance n L and he principle f energy cnervain. Baed n (11, he C gain i hwn in (1. 5 ipri ( d V 0 = (11 T n S 583

4 Gain V 16L 4L CCM = = (1 6 3 n T n n n T Wherein, i he duy cycle, which can be defined ( a: = TS Wih given pecificain, Fig.3 hw he C gain characeriic f hi preened f-wiched PSFB cnverer. Firly, he BCM perain mde nly ha ne pin wih large duy cycle in he C gain curve. I indicae ha hi cnverer can be alway peraed in BCM mde. Secndly, he range f C gain f CCM mde i very narrw. Thu, hi perain mde in uiable fr wide inpu vlage range applicain. Therefre, fr me applicain wih he requiremen f inpu vlage range, i i apprpriae make hi cnverer perae in CM and BCM. Gain G(_CM G(_BCM G(_CCM Fig.3 C gain characeriic f preened cnverer Wih a given inpu vlage range 350V~400V fr inance, baed n Fig.4, i i clearly ha when he cnverer i deigned be peraed in BCM wih he cndiin ha 400 and full-lad, he urn-rai need be decreaed bain enugh C gain mee he requiremen f inpu vlage range. Then he cnducin l and he cre l wuld be increaed. Thu, i i mre apprpriae make he cnverer peraed in BCM mde wih he cndiin ha 350 and full-lad. G ( =350V = 400V Curve 1 Curve 0. n decreaing Curve3 CCM BCM CM G ( 0.04 V IN=350V V IN =400V n decreaing Curve1 Curve Curve 3 Lack f C gain (a BCM wih 350V&full-lad (b BCM wih 400V&full-lad Fig.4 C gain characeriic fr w differen deign chice B. ANALYSIS F VLTAGE STESS ACSS SECNAY- SIE ECTIFIE Accrding he ideal hereical analyi in ecin II, he vlage acr ecndary-ide recifier i clamped a wice f upu vlage. Hwever, when he impac f ecndary-ide leakage inducr i aken in accun, he pracical vlage re acr recifier wuld be higher han wice f he upu vlage. CCM BCM C M Fr a cnveninal ecndary-ide full-wave recifier upu rucure f a PSFB cnverer, large upu filer inducr i puing in frn f upu filer capacir reduce he upu curren ripple. Hence, here lile curren ripple flwing hugh he ecndary-ide leakage inducr, which mean ha hey uffer frm lile vlage-ecnd during a wiching perid. Fr hi preened cnverer uilized capaciive upu filer, large curren ripple reul in a cniderable vlageecnd acr he ecndary-ide leakage inducr and a vlage ep acr he recifier. Fig.5 hw he equivalen circui f hi cnverer when cnidering he impac f he ecndary-ide leakage inducr. Fig.6 hw he hereical wavefrm f hi cae in CM, BCM and CCM repecively. V1~V15 hwn in Fig.6 are expreed in Table I. Thu, ecndary-ide recifier huld be carefully chen accrding Table I. ipri Vec VLk_1 Lk_ Lk_ iec1 Vrec Fig.5 Equivalen circui fr cnidering ecndary-ide leakage inducr IV. EXPEIMENTAL ESULTS In rder verify he hereical analyi and deign menined abve, a 300Wa (1V/5A, 100 khz prype i buil up. Table II hw he baic pecificain and able III li he uilized cmpnen. Wherein, imple L-C auxiliary circui, a prped in [4], i emplyed in hi prype help lagging leg achieve in BCM and CM mde. Table I Baic circui parameer f a ypical applicain V IN_min V IN_max V I _max T S f S 350V 400V 1V 5A 10 u 100 khz Table III Parameer f main cmpnen ued in prype Cmpnen Cmpnen 10uH; Q 1~Q 4 SPI0N60C3 L PQ00 550uH; S FI038AN06 L AUX PQ00 C u 1800uH4 Tranfrmer 48:; M1 Fig.7 hw he curren pike in lagging leg wich a urning n ime wihu L-C auxiliary circui a full lad wih 350V inpu. Apparenly, i caue wiching l in lagging leg wiche. By emplying L-C auxiliary circui, hi curren pike can be eliminaed and lagging leg wiche can achieve lad-independen cndiin. Fig.8 hw he cndiin bh f lagging leg and leading leg wiche a full lad wih 350V. Fig.9 hw he C 584

5 cndiin a ligh lad (5% full-ladbh f lagging leg and leading leg wiche wih 350V inpu. ue he impac f he ecndary-ide leakage inducr, here re vlage ep acr L and ranfrmer a hwn in Fig.10 a full lad wih 350V inpu. Fig.11 hw he vlage ep acr S and he riangular curren hrugh S a full lad wih 350V inpu. i_q4:a/iv Vd_Q4:100V/IV i_q4:a/iv cnverin efficiency. Fig.1 hw he l evaluain a full lad wih 350V inpu. Fig.13 hw he meaured efficiency curve a full lad wih differen inpu vlage. The meaured full lad efficiency wih 350 can achieve 95.9%, which i imilar evaluain reul. Fig.13 hw he meaured efficiency curve a full lad wih differen inpu vlage. Fig.14 hw he meaured efficiency curve a full lad wih differen inpu vlage. L 1 EVALUATIN F MAINLY PAT LSS Fig.7 Curren pike in lagging leg wich a full lad wih 350V inpu Vg:5V/IV Vd:100V/IV Vg:5V/IV Vd:100V/IV Leading leg Lagging leg Fig.8 cndiin bh f leading leg and lagging leg a full lad wih 350V inpu Vg:10V/IV Leading leg Vd:100V/IV Vg:10V/IV Lagging leg Vd:100V/IV Fig.9 cndiin bh f leading leg and lagging leg a 5%lad wih 350V inpu V:100V/IV dv=45v VTran:100V/IV dv=100v Fig.10 Vlage ep acr L and ranfrmer a full lad wih 350V inpu Vg_S:5V/IV dv=6v Vd_S:0V/IV Vd_S:0V/IV dv=6v is:0a/ iv is:0a/iv Fig.11 Vlage ep acr S and riangular curren hrugh S a full lad wih 350V inpu Baed n he deign cniderain analyzed in Secin III, hi preened cnverer hw gd perfrmance in 4 0 Pri-Swiche Energy Tranfrmer Sec-S upu Auxiliary Tal inducr Cu L - C Fig.1 L evaluain a full lad wih 350V inpu PSFB wih Primary- ide Energy rage inducr Eff (% P (Wa Fig.13 Meaured efficiency a differen lad wih 350V inpu Eff (% (V Fig.14 Meaured efficiency curve a full lad wih differen inpu vlage V. CNCLUSIN A ynchrnu recified f-wiched phae-hif fullbridge cnverer wih primary-ide energy rage inducr i preened in rder bain high cnverin efficiency fr lw upu vlage and high upu curren applicain. By emplying primary-ide energy rage inducr, hi cnverer can be peraed in hree differen mde uch a CM, BCM and CCM. Wherein, CM and BCM can help leading leg wiche achieve wide cndiin and help lagging leg wiche achieve ZCS cndiin. Lile vlage pike acr ecndary-ide recifier due lw di/d f riangular curren and he clamping effec f upu vlage. Therefre, lw break dwn vlage MSFET can be ued 585

6 imprve he cnverin efficiency. CCM can bain cndiin bh fr leading and lagging leg wiche, bu i ha maller C gain relaively and fa di/d a ecndary-ide reul in revere recvery l in recifier. Thi paper al preen deign cniderain fr hi cnverer uch a C gain characeriic and vlage re acr ecndary-ide recifier cnidering he impac f ecndary-ide leakage inducr. Finally, a 100 khz, 300Wa (1V/5A prype i buil up verified hereic analyi and evaluain. I high cnverin efficiency 95.9% a full lad wih 350V inpu hw i advanage and applying penial in lw upu vlage and high upu curren area. EFEENCES [1] B.-H.Kwn, J.-H.Kim, G.-Y. Jeng, Full-Bridge Sf Swiching PWM Cnverer wih Saurable Inducr a he Secndary Side, IEE Prc. Elecr. Pwer Appl.,1999,146(1:117-1 [] ber Wan, Fred C. Lee, Analyi, eign, and Experimenal eul f a 1-kW -FB-PWM Cnverer Emplying Magamp Secndary-ide Cnrl, IEEE Tran. n Indurial Elecrnic,1998,45(5:, [3] ichard edl, Nahan. Skal, Lazl Balgh, A nvel Sf-Swiching Full-Bridge C/C Cnverer: Analyi, eign Cniderain, and Experimenal reul a 1.5kW, 100kHz, IEEE Tran. n Pwer Elecrnic,1991,6(3: [4] Ming Xu, Thereic eearch f PWM Sf Swiching Technique, Ph. ierain Zhejiang Univeriy Hangzhu, 1997 [5] e ncker,.w.a.a., ivan..m., Kheraluwala, M.H, A hree-phae f-wiched high-pwer-deniy C/C cnverer fr high-pwer applicain, Indury Applicain, IEEE Tranacin n,vlume 7,Iue 1,Par 1,Jan.-Feb Page(: [6] Junming Zhang, Fan Zhang, Xiaga Xie, ezhi Jia, Zhaming Qian, A nvel C/C cnverer fr high pwer applicain, Pwer Elecrnic, IEEE Tranacin n, Vlume 19, Iue, March 004 Page(:40 49 [7] Jiaru, I.., A 3 kw f wiching C-C cnverer, Applied Pwer Elecrnic Cnference and Expiin, 000. APEC 000. Fifeenh Annual IEEEVlume 1, 6-10 Feb. 000 Page(:86-9 vl.1 [8] I..Jiaru, Sf wiching Cnverer, US Paen pending, 6,86,195 [9] Junming Zhang, Xiaga Xie, ezhi Jia, Zhaming Qian, A high efficiency adaper wih nvel curren driven ynchrnu recifier, IEEE Tran. n IEICE, Vl. E87-B, N.1, ecember 004 iec1 VLk_1 Vrec V1 V9 V V10 nv V3 iec1 VLk_1 Vrec V4 V11 V5 V1 T/ T/ T/ CM BCM CCM Fig.6 Key wavefrm wih impac f ecndary-ide leakage inducr in CM, BCM and CCM nv iec1 VLk_1 Vrec V6 V13 V7 V14 V8 V15 nv Table I Vlage acr ecndary-ide recifier in CM, BCM and CCM perain Mde V rec V pri CM BCM V 4nL I V V =V k_ 1 T 4nL I V k_ =V ( nv T V = V 3 4L I V4 =V T k_ 4nL I V V = n V k_ 9 T 4nL I V k_ 10 = n V ( nv T V 4Lk_I V11 = n V T 4Lk_I 4Lk_I V5 =V V1 = n V ( 1 T ( 1 T CCM 8 Lk_I ( nv 8 Lk_I ( nv V6 =V V13 = n V ( ( n V T ( ( n V T 8Lk_IVV IN 8Lk_IVV IN V7 =V V14 = n V ( ( n V T ( ( n V T 8 Lk_I ( nv 8 Lk_ I ( nv V8 =V V15 = n V ( ( n V T ( ( n V T 586