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3, MARCH 2010
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AbstractA zero-voltage- and zero-current-switching fullbridge (FB) converter with secondary resonance is presented and
analyzed. The primary side of the converter is composed of FB
insulated-gate bipolar transistors, which are driven by phase-shift
control. The secondary side is composed of a resonant tank and
a half-wave rectifier. Without an auxiliary circuit, zero-voltage
switching (for leading-leg switches) and zero-current switching
(for lagging-leg switches) are achieved in the entire operating
range. To implement the converter without an additional inductor, the leakage inductance of the transformer is utilized as the
resonant inductor. Due to its many advantages, including high efficiency, minimum number of devices, and low cost, this converter
is attractive for high-voltage and high-power applications. The
analysis and design considerations of the converter are presented.
A prototype was implemented for an application requiring a 5-kW
output power, an input-voltage range varying from 250 to 350 V,
and a 350-V output voltage. The experimental results obtained
from a prototype verify the analysis. The prototypes efficiency at
full load is over 95.5%.
Index TermsPhase shift, series resonant, zero-voltage and
zero-current switching (ZVZCS).
I. I NTRODUCTION
N high-frequency and high-power converters, it is desirable
to use insulated-gate bipolar transistors (IGBTs) for primary
switches and to utilize soft-switching techniques such as zerovoltage switching (ZVS) and zero-current switching (ZCS)
[1][24]. IGBTs can handle higher voltage and higher power
with lower cost compared with MOSFETs, so IGBTs have been
replacing MOSFETs in applications requiring several or several
tens of kilowatt power [5][13]. In high-frequency converters,
soft-switching techniques are widely used to reduce the switching loss that results from high switching frequency [1][33].
In MOSFETs, because of high drainsource capacitance, ZVS
is more effective than ZCS. On the other hand, in IGBTs,
because of the tail-current characteristic at turnoff, ZCS is
more effective than ZVS. To apply IGBTs for ZVS cases, an
additional lossless turn-off snubber should be added in parallel
with IGBTs.
In many proposed techniques for high-frequency and highpower conversions, zero-voltage- and zero-current-switching
(ZVZCS) full-bridge (FB) PWM converters [1], [6][13],
Manuscript received August 6, 2008; revised July 20, 2009. First published
August 21, 2009; current version published February 10, 2010.
E.-H. Kim is with HAC Control R&D Laboratory, Air Conditioning
Company, LG Electronics, Inc., Seoul 153-802, Korea (e-mail: znight@
postech.ac.kr).
B.-H. Kwon is with the Department of Electronic and Electrical Engineering,
Pohang University of Science and Technology, Pohang 790-784, Korea (e-mail:
bhkwon@postech.ac.kr).
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TIE.2009.2029581
[25][29], which are driven by phase-shifted pulsewidthmodulation control, are most desirable because IGBTs can be
applied with reduced switching loss. ZVZCS means mixed
operation of ZVS for leading-leg switches and ZCS for laggingleg switches. For the leading-leg switches, IGBTs can be used
by reducing the turn-off loss using a lossless turn-off snubber.
For the lagging-leg switches, IGBTs are adequate because of
ZCS. The switching frequency of the converter can be effectively increased due to the soft-switching characteristics of
IGBTs. Mostly in previous ZVZCS FB converters, a secondary
filter inductor is needed. The ZCS of the lagging-lag switches is
achieved by resetting the primary current during the freewheeling period of the filter-inductor current. By employing auxiliary
switches or circuits, such as a secondary passive snubber [12],
a secondary active clamp [6], [10], or a saturable inductor
and a dc blocking capacitor [25], the primary current during
the freewheeling period is reset. However, additional auxiliary
switches or circuits result in either complicated topology or
complex control strategy, so that reliability deteriorates and the
cost is increased.
Among previous soft-switching FB converters, a seriesresonant converter (SRC) [14][21] is the simplest topology.
Moreover, because all switches of the converter are turned on
at zero voltage, the conversion efficiency is relatively high.
However, the SRC has some drawbacks. First, the output
voltage cannot be regulated for the no-load case. Second, it
has some difficulties, such as size reduction and a design of
an electromagnetic-interference noise filter because a wide
variation of the switching frequency is necessary to control the
output voltage.
Some modified converters based on a conventional SRC have
been presented to solve these problems. One is a converter
that utilizes other control methods without additional hardware
[22][24]. By using a control method in [22], regulation problems under low-power conditions can be solved, but the range
of the operating frequency is still wide. Another presented
approach is the phase-shift control of SRC, such as the ZVS FB
converters in [23] and [24]. The ZVS FB converters can achieve
constant-frequency operation, no regulation problem, and ZVS
of all switches that are composed of MOSFETs. However,
the range of ZVS for the leading-leg switches is not wide.
In light-load or overload conditions, the leading-leg switches
may be hardly turned on, and the loss resulting from hard
switching reduces significantly the conversion efficiency. Moreover, because all switches of the converters are MOSFETs,
the converters are not adequate for high-power conversion in
the power range of several or tens of kilowatts. To apply the
converter for high-power conversions, further improvements,
1018
Fig. 2.
1019
Lr
.
Cr
(3)
(4)
(5)
(7)
Vo vc (t2 )
sin r (t t2 ).
Zo
(8)
(1)
where ip is the primary current and iT 1 is the sum of the currents of T1 , its body diodes DT 1 s, and its snubber capacitance
CT 1 . Similarly, iT 2 , iB1 , and iB2 are defined, as shown in
Fig. 1. In Fig. 2, the currents of body diodes are simply the
negative portions of iT 1 , iT 2 , iB1 , and iB2 .
Mode 2 [t1 , t2 ]: At t1 , the lagging-leg switch T2 is turned
off when iT 2 = im . Because im is a very low current, T2
is turned off near zero current. After a short dead time, B2 is
turned on at zero voltage, while the current ip flows through
the body diode of B2 . During this mode, the secondary voltage
across N2 is nVin . Therefore, is builds up from its zero value
and flows through D1 . The state equations can be written as
follows:
Llk
dis (t)
+ Vo vc (t) = nVin
dt
d (Vo vc (t))
= is (t)
Cr
dt
is (t1 ) = 0
(9)
(2)
Q=
4r Llk
.
Ro
(11)
1020
=
2
2Cr
t3
is (t)dt
t1
Io
Vo
Vo
1 FQ .
=
=
2
2Cr fs
2
2
(12)
t1 +T
s /2
nVin is (t)dt
t1
t1 +T
s /2
sin r (t t1 )dt
t1
n
Vo (1 cos F )
2n Cr fs Vin nCr fs Vo +
Ro
2
(13)
where is the phase-shift value and has a value between zero
and one when the phases of two legs have a difference between
0 and . Rearranging (13) with respect to Vo /2nVin gives
Vo
2nVin
2
+ (Cr fs Ro 1) (0.5 0.5 cos F )
Vo
2nVin
(16)
(17)
is (t3 ) =
(14)
G(Q, F, )
(15)
where
A = Cr fs Ro =
2
F Q
Fig. 4. Graphs of the normalized voltage gain G(Q, F, ). (a) Voltage gain
at F = 1. (b) Voltage gain at F = 0.8.
= 0.
Vo vc (t2 )
sin r (t3 t2 )
Zo
(18)
1021
sin r (1 )
Zo
2
(19)
t2
is dt
t1
sin r (t t1 )dt
Vo
= nVin nVin (1 0.5F Q) cos F .
2
(20)
t1
Vo
2 (1
0.5F Q)
1
sin F cos r (1 )
Zo
2fs
Zo
1
sin r (1 )
< 0.
(21)
2fs
With rearrangement and simplification of (21), the ZCS condition with respect to Q, F , and can be written as
ZCS(Q, F, )
= (1 G(Q, F, )(1 0.5F Q)) sin F cos F (1 )
(1 (1 G(Q, F, )(1 0.5F Q)) cos F )
sin F (1 ) < 0.
(22)
1022
TABLE I
S YSTEM PARAMETERS OF THE P ROTOTYPE
Vo
1 F Q > 0.
Vo vc (t1 ) =
2
2
(23)
2
.
F
(24)
im
2
2
> Coss Vin2
(25)
where
im =
Vin
.
2Lm fs
(26)
2min
32Coss fs2
(27)
1023
N22
Rlk1 + Rlk2
(28)
where Rlk1 and Rlk2 are the reluctances of the primaryand secondary-leakage-flux paths, respectively. From (28), the
loosely coupled windings increase Llk , and more turns also
result in larger Llk . Therefore, by changing the coupling methods or adjusting the number of turns, Llk may be adjusted.
The transformer of the prototype was implemented for loosely
coupled windings, as shown in Fig. 8. If the measured leakage
inductance is too small, additional inductor that is in series with
Llk is required, although the absence of an external resonant
inductor makes the converter cost-optimal. Sometimes, fr may
be adjusted due to the available values of Llk and Cr .
B. Experimental Results
Fig. 9(a) shows the collectoremitter voltage vT 1 and the
current iT 1 of T1 at the full-load condition. The leading-leg
switches are turned on while the current flows through their
body diode. It guarantees the ZVS of the leading-leg switches.
Because the primary current ip is the sum of magnetizing
current and reflected current is , the leading-leg switches are
turned on softly under almost the entire operating region.
Fig. 9(b) shows the collectoremitter voltage and current of
T2 at the full-load condition. The lagging-leg switches are also
turned on softly. When T2 is turned off, its current iT 2 is very
low. Therefore, the turn-off loss of T2 is close to zero.
Fig. 9(c) shows the current of D1 and the secondary current
is . Since the deceasing slope of iD1 is slow before D1 is reverse
biased, the reverse-recovery current is close to zero. Therefore,
the losses resulting from the reverse recovery of the rectifying
diodes are close to zero.
Fig. 9(d) shows the tail current of leading-leg switch T1
during turn-off switching. Since the rising slope of the switch
voltage is slow, the turn-off switching loss of the leading leg is
significantly reduced compared to that of hard switching.
Fig. 10 shows the dcdc conversion efficiency of the prototype. As shown in Fig. 10, the efficiency of the prototype is
over 95.5% under the full-load condition. Additionally, the conversion efficiency is relatively high, even under the low-power
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