Zero-Voltage-Switching PWM Full-Bridge Converter Employing

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IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 25, NO. 5, MAY 2010
1149
Zero-Voltage-Switching PWM Full-Bridge Converter
Employing Auxiliary Transformer to Reset the
Clamping Diode Current
Wu Chen, Student Member, IEEE, Xinbo Ruan, Senior Member, IEEE, Qianghong Chen, Member, IEEE, and Junji Ge
Abstract—Introducing clamping diodes into the zero-voltageswitching (ZVS) pulsewidth-modulation (PWM) full-bridge (FB)
converters can eliminate the voltage oscillation across the output
rectifier diodes; however, the clamping diodes result in increase in
conduction loss and suffer from serious reverse recovery at light
load. In order to solve these problems, the clamping diode current
should be reset rapidly. This paper proposes a scheme of resetting
the clamping diode current over the full-load range by introducing
an auxiliary transformer into the ZVS PWM FB converter. The
operation principles of the proposed scheme under heavy-load and
light-load conditions are analyzed in details. The design considerations of the introduced auxiliary transformer are also given. A
performance comparison among the proposed scheme of resetting
the clamping diode current and other ones are addressed. Experimental results verify the effectiveness of the analysis and prove
that the proposed converter has improved reliability and reduced
conduction loss compared with the classical one.
Index Terms—Auxiliary transformer, clamping diodes, fullbridge (FB) converter, light load, zero-voltage-switching.
I. INTRODUCTION
ERO-voltage-switching (ZVS) pulsewidth modulation
(PWM) full-bridge (FB) converters have been widely
used in medium-to-high power applications because they feature the constant frequency operation and easy achievement of
ZVS for power switches with the use of the leakage inductor of the transformer and the intrinsic capacitors of the power
switches [1]–[11]. The major limitation of the ZVS PWM FB
converters is that the lagging switches will lose ZVS under lightload condition, since the energy stored in the leakage inductor
is insufficient to charge and discharge the switch intrinsic capacitors. An external resonant inductor is always added to be
in series with the primary side of the transformer to extend
the ZVS load range; however, the resonant inductor results in
high voltage ringing across the output rectifier diodes. In or-
Z
Manuscript received August 6, 2009; revised October 26, 2009. Current
version published May 7, 2010. This work was supported by the National Natural Science Foundation of China under Award 50837003. Recommended for
publication by Associate Editor M. Alonso.
W. Chen is with the Aero-Power Sci-Tech Center, College of Automation Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China
(e-mail: chenwu@nuaa.edu.cn).
X. Ruan is with the College of Electrical and Electronic Engineering,
Huazhong University of Science and Technology, Wuhan 430074, China
(e-mail: ruanxb@mail.hust.edu.cn).
Q. Chen and J. Ge are with the Aero-Power Sci-Tech Center, College of
Automation Engineering, Nanjing University of Aeronautics and Astronautics,
Nanjing 210016, China (e-mail: chenqh@nuaa.edu.cn; gejunji@nuaa.edu.cn).
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TPEL.2009.2038698
der to overcome this problem, Redl et al. [8]–[10] introduced
two clamping diodes into the primary side, clamping the voltage of the output rectifier diodes at the reflected input voltage
and the voltage ringing is eliminated, thus the output rectifier
diodes with lower voltage rating can be used, thus leading to
a potentially higher efficiency. In [10], the difference between
the two locations of the resonant inductor and the transformer
was analyzed and an optimal scheme, in which the transformer
is connected with the lagging leg, was first presented. Ruan
and Liu [11] also analyzed this issue in details and discussed
the effects of the blocking capacitor in different positions and
pointed out that the blocking capacitor should be in series with
the transformer, which is connected with the lagging leg.
When the FB converter transits from zero state (vA B = 0) to
active state (vA B = +Vin or − Vin ), the clamping diode conducts, and its initial current equals to the peak resonant current
that results by the resonance of the resonant inductor and the
parasitic capacitor of the output rectifier diode. The clamping
diode current decays with the increase of the output filter inductor current. The output filter inductor is always designed to
be very large to obtain a lower current ripple; therefore, the rise
rate of its current is very small, leading to a longer conduction
time of the clamping diodes, and thus relatively larger conduction loss occurs in the clamping diodes, resonant inductor, and
leading switches. In order to accelerate the decline rate of the
clamping diode current, a resistor or two back-to-back Zener
diodes can be added in series with the clamping diodes [10], but
there exists considerable loss in the resistor or Zener diodes. An
auxiliary winding of the main transformer was added in series
with the resonant inductor and it is lossless [12]. However, the
duty cycle is very small at light load, thus leading to an insufficient time for the auxiliary winding voltage to fully reset the
clamping diode current.
The analyses about the operation of the clamping diodes
in [8]–[12] are all under heavy-load condition. At light load,
especially at no load, the operation of the two clamping diodes
is very different from that under heavy-load condition; the two
clamping diodes keep conducting alternately for almost half
of the switching period, resulting in considerable conduction
loss; in the meanwhile, the clamping diodes may be hard to be
turned off with serious reverse recovery. Therefore, the clamping
diodes are easily damaged under light-load condition, especially
in high input voltage application [13]. In [14], a current transformer is introduced to be in series with the clamping diodes,
thus making the clamping diode current to decay rapidly over
the full-load range.
0885-8993/$26.00 © 2010 IEEE
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IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 25, NO. 5, MAY 2010
Fig. 1.
Classical ZVS PWM FB converter with clamping diodes.
Based on [14], this paper proposes an improved scheme of
resetting the clamping diode current rapidly for the ZVS PWM
FB converter by introducing an auxiliary transformer. The proposed scheme can shorten the clamping-diode conduction time
and fully reset the clamping diode current over the full-load
range, leading to reduced conduction loss, and the clamping
diodes turn-OFF naturally.
This paper is organized as follows. In Section II, the insight
into the operation of the clamping diodes in ZVS PWM FB converter under light-load condition is presented. In Section III, the
principle of resetting the clamping diode current is analyzed and
several current resetting schemes are discussed and compared.
In Section IV, an improved current resetting scheme is proposed by introducing an auxiliary transformer, which can reset
the clamping diode current effectively over full-load range, and
moreover, the excessive energy stored in the resonant inductor
is also regenerated to the input voltage source. The operation
principle of the ZVS PWM FB converter with the improved
current resetting scheme is presented. The design considerations of the improved current resetting scheme are discussed in
Section V. The experimental results are presented in Section VI
to verify the validity of the improved current resetting scheme.
Finally, Section VII concludes the paper.
II. INSIGHT INTO THE OPERATION OF THE CLAMPING
DIODES IN ZVS PWM FB CONVERTER
UNDER LIGHT-LOAD CONDITION
Fig. 1 shows the classical ZVS PWM FB converter with
clamping diodes, and the popular phase-shifted control is
adopted. Q1 and Q3 form the leading leg and Q2 and Q4 form
the lagging leg. Lr is the additional resonant inductor, D5 and
D6 are the clamping diodes, and DR 1 and DR 2 are the output rectifier diodes. Lf is the output filter inductor, Cf is the
output filter capacitor, and RL d is the load. The concrete operation principle of the converter depends on the load condition.
As stated earlier, under heavy-load condition, the decline rate
of the clamping diode current is small due to the relative large
output filter inductor; therefore, the clamping diodes conduct
for a long time, thus leading to conduction loss in the clamping diodes, resonant inductor, and the leading switches. The
operation principle of the converter under heavy load has been
intensively discussed in [8]–[12]; therefore, we will here emphasize on the operation principle of the converter under light
load.
To simplify the analysis, the following assumptions are made,
which are as follows:
1) all the switches and diodes are ideal, except for the output
rectifier diode, which is equivalent to an ideal diode and a
paralleled capacitor to simulate the reverse recovery, and
CD R 1 = CD R 2 = CD R ;
2) all the capacitors, inductors, and transformer are ideal;
3) Lf Lr /K 2 , where K is the turns ratio of the primary
and secondary windings of the main transformer.
The key waveforms of the FB converter with clamping diodes
under light-load condition are shown in Fig. 2 (there are two
cases depending on the load), where the details of switching
transitions are not shown explicitly because the intension is to
describe the operation principle of the resonant inductor and the
clamping diodes.
From Fig. 2, it can be seen that except for the operation during
[t1 , t3 ], the two cases almost have the same key waveforms.
Referring to Fig. 2, prior to t0 , Q1 , Q4 , and D5 conduct (the
reason why D5 conducts will be explained later), as shown in
Fig. 3(a), and the primary winding voltage of the transformer
vC B equals to Vin . DR 1 conducts and DR 2 is reversely biased,
and vrect equals to Vin /K, and the output filter inductor current
iL f and ip increase linearly. Lr is shorted by Q1 and D5 , and
its current iL r remains almost unchanged. The difference of iL r
and ip flows through D5 .
At t0 , Q1 is turned off, and Q3 is turned on with hard switching due to light load. As D5 and Q4 still conduct, iL f and ip
continue to increase linearly. vin is negatively applied on Lr , as
shown in Fig. 3(b), forcing iL r to decline linearly. At t1 , iL r
reduces to ip and D5 turns off.
After t1 , Lr resonates with CD R 2 and iL r decreases. The
equivalent circuit of this mode is shown in Fig. 3(c), and it
and iL f are the
is further simplified as Fig. 4(a), where CD
R
reflected CD R 2 and iL f to the primary side, respectively.
According to Fig. 3(c), we have
iD R 1 (t) + iC D R 2 (t) = iL f (t)
(1)
iD R 1 (t) − iC D R 2 (t) = Kip (t).
(2)
From (1) and (2), iD R 1 and iC D R 2 can be derived as
1
iL f (t) + Kip (t)
2
1
iL f (t) − Kip (t) .
iC D R 2 (t) =
2
iD R 1 (t) =
(3)
(4)
According to Fig. 4(a), ignoring the slight change of iL f , the
primary current and the voltage across CD R 2 can be expressed
as
ip (t) = iL r (t) =
2Vin
cos ω1 (t − t1 )
(6)
K
, and Z
= 4CD R K 2 , ω1 = 1
Lr CD
r1 =
R
vC D R 2 (t) =
where CD
R
Lr CD R .
IL f (t1 )
Vin
−
sin ω1 (t − t1 ) (5)
K
Zr 1
CHEN et al.: ZERO-VOLTAGE-SWITCHING PWM FULL-BRIDGE CONVERTER EMPLOYING AUXILIARY TRANSFORMER
Fig. 2.
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Key waveforms of the classical ZVS PWM FB converter with clamping diodes under light-load condition. (a) Case I. (b) Case II.
Substitution of (5) into (3) and (4), leads to
iD R 1 (t) = IL f (t1 ) −
iC D R 2 (t) =
KVin
sin ω1 (t − t1 )
2Zr 1
KVin
sin ω1 (t − t1 ).
2Zr 1
VC B (t1 ) =
(7)
(8)
According to (5) and (6), we can know that if IL f (t1 )/K ≥
Vin /Zr 1 , iL r is still positive when vC D R 2 reduces to zero. After
that, the converter will operate in freewheeling state. It can
be seen that there is no current flowing through the clamping
diodes, just like that under heavy-load condition, which is not
discussed here.
There are two possible cases that depends on the value of
IL f (t1 ) when IL f (t1 )/K < Vin /Zr 1 .
Case I: 0.5 Vin /Zr 1 ≤ IL f (t1 )/K < Vin /Zr 1 .
Referring to (5)–(7), if 0.5 Vin /Zr 1 ≤ IL f (t1 )/K < Vin /Zr 1 ,
when vC D R 2 reduces to zero at t2 , iL r and ip are negative, and
iD R 1 is still positive, so both the output rectifier diodes conduct,
as shown in Fig. 3(d). iL r is
IL r (t2 ) =
IL f (t1 )
Vin
−
.
K
Zr 1
(9)
After t2 , iL f decreases linearly and iL r and ip remain unchanged. At t2 , iL f decreases to −Kip and iD R 1 decreases to
zero correspondingly. Then, CD R 1 tends to be charged, and the
voltage of node C will be lower than zero, thus D6 conducts,
clamping the voltage of node C at zero. After t2 , both ip and
iL f decrease linearly, the difference of iL r and ip flows through
D6 , as shown in Fig. 3(e). At t3 , iL f decreases to zero, then
iL r freewheels through Q3 and D6 , Lf resonates with CD R 1
paralleling with CD R 2 , as shown in Fig. 3(f).
Case II: IL f (t1 )/K < 0.5Vin /Zr 1 .
Referring (5)–(7), if IL f (t1 )/K< 0.5 Vin /Zr 1 , when iD R 1
decreases to zero at t1 , CD R 2 is not fully discharged, and ip ,
iL r , and vC B are
IL r (t1 ) = Ip (t1 ) =
−IL f (t1 )
K
(10)
Vin2 −
2IL f (t1 )Zr 1
K
2
.
(11)
After t1 , DR 1 turns off and CD R 1 is charged, and CD R 2 is still
discharged. Lr resonates with CD R 1 and CD R 2 , thus leading to
the decrease of vrect and vC B . ip and iL r continue to increase in
the negative direction, as shown in Fig. 3(g), which can be further
, CD
, and iL f are the
simplified as Fig. 4(b), where CD
R1
R2
reflected CD R 1 , CD R 2 , and iLf to the primary side, respectively,
= CD
= 4CD R K 2 . ip , iL r , and vC B are given by
and CD
R1
R2
√
VC B (t )
iL r (t) = ip (t) = − √ 1 sin( 2ω1 (t − t1 ))
2Zr 1
√
IL (t1 )
− f
cos( 2ω1 (t − t1 ))
K
√
vC B (t) = VC B (t1 ) cos( 2ω1 (t − t1 ))
(12)
√
IL f (t1 ) √
2Zr 1 sin( 2ω1 (t − t1 )). (13)
K
When vC D R 2 reduces to be equal to vC D R 1 at t1 , both the
primary and secondary voltages of the transformer reduce to
zero, thus the voltage of node C reduces to zero and D6 conducts,
as shown in Fig. 3(h). CD R 1 and CD R 2 share iL f , leading to
decrease in vrect and keeping ip at zero. At t1 , iL r reaches its
peak value −IL r p and flows through Q3 and D6 . According to
(12) and (13), −IL r p can be expressed as
IL f (t1 ) 2
VC2 B (t1 )
−IL r p = IL r (t1 ) = −
+
. (14)
2Zr21
K
−
Substitution of (11) into (14), leads to
IL f (t1 ) 2
Vin2
IL r p =
−
.
2Zr21
K
(15)
After t1 , CD R 1 and CD R 2 share iL f , leading to decrease in
vrect and keeping ip at zero. The equivalent circuit of the mode
is shown in Fig. 3(h). At t2 , vrect reduces to zero and DR 1 and
DR 2 share iL f , as shown in Fig. 3(i). At t3 , iL f decreases to
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IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 25, NO. 5, MAY 2010
Fig. 3. Equivalent circuits of the classical FB converter under light-load condition. (a) Prior to t0 . (b) [t0 , t1 ]. (c) After t1 . (d) [t2 , t2 ] (case I). (e) [t2 , t3 ] (case
I). (f) [t3 , t4 ] (g) [t1 , t1 ] (case II). (h) [t1 , t2 ] (case II). (i) [t2 , t3 ] (case II). (j) [t4 , t5 ].
Fig. 4.
Further simplified equivalent circuits of Fig. 3(c), (g), and (j).
CHEN et al.: ZERO-VOLTAGE-SWITCHING PWM FULL-BRIDGE CONVERTER EMPLOYING AUXILIARY TRANSFORMER
Fig. 5.
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Possible clamping-diode current reset schemes.
zero, then iL r freewheels through Q3 and D6 , Lf resonates with
CD R 1 paralleling with CD R 2 , the equivalent circuit is the same
as Fig. 3(f).
It can be seen that no matter at case I or case II, the converter
passes by the same mode, as shown in Fig. 3(f).
According to (15), we know that the smaller IL f (t1 ) is, the
larger IL r p is. Assuming that IL f (t1 ) = 0, which means noload condition, we can get
IL r
p m ax
Vin
=√
.
2Zr 1
der heavy-load condition, and the critical current is IL f (t1 )
= KVin /Zr 1 . Under light-load condition, the primary current
will change its direction during zero state and the clamping
diode will conduct for almost half of the switching period. Besides the unavoidable serious reverse recovery of the clamping
diodes, the phenomenon also causes large conduction loss on
the clamping diodes and leading-leg switches. Therefore, it is
necessary to reset the clamping diode current to zero rapidly
over the full-load range.
(16)
Based on the critical condition of case I and (9), we can
get that the maximum value of |iL r | in case I is 0.5 Vin /Zr 1 .
Based on the critical condition of case II and (15), we can get
that the minimum and√maximum values of |iL r | in case II are
0.5Vin /Zr 1 and Vin /( 2Zr 1 ), respectively. From the aforementioned analysis, we can conclude that under light-load condition,
the resonant inductor current will change its direction and freewheels during zero state (vA B = 0), and the smaller the load
current is, the larger the resonant inductor current.
For both case I and case II, prior to t4 , D6 conducts and iL r
remains almost unchanged. At t4 , Q4 is turned off and Q2 is
turned on with hard switching, then CD R 1 is charged, vrect increases accordingly, ip also increases rapidly, forcing the clamping diode current iD 6 to decline acutely. The equivalent circuit
of the mode is shown in Fig. 3(j) and the further simplified
equivalent circuit is show in Fig. 4(c). In other words, if ignore
the leakage inductor of the transformer, all the input voltage
Vin is applied on D6 at t4 , forcing D6 to be hardly turned off.
Therefore, D6 suffers from serious reverse recovery and large
losses and it may be even destroyed.
At t5 , Vrect increases to Vin /K and the voltage of node C
reduce to zero. Then, ip declines downward to the reflected
filter inductor current and increases linearly almost from zero
due to the very short time interval of [t4 , t5 ]. iL r remains almost
unchanged and the difference of iL r and ip flows through D6
(this is the reason that why the clamping diode conducts during
active state (vA B = +Vin or − Vin ) under light-load condition).
It can be found that the longest conduction time for the clamping
diode is nearly half of the switching period in this case.
From aforementioned analysis, it can be seen that the operation principle of the FB converter with clamping diodes under light-load condition is remarkably different from that un-
III. CLAMPING DIODE CURRENT RESETTING SCHEME
IN FB CONVERTER
As discussed in Section II, the decline rate of the clamping
diode current depends on the rise rate of the output filter inductor current. The output filter inductor is always intentionally
reduced to increase the decline rate of the clamping diode current, resulting in larger current ripple across the output filter
inductor. In order to reset the clamping diode current rapidly, a
reset voltage source can be brought into the current loop, and
it can be connected in series with the resonant inductor or the
clamping diodes.
Fig. 5(a) shows that the reset voltage source vreset is connected in series with the resonant inductor. The polarity of vreset
must comply with the direction of the resonant inductor current
iL r , i.e., when iL r is positive, vreset should be positive; and
when iL r is negative, vreset should be negative. Such vreset can
be implemented by a transformer reset winding [12]. The voltage polarity of the reset winding complies with the primary
winding voltage of the transformer, as well as the resonant inductor current, and it can effectively reset the clamping diode
current. However, the reset winding voltage is directly linked
to the primary duty cycle, and it will lose its function when the
primary duty cycle is relatively small.
Fig. 5(b) shows that two independent reset voltage sources
are connected in series with the clamping diodes, respectively,
where each reset voltage source is unipolar because the clamping
diode current is unidirectional. Practically, the two reset voltage
sources can be implemented by a resistor or a Zener diode.
The voltage drop on the resistor or Zener diode plays the role
of the reset voltage source when the clamping diode current
flows through them. However, the excessive energy stored in
the resonant inductor is dissipated in the resistor or Zener diode,
leading to a reduced efficiency.
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Fig. 6.
IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 25, NO. 5, MAY 2010
ZVS PWM FB converter with auxiliary transformer.
The two independent reset voltage sources, shown in
Fig. 5(b), can be replaced by a single reset voltage source because they do not work at the same time, as shown in Fig. 5(c).
Similar to Fig. 5(a), the polarity of the reset voltage source
shown in Fig. 5(c) must also comply with the direction of the
current flowing through it. Two concrete cases for Fig. 5(c) are
presented in [10], where a resistor or two back-to-back Zener
diodes are adopted as the reset voltage source. However, all the
excessive energy stored in the resonant inductor will be dissipated in the resistor or Zener diodes. In our previous work [14],
a current transformer is introduced to the FB converter as the
reset voltage source.
Based on [14], an improved scheme of resetting the clamping diode current to zero is proposed for the ZVS PWM FB
converter with an auxiliary circuit consisting of only one auxiliary transformer and two diodes, which is simpler than the
current transformer proposed in [14]. The improved scheme can
shorten the clamping-diode conduction time over the full-load
range, leading to natural turn-OFF of the clamping diodes, and
meanwhile, the excessive energy stored in the resonant inductor
is delivered to the input voltage source, thus a potentially high
efficiency is expected.
IV. OPERATION PRINCIPLE OF THE ZVS PWM FB CONVERTER
WITH AUXILIARY TRANSFORMER
The proposed ZVS PWM FB converter with auxiliary transformer is shown in Fig. 6. The primary winding of the auxiliary
transformer Ta is inserted between nodes C and D, where node
C is the connecting point of the primary winding of the main
transformer and Lr , and node D is the connecting point of D5
and D6 . The secondary winding of the auxiliary transformer is
inserted between nodes D and E, where node E is the connecting
point of the introduced auxiliary diodes Da1 and Da2 . The turns
ratio of the auxiliary transformer is kat = n1 /n2 . The location
of Lr and Tr in Fig. 6 can also be exchanged; however, the
scheme shown in Fig. 6, where Tr connecting with the lagging
leg, is an optimal one, as discussed in [10] and [11].
A. Operation Principle Under Heavy-Load Condition
Fig. 7 gives the key waveforms of the ZVS PWM FB converter with auxiliary transformer operating under heavy-load
condition. The equivalent circuits of each switching modes in a
half period are shown in Fig. 8. The second half period is similar
to the first half period.
Fig. 7. Key waveforms of the FB converter with auxiliary transformer under
heavy-load condition.
Mode 1 [t0 , t1 ] [see Fig. 8(a)]: Prior to t0 , the power is transferred from the input voltage source Vin to the load. At t0 ,
Q1 is turned off with zero voltage, due to C1 and C3 , which
limit the rise rate of the voltage across Q1 . iL r charges C1
and discharges C3 , and the potential voltage of point A decays. In the meanwhile, the capacitor CD R 2 is discharged. As
the potential voltage of point C is greater than zero, D6 is
reverse biased. The voltage of C3 decreases to zero at t1 and
D3 conducts naturally.
Mode 2 [t1 , t2 ] [see Fig. 8(b)]: At t1 , Q3 can be turned on
with zero voltage. CD R 2 continues to be discharged. iL r and
ip continue decaying. This mode finishes when the voltage of
point C reduce to zero.
Mode 3 [t2 , t3 ] [see Fig. 8(c)]: During this mode, iL r is equal
to ip , and the converter operates in freewheeling state.
Mode 4 [t3 , t4 ] [see Fig. 8(d)]: At t3 , Q4 is turned off with
zero voltage due to C2 and C4 , which limit the rise rate of
the voltage across Q4 . C4 is charged and C2 is discharged in
a resonant manner.
Mode 5 [t4 , t6 ] [see Fig. 8(e)]: At t4 , C2 is fully discharged,
and D2 conducts naturally, thus Q2 can be turned on with zero
voltage. iL r is equal to ip , and both of them decay linearly
with the rate of Vin /Lr . At t5 , iL r and ip cross zero and
continue to increase linearly in the negative direction. The
load current flows through both the output rectifier diodes.
Mode 6 [t6 , t7 ] [see Fig. 8(f)]: At t6 , ip increases to the reflected current of iL f , and DR 1 turns off and DR 2 continues
conducting. Lr resonates with CD R 1 after t6 , and CD R 1 is
charged in a resonant manner, ip and iL r continue increasing,
and vrect increases. The voltage of the primary winding vB C
increases and the voltage of node C is reduced accordingly
because the voltage of node B is Vin . The further simplified
CHEN et al.: ZERO-VOLTAGE-SWITCHING PWM FULL-BRIDGE CONVERTER EMPLOYING AUXILIARY TRANSFORMER
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Fig. 8. Equivalent circuits of the FB converter with auxiliary transformer under heavy-load condition. (a) [t0 , t1 ]. (b) [t1 , t2 ]. (c) [t2 , t3 ]. (d) [t3 , t4 ]. (e) [t4 , t6 ].
(f) [t6 , t7 ]. (g) [t7 , t8 ]. (h) [t8 , t9 ].
Fig. 9.
Further equivalent circuits under heavy-load condition. (a) [t6 , t7 ]. (b) [t7 , t8 ].
equivalent circuit of this mode is shown in Fig. 9(a), where
CD
R , iL f are the reflected CD R 1 and iL f to the primary side,
respectively. vrect and ip are given by
Vin
vB C (t)
=
[1 − cos ω1 (t − t6 )]
(17)
K
K
IL (t6 )
Vin
sin ω1 (t − t6 ) + f
ip (t) = iL r (t) = −
.
Zr 1
K
vrect (t) =
(18)
Here, iL f is considered to be unchanged because the interval
of this mode is very short.
At t7 , vrect rises to (Vin + kat Vin )/K, and the primary voltage of the transformer vB C is Vin + kat Vin , the potential
voltage of node C reduces to −kat Vin , thus D6 conducts,
clamping vB C at Vin + kat Vin , and vrect is clamped at
(Vin + kat Vin )/K, accordingly, i.e.,
Vrect (t7 ) =
Vin
Vin + kat Vin
[1 − cos ω1 (t7 − t6 )] =
.
K
K
(19)
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Fig. 10.
IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 25, NO. 5, MAY 2010
Key waveforms of the FB converter with auxiliary transformer under light-load condition. (a) Case I. (b) Case II.
Combining (18) and (19), yields
IL f (t6 )
Vin
2
1 − kat +
IL r (t7 ) = −
.
Zr 1
K
(20)
Mode 7 [t7 , t8 ] [see Fig. 8(g)]: At t7 , as D6 conducts, ip declines downward to the reflected output filter inductor current
and increases in the negative direction. The clamping diode
current flows into the primary winding of the auxiliary transformer, and the reflected current flows through Da1 to Vin ,
and their current can be expressed as
iD 6 (t) = (1 + kat ) [|IL r (t7 )| − |ip (t)|]
iD a1 (t) = kat [|IL r (t7 )| − |ip (t)|] .
(21)
(22)
The induced voltage vC D equals to −kat Vin , which is applied
to Lr , forcing iL r to decrease quickly. |iL r | is greater than
|ip | before t8 , and the difference of iL r and ip flows through
D6 . The further simplified equivalent circuit of this stage is
shown in Fig. 9(b).
At t7 , iD 6 is
Vin
2 .
ID 6 (t7 ) = (1 + kat )
1 − kat
(23)
Zr 1
And, the decline rate of the resonant inductor current is
diL r
kat Vin
=
.
dt
Lr
(24)
Assume that the output filter inductor is infinite, thus the
decline rate of the resonant inductor current is the decline
rate of iD 6 . From (23) and (24), the conduction time of D6 is
t8 − t 7 =
Lr ID 6 (t7 )
ID 6 (t7 )
=
.
diL r /dt
kat Vin
(25)
Mode 8 [t8 , t9 ] [see Fig. 8(h)]: At t8 , iL r decays to ip and D6
and Da1 turn-OFF naturally. During this mode, Lr resonates
with CD R 1 . The rectified voltage vrect is given by
vrect (t) =
kat Vin
Vin
+
cos ω1 (t − t8 ).
K
K
(26)
Equation (26) illustrates that the maximum value of vrect
will never exceed (Vin + kat Vin )/K, though slight oscillation
exists. In practice, vrect will finally converge to the average
value Vin /K, since the inherent parasitic resistor exists in the
power stage, which will be presented in Section VI.
B. Operation Principle Under Light-Load Condition
The detailed operation principle of the proposed ZVS PWM
FB converter under light-load condition is relatively complex
compared with that under heavy-load condition, just like the
classical FB converter presented in Section II. Because the ZVS
PWM FB converter with auxiliary transformer has the same
operation states as that of the classical FB converter when the
clamping diodes are reversely biased, hence, only the states in
which the clamping diodes conduct will be discussed.
The key waveforms of the ZVS PWM FB converter with
auxiliary transformer under light-load condition are shown in
Fig. 10 (there are two cases depending on the load).
Case I: 0.5 Vin /Zr 1 ≤ IL f (t1 )/K < Vin /Zr 1 .
Referring to Fig. 10(a), prior to t2 , both the output rectifier
diodes conduct, iL f decreases linearly and iL r and ip remain
unchanged, the equivalent circuit is similar to Fig. 3(d). At t2 ,
iD R 1 decreases to zero and iL f only flows through DR 2 , and
iL f decreases to the reflected ip . Then, CD R 1 is charged, and
the voltage of node C is lower than zero. When the voltage
of node C reduces to −kat Vin , D6 conducts. iD 6 flows out of
the dot side of the primary winding of the auxiliary transformer.
Thus, the reflected current on the secondary side of the auxiliary
transformer flows into the dot side, forcing Da1 to conduct and
Da2 to block. The induced voltage vC D equals to −kat Vin , and
it forces iL r to decrease rapidly. The equivalent circuit is shown
in Fig. 11(a). At t3 , both iL f and ip decrease to zero, then Lf
resonates with CD R 1 paralleling with CD R 2 , D6 continues conducting, as shown in Fig. 11(b). The peak value of the clamping
diode current is approximate IL r p because the interval [t2 , t3 ]
is very short. D6 still conducts until t3 when iL r decreases to
zero.
CHEN et al.: ZERO-VOLTAGE-SWITCHING PWM FULL-BRIDGE CONVERTER EMPLOYING AUXILIARY TRANSFORMER
1157
Fig. 11. Equivalent circuits of the FB converter with auxiliary transformer under light-load condition. (a) [t2 , t3 ] (case I). (b) [t3 , t3 ] (case I). (c) [t4 , t5 ] (case
I). (d) [t5 , t6 ] (case I). (e) [t2 , t3 ] (case II).
At t4 , Q4 is turned off and Q2 is turned on with hard switching, then CD R 1 is charged, vrect increases accordingly, ip and
iL r also increase rapidly. The equivalent circuit of the mode is
shown in Fig. 11(c). Compared with the same mode of the classical FB converter shown in Fig. 3(j), it can be seen that D6 has
been turned off before this mode; therefore, no serious reverse
recovery occurs in the clamping diode in the FB converter with
auxiliary transformer.
At t5 , vrect rises to (Vin + kat Vin )/K, and the potential voltage of node C reduces to −kat Vin , thus D6 conducts. iL r will
reduces to ip rapidly. The equivalent circuit of the mode is shown
in Fig. 11(d). The other modes are similar to the classical FB
converter.
Case II: IL f (t1 )/K < 0.5 Vin /Zr 1 .
Referring to Fig. 10(b), If IL f (t1 )/K < 0.5Vin /Zr 1 , iD R 1
will decrease to zero earlier than vC D R 2 at t1 , then Lr resonates
with the CD R 1 and CD R 2 , leading to the decrease of vrect and
vC B , as shown in Fig. 4(b). Then, the voltage of node C reduces
to zero and iL r reaches its peak value −IL r p at a given time t2 ,
when the voltage of node C reduces to −kat Vin , D6 will conduct.
The peak value of the clamping diode current is approximate
IL r p because kat Vin is relatively smaller than Vin . iD 6 flows
out of the dot side of the primary winding of the auxiliary
transformer. Thus, the reflected current on the secondary side of
the auxiliary transformer flows into the dot side, forcing Da1 to
conduct and Da2 to block. The induced voltage vC D equals to
−kat Vin , and it forces iL r to decrease rapidly. Since the primary
winding voltage of Tr is clamped by the auxiliary transformer
and D6 , CD R 1 and CD R 2 share the current of Lf , leading to the
decrease in vrect and keeping ip at zero. The equivalent circuit
of the mode is shown in Fig. 11(e). vrect is given by
kat Vin
kat Vin
>
(27)
K
K
2vC B (t)
vC D R 2 (t) − vC D R 1 (t) =
< 0.
(28)
K
Therefore, vC D R 2 will be first discharged to zero. At t3 , vC D R 2
equals to zero, thus DR 2 conducts. Then, iL f decreases linearly.
If iL f decreases to zero before t5 , Lf will resonate with CD R 1
paralleling with CD R 2 , as shown in Fig. 10(b).
After t3 , DR 2 conducts and vrect remains at kat Vin /K. D6
still conducts, forcing iL r to decrease. ip equals to the reflected
current of iL f , and the equivalent circuit is the same as Fig. 11(a).
D6 still conducts until t4 , when iL r decreases to zero. After t4 ,
the modes are similar to that of case I.
It can be seen that the clamping diode current is forced to
decline rapidly under light-load condition in the proposed FB
converter, reducing the conduction loss and avoiding the reverse
recovery of the clamping diodes.
In the aforementioned analysis, the magnetizing inductor of
the main transformer is regarded as infinite and its effect on
the operation principle of the ZVS FB converter is ignored.
In [9], it is pointed out that the magnetizing inductor of the main
transformer has a substantial effect on the light-load condition
operation, and a relatively low magnitude of the magnetizing
inductor helps maintaining ZVS for switches under light-load
condition. The magnetizing inductor current flows through the
lagging-leg switch and the corresponding clamping diode and
vrect (t) = vC D R 2 (t) +
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IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 25, NO. 5, MAY 2010
remains unchanged at zero state (vA B = 0) under light-load condition in classical FB converter, for example, in Fig. 3(e) or (g),
the magnetizing inductor current will flow through Q4 and D6
and under freewheeling state. When the classical FB converter
transits from zero state (vA B = 0) to active state (vA B = +Vin
or −Vin ), the energy stored in the magnetizing inductor can be
used to achieve ZVS for switches, as presented in [9]. In the proposed ZVS PWM FB converter with auxiliary transformer, the
auxiliary transformer will play its role and transfer the energy
stored in the magnetizing inductor to the input voltage source
when the magnetizing current flows through the clamping diode
under light-load condition, and the magnetizing current will reduce to zero rapidly. Hence, the low magnetizing inductor is not
effective for soft switching under light-load condition. Under
heavy-load condition, the magnetizing inductor current flows
through the lagging-leg switch and the corresponding leadingleg switch at zero state (vA B = 0), and the auxiliary transformer
has no influence on the magnetizing inductor current; therefore,
the low magnetizing inductor is helpful to achieve ZVS for
switches [15].
V. THEORETICAL ANALYSIS
A. Conduction Loss
Under heavy-load condition, before the auxiliary transformer
is introduced, when the clamping diode conducts, the resonant
inductor is shorted and its current remains constant, the difference between the resonant inductor current and the primary
current flows through the clamping diode. The conduction time
of the clamping diode depends on the rise rate of the output
filter inductor current. The output filter inductor is usually quite
large; therefore, the conduction time of the clamping diode is
very long.
Under light-load condition, before the auxiliary transformer
is introduced, the clamping diode keeps conducting almost half
of the switching period.
When the auxiliary transformer is introduced, the reset voltage is applied to the resonant inductor when the clamping diode
conducts, forcing iL r to decay rapidly, so the clamping diode
current declines to zero rapidly correspondingly and its average
value is also reduced, as well as the RMS current of the leadingleg switch. Hence, the conduction loss in the primary side is
reduced.
B. Clamping Diode
1) Heavy-load condition: Equation (23) demonstrates the
peak current of clamping diode; generally, kat Vin is
smaller than Vin by choosing kat properly. Hence, the
peak current of clamping diode can be obtained according
to (23), i.e.,
Vin
2 ≈ Vin .
1 − kat
(29)
Ip h = (1 + kat )
Zr 1
Zr 1
It can be seen that the peak current is independent of
the load current, and it depends on the input voltage, the
characteristic impedance of the resonant inductor, and the
junction capacitor of the output rectifier diode.
Equation (25) shows the clamping-diode conduction
time, combining (23), (25) and (29), the clamping-diode
conduction time is given as
Tc
h
=
1
.
kat ω1
(30)
2) Light-load condition: According to Fig. 10, the peak current of clamping diode under light-load condition equals
to IL r p . From aforementioned analysis, it can be seen that
IL r p depends on IL f (t1 ), which reflects the different load
current under light-load condition. According to (9) and
(15), the maximum value of IL r p appears under no-load
condition, i.e.,
Ip
l m ax
Vin
=√
.
2Zr 1
(31)
The maximum clamping-diode conduction time is given
by
Tc
l m ax
=√
1
.
2kat ω1
(32)
C. Output Rectifier Diode
The voltage stress of the output rectifier diode in the FB converter with auxiliary transformer is 2(Vin + kat Vin )/K, which
is slightly higher than the classical FB converter, and the difference is
Vin
2kat Vin
Vin + kat Vin
−2
=
.
(33)
∆V = 2
K
K
K
D. Design Considerations of the Auxiliary Transformer
From (30), (32) and (33), we can see that the larger kat is,
the shorter the clamping-diode conduction time; however, the
higher the voltage stress of the output rectifier diode. Therefore,
there is a tradeoff in the choice of kat .
Under light-load condition, referring to Fig. 10, the conduction time of the clamping diode must be lesser than the time
interval of zero state to avoid the reverse recovery of the clamping diode. Generally, the primary duty cycle is relatively smaller
under light-load condition, hence, we have
Ts
Ts
(1 − D) ≈
(34)
2
2
where D is the primary duty cycle of the FB converter.
Assume that maximum clamping-diode conduction time under light-load condition is 10% of the switching period, and we
get
Tc
l m ax
<
Tc
l m ax
=√
1
Ts
.
<
10
2kat ω1
(35)
In order to get the concrete design process, a prototype is designed and built with the following parameters:
r input voltage Vin : 270(±10%) Vdc ;
r output voltage Vo : 54 Vdc ;
r maximum output current Io : 20 A;
r switching frequency fs : 100 kHz;
r resonant inductor Lr : 9 µH;
r output filter inductor Lf : 23 µH;
CHEN et al.: ZERO-VOLTAGE-SWITCHING PWM FULL-BRIDGE CONVERTER EMPLOYING AUXILIARY TRANSFORMER
1159
Fig. 12. Waveforms comparison of four kinds of FB converters at full-load condition (Io = 20 A). (a) Classical FB converter [11]. (b) With reset winding [12].
(c) With back-to-back Zener diodes [10]. (d) FB converter with auxiliary transformer.
r
r
r
r
r
main switches Q1 −Q4 : IRFP450;
clamping diodes D5 −D6 : DSEI 30–06 A;
output rectifier diodes DR 1 −DR 2 : DSEP 30–03 A;
turns ratio K: 15:4;
reflected capacitor CD
: 600 pF, which is approximately
calculated from the experimental results.
According to (35), we can get that kat should be larger than
0.052.
VI. EXPERIMENTAL VERIFICATION
A prototype with 54 V/20 A output of the ZVS PWM FB
converter with auxiliary transformer was built and tested to
verify the operation principle. The turns ratio of the auxiliary
transformer is 6: 77, which means kat = 0.078. A ring Mn–
Zn ferrite core (10 K, 12.7 mm × 7.9 mm × 7 mm) is used.
BYV26 C (PHILIPS) is taken as the auxiliary diode Da1 and
Da2 and the other parameters are the same as listed in Section
V. For the purpose of comparison, a classical FB converter with
clamping diodes [11], a FB converter with reset winding, where
the main transformer turns ratio is n1 :n3 :n2 = 14:1:4 [12], and
an FB converter using back-to-back Zener diodes (1N4747) as
the reset voltage source [10] were all built in laboratory.
Fig. 12 shows the waveforms of vA B , ip , iL r , iD 5 , iD 6 , and
vrect (from the top to the bottom) of the four kinds of FB con-
verters at full load under the nominal input voltage of 270 V. As
seen in Fig. 12, compared with the classical FB converter, the
conduction time of the clamping diode in the other three kinds
of FB converters are all shortened under heavy-load condition.
Fig. 13 shows the waveforms of the four kinds of FB converters at light load (Io = 30 mA) under the nominal input voltage
of 270 V. It can be seen from Fig. 13(a) that if no reset voltage is added, the two clamping diodes conduct for nearly half
of the switching period alternately. When the converter transits from zero state (vAB = 0) to active state (vAB = +Vin or
−Vin ), the clamping diodes are turned off with reverse recovery
and are apt to be destroyed, which deteriorates the reliability
of the converter dramatically, especially in high input voltage
application. As seen in Fig. 13(b), the reset winding can not
decay the clamping diode current during zero state because the
primary winding voltage of the main transformer is clamped
at zero under light-load condition. Hence, when the converter
transits from zero state to active state, the clamping diodes are
in conduction state and will be turned off hard, suffering from
reverse recovery. During active state, the clamping diode current
is declined to zero rapidly. Fig. 13(c) shows the waveforms of
the FB converter using back-to-back Zener diodes as the reset
voltage source, it can be seen that this method is effective at resetting the clamping diode currents under light-load condition.
1160
IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 25, NO. 5, MAY 2010
Fig. 13. Waveforms comparison of four kinds of FB converters at light-load condition (Io = 30 mA). (a) Classical FB converter [11]. (b) With reset winding [12].
(c) With back-to-back Zener diodes [10]. (d) FB converter with auxiliary transformer.
Fig. 14.
Q4 .
Waveforms of the leading switch and the lagging switch. (a) v G S , v D S , and iD of the leading switch Q 1 . (b) v G S , v D S , and iD of the lagging switch
Fig. 13(d) shows the waveforms of the FB converter with auxiliary transformer. It can be seen that the clamping diode current
decay rapidly without reverse recovery and the conduction time
is shortened.
Fig. 14(a) and (b) show the waveforms of the gate–source
voltage vG S , the drain–source voltage vD S , and the drain current
iD of Q1 and Q4 , respectively. It can be seen that all switches
realize ZVS.
Fig. 15 shows the comparison in the conversion efficiency of
four kinds of FB converters. Fig. 15(a) shows the efficiency at
different output currents under normal input voltage of 270 V.
Fig. 15(b) shows the efficiency at full load under different
CHEN et al.: ZERO-VOLTAGE-SWITCHING PWM FULL-BRIDGE CONVERTER EMPLOYING AUXILIARY TRANSFORMER
1161
Fig. 15. Efficiency comparison of four kinds of FB converters. (a) Efficiency at different output currents under normal input voltage. (b) Efficiency at full load
under different input voltages.
input voltages. It can be seen that the efficiency of the FB converter with reset winding and the FB converter with auxiliary
transformer is higher than that of the classical FB converter
due to the reduced conduction loss of the clamping diodes, the
leading switches, and the resonant inductor. The efficiency of
the FB converter with back-to-back Zener diodes is almost the
same as that of the classical FB converter, the reason is that the
reduced losses of the clamping diodes and the leading switches
are transferred to the two back-to-back Zener diodes, and the
total losses are almost the same. It should also be noted that
the back-to-back Zener diodes method is effective at resetting
the clamping diode currents under light-load condition. Compared with the FB converter with auxiliary transformer, the FB
converter with reset winding has relatively higher efficiency due
to no lossy device and component needed.
VII. CONCLUSION
The operation principle of the classical FB converter with
clamping diodes under light-load condition is analyzed in detail, which is remarkable different from that under heavy-load
condition. It is shown that the primary current will change its direction during zero state and the clamping diode will conduct for
almost half of the switching period under light-load condition,
which causes large conduction loss on the clamping diodes and
leading-leg switches and unavoidable serious reverse recovery
of the clamping diodes. A new ZVS PWM FB converter with
high reliability and reduced conduction loss is proposed to overcome aforementioned problems, which employs an additional
auxiliary transformer to make the clamping diode current decay rapidly over the full-load range, thus the conduction losses
of the clamping diodes, the leading switches, and the resonant
inductor are reduced and the conversion efficiency can be increased. In the meanwhile, the clamping diodes can be turned off
naturally without reverse recovery over the whole input voltage
range and load range, hence, the reliability of the FB converter is
improved. The operation principles, features, and comparisons
are illustrated. The experimental results from the prototype are
shown to verify the feasibility of the proposed converter.
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Wu Chen (S’05) was born in Jiangsu Province,
China, in 1981. He received the B.S., M.S., and
Ph.D. degrees in electrical engineering from Nanjing
University of Aeronautics and Astronautics (NUAA),
Nanjing, China, in 2003, 2006 and 2009, respectively.
He is currently a Senior Research Assistant
with the Department of Electronic Engineering,
City University of Hong Kong, Hong Kong, China.
His research interests include soft-switching dc/dc
converters, inverters, and power electronic system
integration.
Xinbo Ruan (M’97–SM’02) was born in Hubei,
China, in 1970. He received the B.S. and Ph.D. degrees in electrical engineering from Nanjing University of Aeronautics and Astronautics (NUAA), Nanjing, China, in 1991 and 1996, respectively.
In 1996, he was with the Faculty of Electrical Engineering Teaching, and Research Division, NUAA,
where he was a Professor in 2002 with the College
of Automation Engineering and has been engaged in
teaching and research in the field of power electronics. From August to October 2007, he was a Research
Fellow with the Department of Electronics and Information Engineering, Hong
Kong Polytechnic University, Hong Kong, China. He is a Guest Professor with
Beijing Jiaotong University, Beijing, China and Hefei University of Technology, Hefei, China. Since March 2008, he has been with the College of Electrical
and Electronic Engineering, Huazhong University of Science and Technology,
Wuhan, China. His current research interests include soft-switching dc/dc converters, soft-switching inverters, power factor correction converters, modeling
the converters, power electronics system integration, and renewable energy generation system. He has authored or coauthored more than 100 technical papers
in journals and conferences and three books.
Dr. Ruan is a Senior Member of the IEEE Power Electronics Society and
the IEEE Industrial Electronics Society. He was the Vice President of the China
Power Supply Society, and from 2008, he has been a member of the Technical
Committee on Renewable Energy Systems within the IEEE Industrial Electronics Society. He was the recipient of the Delta Scholar by the Delta Environment
and Education Fund in 2003 and was awarded the Special Appointed Professor
of the Chang Jiang Scholars Program, by the Ministry of Education, China, in
2007.
Qianhong Chen (M’06) was born in Hubei, China,
in 1974. She received the B.S., M.S., and Ph.D. degrees in electrical engineering from Nanjing University of Aeronautics and Astronautics (NUAA),
Nanjing, China, in 1995, 1998 and 2001, respectively.
From April 2007 to January 2008, she was a Research Associate with the Department of Electronic
and Information Engineering, Hong Kong Polytechnic University, Hong Kong, China. Since 2001, she
has been with the Faculty of Electrical Engineering,
Teaching and Research Division, NUAA, where she
is currently a Professor with the Aero-Power Sci-Tech Center, College of Automation Engineering. Her research interests include soft-switching dc/dc converters, application of integrated magnetics, and contactless resonant converters.
Junji Ge was born in Jiangsu, China, in 1987. He received the B.S. degree in electrical engineering from
Nanjing University of Aeronautics and Astronautics,
Nanjing, China, in 2009, where he is currently working toward the M.S. degree in electrical engineering.
His current research interests include softswitching dc–dc converters.
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