Journal of Power Electronics

The Korean Institute of Power Electronics (전력전자학회)
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Active Controlled Primary Current Cutting-Off ZVZCS PWM Three-Level DC-DC Converter

  • Shi, Yong (College of Electrical & Information Engineering, Shaanxi University of Science & Technology)
  • Received : 2017.03.30
  • Accepted : 2017.11.04
  • Published : 2018.03.20
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Abstract

A novel active controlled primary current cutting-off zero-voltage and zero-current switching (ZVZCS) PWM three-level dc-dc converter (TLC) is proposed in this paper. The proposed converter has some attractive advantages. The OFF voltage on the primary switches is only Vin/2 due to the series connected structure. The leading-leg switches can obtain zero-voltage switching (ZVS), and the lagging-leg switches can achieve zero-current switching (ZCS) in a wide load range. Two MOSFETs, referred to as cutting-off MOSFETs, with an ultra-low on-state resistance are used as active controlled primary current cutting-off components, and the added conduction loss can be neglected. The added MOSFETs are switched ON and OFF with ZCS that is irrelevant to the load current. Thus, the auxiliary switching loss can be significantly minimized. In addition, these MOSFETs are not series connected in the circuit loop of the dc input bus bar and the primary switches, which results in a low parasitic inductance. The operation principle and some relevant analyses are provided, and a 6-kW laboratory prototype is built to verify the proposed converter.

Keywords

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Fig. 1. Active controlled primary current cutting-off ZVZCSPWM TLC.

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Fig. 2. Basic operation principle.

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Fig. 3. Operation stages of the proposed converter: (a) stage 1; (b) stage 2; (c) stage 3; (d) stage 4; (e) stage 5; (f) stage 6; (g) stage 7.

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Fig. 4. Conventional ZVZCS TLC. (a) Diode cut-off. (b) Secondaryside active reset.

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Fig. 5. Layouts of the IGBTs and lamination bus bars for: (a)proposed converter and Fig. 4(b), (b) Fig. 4(a).

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Fig. 6. Control signals of S1, S3, S4 and S5.

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Fig. 7. Waveform of vBC.

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Fig. 8. Waveform of iP.

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Fig. 9. Waveform of vCBL.

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Fig. 10. Waveforms of vS5 and vS6.

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Fig. 11. Waveform of vDo1.

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Fig. 12. Waveform of iLo.

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Fig. 13. ZCS of S5 and S6.

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Fig. 14. ZCS of S3.

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Fig. 15. ZVS of S1.

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Fig. 16. Waveforms of vS4 and iS4.

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Fig. 17. Waveforms of vS2 and iS2.

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Fig. 18. Efficiency comparison results.

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Fig. 19. Main power loss distribution with a 400A load current.

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Fig. 20. Photo of the prototype.

TABLE I ADDED COMPONENTS, ADDED COST AND A PERFORMANCE COMPARISON

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Table II MAIN PARAMETERS OF THE PROTOTYPE

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