This paper introduces a high-frequency soft-switching pulse-width modulation DC-DC power converter with secondary active rectifier tested as a DC current source for arc welding applications. The soft-switching DC-DC converter consists of a high-frequency full-bridge inverter, high-frequency power transformer, and a controlled output rectifier with new secondary energy recovery turn-off snubber. Circulating currents in the converter are reduced by using active rectifier, and RMS values of the currents in primary and secondary switches are decreased by utilizing a novel control algorithm. The experimental results of a 4.5 kW DC-DC converter working at switching frequency of 100 kHz are presented.

High-Frequency Soft-Switching PWM DC-DC Converter with Active Output Rectifier Operating as a Current Source for Arc Welding Applications

This paper describes a high-frequency soft-switching dc-dc converter with a simple energy recovery capacitor snubber on the secondary side. The presented dc-dc full-bridge converter with the energy recovery snubber removes the main drawbacks of the classic Phase Shifted PWM (PS-PWM) dc-dc converter, e.g., the circulating current flowing during the free-wheeling interval and dependency of the soft switching on the load current. The converter utilizes a full-bridge topology with pulse-width modulation and a centre-tapped full-wave controlled rectifier with one active switch. The zero-voltage switching on the primary side is ensured by utilising only the magnetizing current of the high-frequency transformer, and thus is load-independent. The proposed energy recovery snubber is described in detailed time waveforms of the converter and verified by simulation. The control algorithm also removes the circulating current, which is typical for PS-PWM converters. The soft-switching of the secondary side transistor is achieved by a simple capacitor snubber with an energy-recovery circuit connected to the output of the dc-dc converter. The principle of operation is verified by measurements on a 2 kW, 50 kHz laboratory model of the proposed dc-dc converter.

/pdf/soft-switching-full-bridge-dc-dc-converter-with-energy-39tgn64n.pdf

Soft-Switching Full-Bridge DC-DC Converter with Energy Recovery Capacitor Snubber

In order to enable a switching process with a zero-voltage sequence (ZVS) in a full bridge DC/DC converter ( 1 ) with phase shift control without having to provide an additional inductor for this purpose, it is provided that a short-circuit is generated in the secondary-side output rectifier ( 5 ) in the transition phase from the active to the passive phase prior to switching to a passive phase of the full bridge ( 2 ), said short-cut increasing the primary current (i p ) across the primary side of the transformer (T) by means of the resulting short-circuit current (i k ) across the secondary side of the transformer.

Method for controlling a full-bridge dc-dc converter

This paper proposes a novel, reliable, efficient and cost-effective implementation of partial soft switching in a silicon carbide (SiC)-based variable-frequency phase-modulated resonant transition converter (PMRTC) used in manual metal arc welding (MMAW) applications at a peak power of 1.3 kW. The switching frequency (
 $$f_{sw}$$
 ) of the converter is increased from 100 kHz at no load to around 150 kHz for a rated power of 1.0 kW. Such an approach is not found in the existing literature. At such frequencies, a significant proportion of the output filter inductance is contributed by the inherent self-inductance of the output “lead cables”. The switching losses in the semiconductor devices are reduced at no-load condition by reduction of the operating frequency. Load regulation is achieved at 150 kHz by implementing phase-shifted PWM technique. Implementation of partial soft switching without using additional components is another significant contribution of this work. The reduced size and weight of the filter inductor in turn reduces the overall size, weight and cost of the system but puts a restriction on the output lead cable length, which is another salient finding of this work. Since at high frequency the transformer model changes, design and finite-element method (FEM)-based simulation of the transformer are also presented in this paper. Loss calculations at 100 and 150 kHz are discussed. The entire converter is fabricated in the laboratory. Experimental and simulated results are found to be in excellent agreement.

Design, analysis and experimental validation of a variable frequency silicon carbide-based resonant-converter for welding applications

The paper presents the design of a PI digital controller used to control the output voltage of a switched mode DC-DC buck converter. The digital controller is implemented with the help of an 8 bit microcontroller. To derive the control law of the PI controller, the switched mode DC-DC converter is modeled as a linear system using the state variables averaging technique. The authors also present the simulation and experiments results related to the theoretical aspects mentioned in the paper.

Digital control for switched mode DC-DC buck converters

A full-bridge PWM DC/DC converter with controlled output rectifier is presented in this paper. Soft switching for all power switches is achieved by using controlled output rectifier with new lossless energy recovery turn-off snubber on the secondary side of the converter. No circulating current is occurred in the proposed converter with used new control method. The principle of operation is explained and analyzed and the experimental results on a 1.2kW, 50 kHz laboratory model of the converter are presented.

Zero-voltage and zero-current switching DC-DC converter with controlled output rectifier

A novel full-bridge PWM DC/DC converter with controlled secondary side rectifier using secondary snubber is presented in this paper. Circulating current of the converter was eliminated and soft switching for all power switches of the inverter is achieved for full load range from no-load to short circuit by using controlled rectifier and snubber on the secondary side. The principle of operation is explained and analyzed and the experimental results on a 4,5kW, 100 kHz laboratory model of the converter are presented.

Novel soft switching DC/DC converter with controlled output rectifier

A novel zerovoltage and zerocurrent switching (ZVZCS) fullbridge (FB) phase shifted pulsewidth modulation (PWM) converter is presented in this paper. A simple auxiliary circuit on the secondary side provides conditions for ZVZCS of insulated gate bipolar transistors (IGBTs) on the primary side of the DC/DC converter. The turning off the MOSFET transistor located on the secondary side provides reset both secondary and primary current and thus the conditions for ZVZCS is achieved. The features, principle operation and design considerations of the converter are illustrated and verified on proposed converter.

http://mechatronika.polsl.pl/owd/pdf2010/147.pdf

Novel Zero-Voltage and Zero-Current Switching Full-Bridge PWM Converter Using Simple Secondary Active Clamp Circuit

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Zero-voltage and zero-current switching DC-DC converter with controlled output rectifier

Novel soft switching DC/DC converter with controlled output rectifier

Novel Zero-Voltage and Zero-Current Switching Full-Bridge PWM Converter Using Simple Secondary Active Clamp Circuit