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1 Series Resonant Converter with Series-Parallel Transformers for High Input Voltage Applications C-H Chien 1,B-R Lin 2,and Y-H Wang 1 1 Institute of Microelectronics, Department of Electrical Engineering, National Cheng-Kung University, Tainan 701, Taiwan 2 Department of Electrical Engineering, National Yunlin University of Science and Technology, Yunlin 640, Taiwan
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2 Outline Introduction Circuit configuration Experimental results Conclusion
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3 Introduction
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4 For 3-phase 380V (or 480V) AC/DC converters the DC bus voltage > 500V (or 650V) ∴ select suitable power MOSFETs → difficult 3 level neutral-point clamp converter → overcome these drawbacks more power switches more circuit components high cost complicated control schemes split capacitors and clamp diodes the V stress of MOSFETs → ½ DC bus voltage What ’ s for in this study?
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5 What ’ s new in this study? A novel DC/DC converter (24V/40A, 960W) 2 circuit modules for high voltage application 2 capacitors and 2 half-bridge series in high Voltage clamp the V stress of MOSFET V stress = ½ input V interleaved switching signal → phase-shift ¼ switching T → 90° reduce ripple current (input and output) share the load current reduce the size of magnetic core
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6 Why is the topology ? A series resonant tank high conversion efficiency high power density 2 series Transformers balance the 2 winding current all semiconductors soft switching switching loss ↓ ∵ (ZVS & ZCS) wide input voltage and load 480V~600V all load 2 windings in parallel I stress ↓
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7 Circuit configuration
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8 Circuit configuration and key waveforms Key waveforms Circuit configuration
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9 Different modes during 1 period Mode 1 Mode 2 Mode 3 Mode 4 Mode 5 Mode 6
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10 Mode 1 ( t 0 ≦ t < t 1 ) S 1 off, S 2 → off V Lm1 =nV o = V Lm2 C s1, C s2, and L r1 → resonant i Lr1 C s2 => from 0 V → V in /2 → charge C s1 => from V in /2 → 0 V → discharge i Lm1 → i Lm2 → i D1 → i D3 →
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11 Mode 2 ( t 1 ≦ t < t 2 ) S 2 off, S 1 → ZVS → on i Lm1 = i Lm2 = i Lr1 → mode end V Lm1 =nV o = V Lm2 C r1 and L r1 → resonant applied voltage = (V in /2 - 2nV 0 ) i Lm1, i Lm2 linearly ↑ slope = nV 0 /L m i Lr1 → V cr1 →
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12 Mode 3 ( t 2 ≦ t < t 3 ) S 2 off, S 1 → on → off i Lm1 = i Lm2 = i Lr1 → mode start S 1 off → mode end i D1 =i D2 =i D3 =i D4 =0 C r1, L r1, L m1, and L m2 → resonant i Lr1 → V cr1 →
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13 Mode 4 ( t 3 ≦ t < t 4 ) S 2 off, S 1 → off V Lm1 =-nV o = V Lm2 C s1, C s2, and L r1 → resonant i Lr1 C s1 => from 0 V → V in /2 → charge C s2 => from V in /2 → 0 V → discharge i Lm1, i Lm2 linearly ↓ slope = -nV 0 /L m V cs1 → V cs2 → i D2 → i D4 →
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14 Mode 5 ( t 4 ≦ t < t 5 ) S 1 off, S 2 → ZVS → on i Lm1 = i Lm2 = i Lr1 → mode end V Lm1 =-nV o = V Lm2 C r1 and L r1 → resonant applied voltage = 2nV 0 i Lm1, i Lm2 linearly ↓ slope = -nV 0 /L m i Lr1 → V cr1 →
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15 Mode 6 ( t 5 ≦ t < t 0 ) S 1 off, S 2 → on → off i Lm1 = i Lm2 = i Lr1 → mode start S 2 off → mode end i D1 =i D2 =i D3 =i D4 =0 C r1, L r1, L m1, and L m2 → resonant i Lr1 → V cr1 →
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16 Key circuit parameters of the prototype circuit Input voltage V in → 480V ~ 600V Input nominal V in,norm → 530V Output voltage V o and current I o → 24V / 40A Series resonant frequency f r → 100kHz Switches S 1 ~S 4 → IRFP460 Diodes D 1 ~D 8 → MBR3060PT Turns ratio of T 1 ~T 4 → n p :n s1 :n s2 =20:6:6 Resonant inductances L r1 ~ L r2 → 21 μH Magnetizing inductances L m1 ~ L m4 → 82 μH Resonant capacitances C in1 ~ C in2 → 330 μF/400V Output capacitances C o → 2200 μF/50V
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17 Experimental results
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18 The interleaved signals of switches Experimental waveforms of gate voltages S 1 ~S 4 at full load V in =530V
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19 The ZVS of switches under input 530V Experimental gate V, drain V and drain I of switch S 1 V in → 530V load → 25% Experimental gate V, drain V and drain I of switch S 1 V in → 530V load → 100%
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20 The ZCS of rectifier diodes under input 530V Measured waveforms of gate voltages v S1,gs and v S3,gs Output currents of each center tapped rectifier at full load nominal input voltage V in =530V turn off ZCS
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21 Switching Frequency VS. Output Power Measured switching frequencies at different input voltages at different load
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22 Conclusion
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23 A resonant converter with the series half-bridge legs for high DC bus voltage application Two circuit modules share the load power For each module series-connected in primary side parallel-connected in secondary side power MOSFETs → turn on ZVS rectifier diodes → turn off ZCS Conclusion switching loss ↓ balance 2 winding current share the load current The voltage stress of each switch=0.5V in
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24 Thanks for your attention!
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