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A ZVZCS Full-Bridge DC/DC Converter with a Passive Auxiliary Circuit

in the Primary Side


Wuhua Li, Yanqun Shen, Yan Deng, Xiangning He
College of Electrical Engineering
Zhejiang University
Hangzhou, 310027, P.R. China
Email: woohualee@yahoo.com.cn

AbstractA ZVZCS full-bridge converter with phase-shift


control is proposed in this paper. The ZCS condition of the
lagging-leg is achieved by using a simple auxiliary circuit, which
resets the primary-side current during the freewheeling stage.
The ZVZCS operation can reduce the switching losses and the
circulating conduction losses. The auxiliary circuit is composed
of only a small transformer and two clamp diodes, which is
inserted in the primary side of the main transformer. There are
neither additional active switches nor resistors in the resetting
circuit. A prototype with 1kW operating at 50kHz is built in the
lab to confirm the effectiveness of the presented converter.

I.

INTRODUCTION

The traditional ZVS phase-shift full-bridge converter is


adopted widely in the middle and high power applications
due to its soft-switching conditions, lower voltage and
current stresses on the switching devices. But there are
several disadvantages for the normal ZVS full-bridge PWM
converter. Firstly, the large circulating current during the
freewheeling period increases the conduction losses.
Secondly, a large leakage inductor is necessary to realize
ZVS at light load, which induces extra duty cycle losses [1],
[2].
Many ZVZCS phase-shift full-bridge converters are
proposed to reset the primary current during the freewheeling
stage. But they all have some limitations. For example, extra
active switches [3] or additional complex clamp circuits [4]
are inevitable, which increases the circuit complexity and
cost and decreases the reliability.
DP1

S3

n1

Vin

b
S2

S1

n1
DP2

S4

Lf

Llk

of the main transformer. During the freewheeling stage, a


resetting voltage is added across the leakage inductor, which
accelerates the falling rate of the primary-side current. Thus
the ZCS condition is realized easily.
II.

Vgs

S1

S1

S4
S2

Vb'b

DS1 DS3

OPERATION PRINCIPLE

The steady operation principle and some key waveforms of


the proposed converter are shown in Fig.2. The dotted line of
the primary current Ip is the waveform with the traditional
phase-shift control during the freewheeling stage, which
demonstrates that the circulating current is greatly higher
than that of the presented converter. Thus the conduction
losses caused by the circulating current can be reduced.
Meanwhile, the ZVZCS operation is realized easily even in
very light load with a small leakage inductor, because an
equivalent DC source is introduced during the freewheeling
stage.
In order to simplify the analysis, it is assumed that all the
devices are ideal, and the auxiliary transformer is modeled as
an ideal transformer with corresponding turns ratio, its
magnetizing inductor and leakage inductor are ignored here.
The magnetizing inductor of the main transformer is also
neglected. There are ten modes in a switching period.
Because of the symmetry of the topology, only five modes
are analyzed here. The theoretical equivalent circuit for each
mode is demonstrated in Fig.3.

S3
Vin / n

Vin

'

Cf

1:

Rload

DS2 DS4

Fig.1 The proposed DC/DC converter

A novel ZVZCS converter with a simple auxiliary circuit


in the primary side is shown in Fig 1. A small transformer
with two clamp diodes is introduced in the primary winding

Vab
Circulating
Current

Ip
t0 t1

t 2 t3 t 4 t 5 t 6

Fig.2 Principal waveforms of the proposed converter

MODE 1 [t0~t1]:
Before t0, S1 is on state, the primary current is reset to
zero and the output diodes are in freewheeling stage. At t0, S2
turns on with the ZCS condition due to the presence of the
leakage inductor Llk of the main transformer. The input
voltage Vin is totally added across the leakage inductor Llk and
the primary current Ip begins to increase linearly through the
switches S1 and S2 until it reaches the reflected output current
Iout/n. The secondary winding of the auxiliary transformer is
shorted-circuit by the auxiliary diodes DP1 and the switch S1.
The output rectifier diodes DS1~DS4 are freewheeling during
this mode. The equivalent circuit, as reflected to the primary
side, is shown in Fig.4 (a). The primary current ip(t) and the
current iS1(t) through S1 respectively are:
(1)
i p (t ) = (Vin / Llk ) (t t0 )

iS 1 (t ) = i p (t )(1 + 1/ n1 )

(2)

MODE 2 [t1~t2]:
At t1, the primary current Ip reaches the reflected output
current Iout/n. The power is delivered to the load through the
switches S1, S2, the main transformer and the secondary
rectifier diodes DS1 and DS4. And the diodes DS2 and DS3
turn off with ZCS condition. The primary current ip(t)
increases as the increase of the reflected output current Iout.
The diode DP1 is still in on state and the reflected current of
the auxiliary transformer flows through S1, which increases
the conduction losses of S1. The equivalent circuit of this
mode is shown in Fig.4 (b).
(3)
i p (t ) = I p (t1 ) + (Vin nVout )(t t1 ) /( Llk + n 2 L f )

iS 1 (t ) = i p (t )(1 + 1/ n1 )

vC 4 (t ) = Vin vC1 (t )
Cequ
And

MODE 5 [t4~t5]:
At t4, the primary current decreases to zero due to the
auxiliary transformer and it remains zero during this mode.
The output rectifier diodes D1~D4 are freewheeling during
this mode. The switch S2 turns off with ZCS operation.
MODE 6 [t5~t6]:
A new switching cycle starts with the similar mode 1
operation.
DP1

S3

S1

n1

Vin

b
DP2

S2

Lf
DS1 DS3

b'

Cf

Rload

Cf

Rload

1:
DS2 DS4

S4

(Mode 1) [t0~t1]

S3

DP1

S1

n1

Vin

Llk

n1
DP2

S2

Lf
DS1 DS3

b'
1:
DS2 DS4

S4

(Mode 2) [t1~t2]

S3

DP1

n1
DP2

C1

S1

n1

Vin

S2

Llk

n1

(6)

Where

(8)

MODE 4 [t3~t4]:
At t3, S4 turns on with ZVS since the anti-parallel diode
of S4 is in conduction state. And the primary current
freewheels through the switch S2 and the diode D4. The input
voltage is applied across the secondary winding of the
auxiliary transformer and is reflected to the primary side. The
equivalent circuit is illustrated in Fig.4 (d).
i p (t ) = I p (t3 ) (Vin / n1 Llk ) (t t3 ) (9)

(4)

MODE 3 [t2~t3]:
At t2, S1 turns off with ZVS due to its parasitic capacitor
C1. And a resonant circuit occurs with the equivalent
capacitor Cequ, the leakage inductor Llk, the output filter
inductor Lf. The Cequ is composed of the parasitic capacitors
C1, C4 and the auxiliary transformer. The equivalent circuit,
as reflected to the primary side, is shown in Fig.4 (c). Since
this time interval is very short and the reflected output filter
inductor n2Lf is very large, the primary current ip(t) is
considered nearly constant during this mode. Thus the
voltage across the parasitic capacitor of S1 increases in an
approximately linear way. The voltage across the parasitic
capacitor of S4 decreases correspondingly. This mode
finishes when the voltage across the parasitic capacitor of S1
reaches the input voltage Vin and the anti-parallel diode of S4
begins to conduct.
(5)
vC1 (t ) = I p (t2 )(t t2 ) / Cequ

n
= 2C 1
1 + n1

C = C1 = C4

S4

Llk

Lf
DS1 DS3

b'

Cf

1:

C4

(7)
(Mode 3) [t2~t3]

DS2 DS4

Rload

III.
DP1

S3

S1

Lf

n1

Vin

n1
DP2

S2

DS1 DS3

Llk

b'

Cf

1:
D4

S4

Rload

DS2 DS4

(Mode 4) [t3~t4]
DP1

S3

S1

n1

Vin

Llk

n1
DP2

S2

D2

Lf
DS1 DS3

b'

Cf

1:

Rload

DS 2 DS 4

S4

(Mode 5) [t4~t5]

DP1

S3

n1

Vin

b
S2

S1

n1
DP2

Llk

Lf
DS1 DS3

b'

Cf

1:

Rload

DS2 DS4

S4

(Mode 6) [t5~t6]
Fig.3 Equivalent circuits for each operating mode

Vin

Llk

Iout /n

Vin

n2Lf

Llk

nVout
(a)
Vin

Cequ Llk

(b)
n2Lf

Vin/n1

Llk

Iout /n

nVout

(c)

(d)

Fig.4 Simplified equivalent circuit for the modes: (a) mode 1, (b) mode 2,
(c) mode 3, (d) mode 4.

DESIGN CONSIDERATIONS

This section presents the design considerations for the


ZVS range, the ZCS range and the turns ratio design for the
auxiliary transformer.
1) ZVS Range
During the deadtime [t2~t3], the ZVS for switch S1 is
realized due to the equivalent capacitor Cequ in parallel with
S1. When VC1 reaches the input voltage Vin and VC4 reaches
the zero point during this interval, the ZVS-on for switch S4
is achieved. So the ZVS range is as follows:
(10)
tZVS = CequVin / I p (t2 )
The ZVS range only has the relationship with the
equivalent capacitor Cequ, the input voltage Vin and the
primary current Ip. The ZVS range is at its minimum when
the input voltage Vin is at its minimum and the output current
is at its maximum.
2) ZCS Range
During the time interval [t3~t4], the secondary rectifier
diodes are freewheeling and the primary current Ip is reset by
the auxiliary transformer, because an equivalent negative
voltage Vin/n1 is added across the leakage inductor Llk, which
provides ZCS-off operation for S2 and ZCS-on operation for
switch S3. So the ZCS range is as follows:
(11)
tZCS = Llk I p (t3 ) n1 / Vin
The ZCS range depends on the leakage inductor Llk, the
primary current Ip, the turn ratio of the auxiliary transformer
n1 and the input voltage Vin. As the increase of the primary
current Ip and the decrease of the input voltage Vin, the ZCS
range is enhanced. There must be a compromise between the
ZVS range and the ZCS range.
3) Design of the auxiliary transformer
From (4), the larger the turns ratio of the auxiliary
transformer is, the lower the additional current passes
through switch S1, thus the additional conduction losses is
reduced during mode 1 and mode 2. But in order to accelerate
the primary-side current falling rate and to reduce the
circulating conduction losses during the freewheeling stage,
a small turns ratio is a good selection. So a compromise
should be made carefully.

IV.

SIMULATION AND EXPERIMENTAL RESULTS

In order to verify the theoretical analysis in the previous


sections, a 1kW prototype with 200V input and 210V output
battery charger is built in the lab and some simulations with
Saber have been done with the components and parameters
summarized in Table.
The main switches S1~S4 are IGBTs IXFK48N50 from
IXYS. The turns ratio of the main transformer is 1:1.4 with
EE55 core and the auxiliary transformer with 5 turns in the
second and the third winding and only one turn in the primary
winding. The switching frequency is 50kHz to reduce the
size of the passive component.

TABLE
PARAMETERS AND COMPONENTS USED IN THE PROTOTYPE
Parameter
Value
Vin(input voltage)
200V
Vo(output voltage)
210V
Pout(output power)
1kW
fs (Switching frequency)
50kHz
Lf(output filter inductance)
0.4mH
Cf(output capacitance)
940uF
Turns ratio of the main transformer (n)
1:1.4
Turns of the auxiliary transformer (n1)
5
S1-S4
IXFK48N50
DS1-DS4
RHRP30120
DP1 and DP2
RHRP8120
Fig.5 shows the Saber simulation results with the
parameters listed in Table at 100W light load. Fig.6
demonstrates the Saber simulation results with the
parameters listed in Tableat 1kW full load. As can be seen,
the simulation results are consistent with the analysis in the
previous sections. As can be seen, an equivalent DC source is
inserted across the leakage inductor to reset the primary
current during the freewheeling period, which makes the
output current has little impact on the ZCS range. The
circulating current is reset quickly. Therefore, the conduction
losses reduce greatly. The primary current of the main
transformer has some rings, which is induced by the leakage
inductor and the parasitic capacitors of the rectifier diodes in
the secondary side.

Fig.5 Simulation waveforms at 100W load: (a) ZVS for switch S1; (b)
ZCS for switch S3; (c) primary-side voltage and current of the main
transformer and the voltage of the auxiliary transformer

Fig.6 Simulation waveforms at 1kW load: (a) ZVS for switch S1; (b)
ZCS for switch S3; (c) primary-side voltage and current of the main
transformer and the voltage of the auxiliary transformer

Fig. 7 shows the waveforms of the primary-side current of


the main transformer and the primary-side voltage waveform
of the auxiliary transformer. The equivalent DC source with
nearly 35V resets the leakage current and the leakage
inductor current decreases to zero quickly. Fig.8 is the
primary-side current waveform and the voltage waveform of
the bridge leg output. From Fig.7 and Fig.8, it can be seen
that the ZVZCS operation is realized.

REFERENCES
[1]

[2]

[3]

[4]

Fig.7 Experimental results of primary current of the main


transformer and the primary voltage of the auxiliary
transformer

Fig.8 Experimental results of primary current of the main


transformer and the bridge output

V.

CONCLUSION

In this paper a novel ZVZCS full-bridge converter with


phase-shift control is presented and analyzed. The simulation
and experimental results are given. The auxiliary circuit is
very simple and theoretical lossless. The switching losses and
circulating losses are reduced due to the ZVZCS operation.
The range of the ZCS is extended because the output current
has little impact on it.
ACKNOWLEDGEMENTS
The work is supported by the Delta Science and Education
Foundation for Power Electronics Research and
Development (DREG2005010) and the State Education
Ministry of China (20050335059).

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zero-current-switching full bridge PWM converter for high-power
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