a zcs full-bridge converter without voltage
TRANSCRIPT
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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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ZCS and ZVS waveforms at an input
of 20V
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ZCS and ZVS waveforms at an input
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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REFERENCES[10] Tsai-Fu Wu, Yung-Chu Chen, Jeng-Gung Yang, and Chia-Ling Kuo Isolated Bidirectional Full-Bridge DCDC Converter With a Flyback
Snubber IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 25, NO. 7, JULY 2010.
[11] Chris Iannello,Shiguo Luo, Issa Batarseh Full Bridge ZCS PWM Converter for High-Voltage High-Power Applications IEEE
TRANSACTIONS ON AEROSPASE AND ELECTRONIC SYSTEMS VOL. 38, NO. 1,APRIL 2002.
[12] Jung-Goo Cho,Ju-Won Baek, Chang-Yong Jeong, and Geun-Hie Rim, Novel Zero-Voltage and Zero-Current-Switching Full-Bridge PWM
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