A ZCS Full-Bridge Converter Without Voltage

7/22/2019 A ZCS Full-Bridge Converter Without Voltage

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By

Avinash. Patil

Under the guidance of

Prof. M.S.Aspalli


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CONTENTS Introduction

Literature Survey

Soft switching techniques

Block Diagram and its explanation

Circuit diagram and its working Design and development of hardware

Simulation and its results

Experimental setup and its ResultsAdvantages and Applications

conclusion


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Introduction Modern electronic systems require high-quality, small,

lightweight, reliable, and efficient power supplies.

PWM Full-Bridge (FB) converters have been popularly used for

high-power DCDC power conversion.

Indirect DC/AC/DC converters are used in many applications.

In designing the converter power density should me more.

To reduce switching losses soft-switching methods areimplemented.

Among different topologies, the phase-shifted ZVS- Full-

Bridge (FB) converter is the most widely used topology


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Contd Zero-Voltage Switching(ZVS) technique is more suitable for

converters using majority-carrier-type switching devices,

such as MOSFET.

For high voltage and power applications, insulated gatebipolar transistor (IGBT) is preferred

Indirect DC/AC/DC converters utilizing an isolation

transformer are widely used in different applications.

The current driven converter has the advantage of having

continuous input current without using large input filter.


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Contd

Here the concept is placing an active switch in parallel withpassive component. But auxillary switches will prouce

switching losses.

Some ZCS-FB converters utilize snubbers on the secondary

side. And antiparallel diodes are used to reduce circulating

current.

Current driven soft switched FB converter will be developed.


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Literature surveyYungtaek Jang and Milan M. Jovanovic A NEW

PWM ZVS FULL-BRIDGE CONVERTER IEEETransactions On Power Electronics, VOL. 22, NO.

3, MAY 2007

This is constant-frequency converter employs phase-shift (PS)control and features ZVS of the primary switches with relativelysmall circulating energy.

For implementations with an external primary inductor, the

ringing can also be effectively controlled Zero-Voltage-Switching (ZVS) of the bridge switches over a

wide output-load range.

The proposed converter achieves ZVS with substantially

reduced duty-cycle loss.


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ContdKhalil Rahimi, Ali Nazeran Motlagh and MajidPakdel A

Novel Soft-Switched Synchronous Buck Converter IEEETRANSACTIONS 2009

Synchronous buck converter, is designed to operate at low voltage and high

efficiency typically required for portable systems.

Here auxiliary switch is different from main switch as they are ON for short

period of time.

Designed for a low voltage, high-current circuit, and it is found to be highly

efficient.

zero-voltage switching for the main switch and zero-current switching for the

auxiliary switch is achieved so stresses on the switches is reduced.


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ContdTing Ting Song and Nianci Huang A Novel Zero-

Voltage and Zero-Current-Switching Full-Bridge PWMConverter IEEE TRANSACTIONS ON POWERELECTRONICS, VOL. 20, NO. 2, MARCH 2005

ZVS full-bridge PWM converter is preferred for its simple circuitand lower voltage and current stress on the switching devices toachieve soft-switching.

Here the circular current of the primary in the freewheeling

period increases the conduction loss .These drawbacks makeZVS not suitable for high power applications, in which IGBTshave to be used as power switches.

Holding capacitor is used to reduce the duty cycle loss.


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ContdHuai Wang Qian Sun and Henry Shu Hung Chung, A ZCS

Current-Fed Full-Bridge PWM Converter With Self-Adaptable

Soft-Switching Snubber Energy IEEE TRANSACTIONS ONPOWER ELECTRONICS, VOL. 24, NO. 8, AUGUST 2009

The structure utilizes a simple snubber formed by two unidirectional

switches and a capacitor to realize soft switching operation over a wide line

and load range.

All primary side switches are operated with zero-current switching (ZCS)

and the snubber switches are operated with zero-voltage switching.

The energy used for soft-switching is self-adaptable.

Thus, less resonant energy is used and the conduction loss can be kept

minimal.


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ContdFuxin Liu, Jiajia Yan, and Xinbo Ruan Zero-Voltage

and Zero-Current-Switching PWM Combined Three-Level DC/DC Converter IEEE TRANSACTIONS ONINDUSTRIAL ELECTRONICS, VOL. 57, NO. 5, MAY 2010

Here the converter is half bridge so all power switchessuffer only half of the input voltage.

For applications like railway power supply systems or shipelectric power distribution systems, the input voltage is not

only very high but also variable in a wide range so largeinductor is provided in o/p

The output filter inductance and the voltage stress onrectifier diodes are reduced so dynamic response of systemis good.


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ContdEhsan Adib, and Hosein Farzanehfard, Zero-

Voltage Transition Current-Fed Full-Bridge PWMConverter IEEE TRANSACTIONS ON POWERELECTRONICS, VOL. 24, NO. 4, APRIL 2009 .

In order to achieve high-density power conversion,high switching frequency is essential in dcdcconverters.

The snubber capacitor is placed at the primary side,

and thus limits the voltage spikes caused by thetransformer leakage inductance

The auxiliary circuit is in parallel with the mainswitches, so this provides ZVS condition for the mainswitches.


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Problem statement

In all Pulse Width Modulated DC-DC and DC-AC

converters the controllable switches are operated in a

switched mode.

The need for full bridge converter is, all other DC-DCconverter are unidirectional whereas Full Bridge (FB) is

bidirectional

The transformer will be added to provide desired output

voltage of desired magnitude as well as electrical isolation

between input and output


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Contd

By connecting a switched capacitor snubber in parallel with

the primary winding of the coupling transformer, all main

switches are zero-current-switched (ZCS) and the switches in

the snubber are zero-voltage-switched (ZVS).

The proposed converter has the following key features

1. Transformer leakage inductance

2. Snubber capacitor

3. No extra voltage stress on the switches


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SOFT SWITCHING TECHNIQUES.

Advances in power electronics in the last few decades haveled not only to improvements in power devices, but also tonew concepts in converter topologies and control.

Power switches have to cut off the load current within theturn-on and turn-off times under the hard switchingconditions.

During the turn-on and turn-off processes, the power devicehas to withstand high voltage and current simultaneously,which results in high switching losses and stress.


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Contd Snubbers are usually added to the power circuits so that the

dv/dt and di/dt of the power devices can be reduced.

Soft switching PWM converters can be classified as follows:

1 ZVS PWM converters2 ZCS PWM converters

In the 1980s much research was focused on the use ofresonant converters

The concept was to incorporate resonant tanks in theconverters


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Contd These soft-switched converters have switching waveforms

similar to those of conventional PWM converters except thatthe rising and falling edges of the waveforms are smoothed.

Hard Switching wave forms.


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Contd By including capacitor and inductor to limit the rate of rise of

voltage and current across the switch, we can reduce thestress on the switches.

Zv/Zc switching loci

ZVS is preferred more for its simple CKT topology.


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Contd But the normal ZVS full-bridge PWM converter present some

disadvantages.

1. The circular current of the primary in the freewheeling periodincreases the conduction loss.

2. The need of high energy storing in the leakage inductance toachieve ZVS lead to effective duty cycle loss.

Due to this reason ZVS is not suitable for high power

applications in which IGBTs have to be used as powerswitches.


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Comparison between ZVS and ZCS


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BLOCK DIAGRAM


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Contd

REGULATED DC POWER SUPPLY.

1. 10v ~ 30v DC supply as the input for the converter.2. +12v is for the driver circuit of 6 controllable switches.

3. +5V for the microcontroller

ZCS FULL BRIDGE INVERTER UNIT.

DC input voltage is converted to AC in order to increase the

efficiency of the converter.

Each IGBT used in inverter acts as a switch without anyswitching losses and facilitates the operation of the converter


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ZVSSNUBBER CIRCUIT. We have used MOSFETs in the snubber circuit

Reduce voltage or current spikes

Limit di/dt or dv/dt

Shape the load line to keep it within the SOA Reduce total loss due to switching

Isolation transformer.

This is used to isolate output from the input variations ifany and also the input from the load variations


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DIODE RECTIFIER UNIT

In bridge rectifier the diodes may be of variable types butfor our application we need power diodes with fastrecovery time.

Here there are two diodes in each leg. To reduce ripplesthe DC link capacitor filter Co is used. The supply to therectifier is given from secondary part of the transformer.


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The control unit here is microcontroller AT89S52

The microcontroller is operated at 24 MHz crystal frequency.

8K Bytes of Flash Memory,

4.0V to 5.5V Operating Range,

256 x 8-bit internal RAM, 32 programmable I/O lines,

Three 16-bit timer/counters,

Eight interrupt sources,

full duplex UART serial channel,

interrupt recovery from power-down mode, watchdog timer,power-off Flag

CONTROL UNIT.


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DRIVER UNIT

Driver unit will receive gate pulses from microcontroller.

In this project an optocoupler IC MCT2E is used to isolate the

gate drive circuit and the switches

It is required because microcontroller and switches

cannot be connected directly since both works at

different voltage levels.


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Circuit Diagram and its Working


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The front-stage DC/AC converter formed by the

switches S1S4, D1D4, and an output-stage rectifierformed by DADD. D1S1 D4S4 form fourunidirectional switches for achieving ZCS. The twostages are interconnected by a coupling transformerTrwith the turns ratio n: 1 leakage inductance Llk,and parasitic capacitance Cp

A snubber formed by a resonant inductor Lrand a

switched capacitor circuit consisting of twoMOSFETs, Sa1 and Sa2, and a resonant capacitor Crisconnected across the primary side of the couplingtransformer.

Contd


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Timing Diagram


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Contd

It is assumed that the resistance of each conductingsemiconductor switch is zero, whereas the resistance of eachnon-conducting switch is infinite.

In the timing diagram vp is the voltage across the primaryside of the transformer, Vout is the output voltage, vCr is thevoltage across Cr , iLr is the resonant inductor current, ilk isthe leakage inductor current, isis the output current ofTr, Vx

is the minimum required voltage for making the mainswitches switch at zero current, and vSa1 and vSa2 are thevoltages across Sa1 and Sa2 , respectively.


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Contd

From the timing diagram we can see there are 12operating modes from t0 to t12 in one switching periodTs. However, as the operation is symmetrical in every

one half of the switching cycle, so the operation fromt0 to t6 is described.


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Mode 0 [Before t0]

As we can see in this mode S1 and S4 are on so the energy is

transferred from the input to the output via L1, S1 , S4 , Tr, DB, and DC. Here we have to assume initial conditions like therewill be charge in the capacitor Cr

M d 1 [t t ]


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Mode 1 [t0t1]At t0, S3 is turned on with zero current because previously

there was no current flowing through it.

Then, Lrand Llkin the current path assure a soft increase incurrent


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contd

A resonance path is formed by Lr, Llk and outputcapacitance ofSa1 , CSa1

Thus, the current through S4, i

S4, decreases while the

current through S3 , iS3 , increases.

The variable iS4, which is equal to iLr, decreases until itreaches zero. S4 is turned off with zero current. This

mode ends at t1.


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Mode 2 [t1t2] L1 undergoes charging. Thus, this mode ends when S2 and Sa2

are switched on for regulating the output voltage as shown intiming diagram.


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Mode 3 [t2t3] S

2is turned on with zero current and S

a2is turned on with

zero voltage. A resonant path formed byS2 , Lr, Sa1 , Cr, Sa2 ,and S1 is created


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Mode 4 [t3t4] Crundergoes constant current discharging and then charging

byIin, so that its voltage is reversed, i.e., from Vxto Vx. Thismode ends at t4 when the voltage on Crreaches Vx. Sa2 isswitched off at zero voltage.


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Mode 5 [t4t5]

The junction capacitance ofSa2 is charged up linearly byIinuntil vSa2 (t5) = nVout Vx.


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Mode 6 [t5t6] When the terminal voltage across the primary side ofTrreaches

nVout .

This completes the operation in one half of the switching period

It can be noted that all switches in the converter are soft-switched

Of particular importance, no extra voltage and current stressesare imposed on the switches


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DESIGN AND DEVELOPMENT OF

HARDWAREA prototype is built with the following specifications

1. Input voltage, Vin : 30V

2. Output voltage , Vout : 90V

3. Input current, Iin : 2.5A

4. Transformer turns ratio: 1:4


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Value of Lr To achieve ZCS for the leading switches, switches should

have sufficient dead time. In order to assure that theleading switches can complete the current transfer process

within t01, the maximum value ofLr, Lr(max) is .

Where t01 is time taken duration of first mode to chargeinput inductor that is taken as 0.14H. We will assumeLlk=8.6H.by putting all the values we get

Lr(max)=11.56H


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Value of Cr In order to get soft switching the resonant capacitor will pay a

vital role. We have following formula for resonant capacitor

Substituting all the values in above equation where Lr=11.56H, Iin=2.5, n=4, Vout=90v we can get


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Selection of IGBT. The selection of IGBT is done on the basis of minimum

voltage required for switching in Zero CurrentTransition.

So we have

Where Vx is the minimum voltage across the switch forZCS action. Simplifying above equitation we get

So we have chosen IRG4BC20S which has max VCES of 600v

VGE = 15Vwhich will satisfy our required ratings

S l i f MOSFET


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Selection of MOSFET The selection of MOSFET is done on the basis of minimum

voltage required for switching in Zero Voltage Transition. Sowe have same formula as the selection of IGBT.

so we have chosen IRF840 which has VDSS of 500v which willsatisfy our required ratings

S l i f P Di d


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Selection of Power Diodes.

We have used power diodes in rectifier part where these

diodes are designed to have a very short reverse-recoverytime trr and are typically used in high-frequencyapplications.

The diodes must be able to handle the peak voltage inreverse direction (PIV).

We know that

So in this project MRU820 is used because it canwithstand up to 200V which will satisfy our required

ratings


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DESIGN OF CONTROL CIRCUIT

USING AT89S52 The AT89S52 is a low-voltage, high-performance

CMOS 8-bit microcomputer

8K Bytes of Flash Memory, 4.0V to 5.5V OperatingRange, 256 x 8-bit internal RAM, 32 programmableI/O lines, three 16-bit timer/counters, eight interruptsources, full duplex UART serial channel, interrupt

recovery from power-down mode, watchdog timer,dual data pointer, power-off Flag


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Detailed pin diagram

VCC

VCC

VCC

P2_0

P2_1P2_2P2_3

P1_7

P1_6

P1_1P1_0

P1_3P1_2

P1_5P1_4

P3_7

P3_5P3_6

P0_1P0_2

P0_0

P0_3P0_4

P0_7

P0_5P0_6

R38K2

C5

10uF

U2

AT89S51

918

19

20

293031

40

1234567

8

2122232425262728

1011121314151617

39383736353433

32

RST

XTAL2XTAL1

GND

PSENALE/PROG

EA/VPP

VCCP1.0

P1.1P1.2P1.3P1.4P1.5

P1.6P1.7

P2.0/A8

P2.1/A9P2.2/A10P2.3/A11P2.4/A12P2.5/A13P2.6/A14P2.7/A15

P3.0/RXDP3.1/TXDP3.2/IN TOP3.3/IN T1P3.4/TOP3.5/T1P3.6/WRP3.7/RD

P0.0/AD0P0.1/AD1P0.2/AD2P0.3/AD3P0.4/AD4P0.5/AD5

P0.6/AD6P0.7/AD7

X111.0592MHz

C733PF

C6

33PF

C

R2

SIP 9 1k

12345678

9

C4 0.1uF

SW0

RST


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Contd

FEATURES of W10M Low cost

High forward surge current capability

Ideal for printed circuit board

High temperature soldering guaranteed:2600C /10

second, 0.375(9.5mm) lead length. Its maximum rms voltage capacity is 700v and

maximum DC blocking voltage is 1000v.

Pi d


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Pins used Supply to the controller is given to the pin number 40 from

the step-down transformer followed by power regulator ICproviding 5v and rectifier.

The code is loaded to microcontroller using pins 5,6,7 and8 . We have connected reset switch to pin number 9,

crystal oscillator is connected between pin number 18 and19 for generating clock frequency. Pin numbers 32 to 39 arethe 8 PWM output channels in which we have used 6PWM output channels which are connected to the gate

drive circuit.

DESIGN OF DC REGULATED


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DESIGN OF DC REGULATED

POWER SUPPLY

Regulated output Isolation

Multiple outputs

Here W10M diode rectifier IC


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Heat Sinks The main power loss in power electronic circuits occurs

in power semiconductor devices The resulting heat hasto be removed from the components and eventuallytransferred to the atmosphere/ambient surroundings.

Power semiconductors have a maximum junctiontemperature rating beyond which the devices fail tooperate

As a result lifetime reduces with increase in temperature.

So we have used heat sinks for IGBT switches in ourhardware.

SIMULATION MODEL


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SIMULATION MODEL

Gate pulses applied to all the six


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Gate pulses applied to all the six

switches


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ZCS scheme involved in IGBTs


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ZVS across MOSFETs


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DC output across scope at an input

of 10v

EXPERIMENTAL SETUP AND ITS


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EXPERIMENTAL SETUP AND ITS

RESULTS The developed ZCS full bridge converter hardware is tested in

power electronics laboratory for different input voltage andload conditions

The input voltage to the ZCS full bridge converter is variedfrom 10v to 30v and corresponding output voltage is observedfor no load and full load conditions

xper men a resu s or var a e


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xper men a resu s or var a einput voltage and load conditions

Input voltage Output voltage

Without load

Output voltage

With load

Voltage

regulation

10 60 30 1

15 72 35 1.05

20 80 40 1

25 83 40 1.075

30 85 46 0.84


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Characteristics of input to output voltage at

no load and full load conditions


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ZCS and ZVS waveforms at an input

of 10V


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of 20V


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of 30V

ADVANTAGES AND APPLICATIONS


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G S C O S

ADVANTAGES

1. Transformer leakage inductance is utilized as a partof the resonant circuit for the soft-switching actions

2. Due to the snubber capacitor less resonant energy is

circulated.3. There is no extra voltage stress on the switches and

the current through the switches is limited

4. As a result ZCS for a very large range of the line

voltage and load is obtained


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Contd APPLICATIONS

1. They are widely used fuel-cell converters where low inputvoltage or high output voltage is required

2. FB converters are used in distributed power systems where

voltage boost and efficiency are key issues3. These are widely used in different type of electronic

equipments such as industrial and medical X-ray imaging

4. They are also used in traveling wave tube and RF(Radio

Frequency) generation5. DC to AC conversion in uninterruptable AC power supplies

and also switched mode isolation transformer DC powersupplies


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Contd

6. It is used it motor control in automobiles, trolley cars,marine hoists.

7. In some applications such as railway power supply

systems or ship electronic power distribution systemsthe input voltage not only very high but also variable inwide range where they will use these converters


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Conclusion

The developed current-driven zero current switched(ZCS) full bridge converter is tested in power electronicslaboratory.

From the waveforms we can see that using a simple

snubber, ZCS of the inverter switches can be achieved ina wide input and load range and also ZVS of the auxiliaryswitches is taking place in snubber

As a result less resonant energy is circulated.As a result the stress on the switches can be reduced,

which will help in increasing the life of the switches

REFERENCES


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[1] Y. Jang and M. Jovanovic, A new PWM ZVS full-bridge converter, IEEE Trans. Power Electron., vol.22, no. 3, pp. 987994, May 2007.

[2] Khalil Rahimi, Ali Nazeran Motlagh, Majid Pakdel A Novel Soft-Switched Synchronous BuckConverter IEEE TRANSACTION 2009.

[3]TingTing Song and Nianci Huang A Novel Zero-Voltage and Zero-Current-Switching Full-Bridge PWMConverter IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 20, NO. 2, MARCH 2005.

[4] Huai Wang, Qian Sun, Henry Shu Hung Chung, , Saad Tapuchi, and Adrian Ioinovici, A ZCS Current-Fed Full-Bridge PWM Converter With Self-Adaptable Soft-Switching Snubber Energy IEEETRANSACTIONS ON POWER ELECTRONICS, VOL. 24, NO. 8, AUGUST 2009 1977.

[5] Chris Ianello,Shiguo Luo Full Bridge ZCS PWM Converter For High Voltage And High PowerApplicationsIEEE TRANSACTIONS On Aerospace And electronic systems VOL 38,NO.2 APRIL 2002

[6] Ehsan Adib and Hosein Farzanehfard, Zero-Voltage Transition Current-Fed Full-Bridge PWMConverter IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 24, NO. 4, APRIL 2009

[7] Wu Chen, Xinbo Ruan , Junji Ge A Novel Full-Bridge Converter Achieving ZVS over Wide load Rangewith a Passive Auxiliary Circuit IEEE TRANSACTIONS ON POWER ELECTRONICS, 2010.

[8] Deepak Kumar Nayak and S.Rama Reddy Simulation of Soft Switched Pwm Zvs Full Bridge ConverterInternational Journal of Computer and Electrical Engineering, Vol. 2, No. 3, June, 2010.

[9] J M. Zhang X.G Xie X.K. Wu Zhaoming Qian A Novel Zero-Current-Transition Full Bridge DC-DCConverter0-7803-8975-1/05/$20.00 8200.5 IEEE.

REFERENCES


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Snubber IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 25, NO. 7, JULY 2010.

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[13] Dakshina Murthy Bellur and Marian K. Kazimierczuk REVIEW OF ZERO-CURRENT SWITCHING FLYBACK PWM DC-DC

CONVERTERS Wright State University.

[14] J M. Zhang X.G Xie X.K. Wu Zhaoming Qian A Novel Zero-Current-Transition Full Bridge DC-DC Converter 7803-8975-1/05/$20.00

8200.5 IEEE.

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Converter IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 52, NO. 1, FEBRUARY 2005.

[16] M. Marx Student Member,IEEE D. Schroder Senior Member, IEEE A NOVEL ZERO-CURRENT-TRANSITION FULL-BRIDGE DC-DCCONVERTER Institute of Electrical Drives, Technical University of Munich. 1996 IEEE

[17] Pinghua Tang, Guijie Yang, Tiecai Li, Yajing Liu A Novel FB ZVS PWM DC-DC Converter Based on Digital Control Department of

Electrical Engineering Harbin Institute of Technology

Harbin 150001,China 2006 IEEE

[18] Bin Su and Zhengyu Lu An Improved Single-Stage Power Factor Correction Converter Based On Current-Fed Full- Bridge Topology

2008 IEEE.

References


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References[19]S.A. Elankurisil,. and Dr. S.S. Dash Digital simulation of closed loop control of bi-directional DC - DC converter S.A.

Elankurisil et al. / International Journal of Engineering Science and Technology (IJEST) Vol. 3 No. 2 Feb 2011.

[20] Soon-Kurl Kwon, Bishwajit Saha, Sang-Pil Mun, Kazunori Nishimura and Mutsuo Nakaoka, Series Resonant ZCS-PFM DC-DC Converter using High Frequency Transformer Parasitic Inductive Components and Lossless InductiveSnubber for High Power Microwave Generator Journal of Power Electronics, Vol. 9, No. 1, January 2009

[21] Xin Zhang, Henry Shu-hung Chung, Xinbo Ruan, and Adrian Ioinovici,A ZCS Full-Bridge Converter Without VoltageOverstress on the Switches IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 25, NO. 3, MARCH 2010.

[22] Stanislaw Jalbrzykowski and Tadeusz Citko, Senior Member, IEEE Current-Fed Resonant Full-Bridge BoostDC/AC/DC Converter IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 55, NO. 3, MARCH 2008.

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[25] MUHAMMAD.H.Rashid Ph.D., Fellow IEE, Fellow IEEE Professor and Director, 3

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A ZCS Full-Bridge Converter Without Voltage

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