Open AccessArticle

Soft-Switching Full-Bridge Converter with Multiple-Input Sources for DC Distribution Applications

Sheng-Yu Tseng

and

Jun-Hao Fan

Department of Electrical Engineering, Chang Gung University, Taoyuan 33302, Taiwan

Author to whom correspondence should be addressed.

Symmetry 2021, 13(5), 775; https://doi.org/10.3390/sym13050775

Submission received: 5 February 2021 / Revised: 15 April 2021 / Accepted: 20 April 2021 / Published: 29 April 2021

(This article belongs to the Special Issue Symmetry in Renewable Energy and Power Systems Ⅱ - Including Wind Energy and Fluid Energy)

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Figure 1
Block diagram of the proposed DC distribution system with multipleinput power sources. "> Figure 2
Schematic diagram of power factor correction (PFC) inthe proposed DC distribution system for generating power from the utility line. "> Figure 3
Schematic diagram of DC/DC converter with PV arrays ofthe proposed DC distribution system for generating power from PV arrays. "> Figure 4
Schematic diagram of the proposed DC distribution system. "> Figure 5
Conceptual gate signal waveforms of switches M1–M4 for full-bridge converter: (a) phase-shift control method, (b) the conventional PWM control method, and (c) the proposed PWM control method. "> Figure 6
Equivalent circuit of the proposed full-bridge converter with dual-input sources operated in a complete switching cycle. "> Figure 6 Cont.
Equivalent circuit of the proposed full-bridge converter with dual-input sources operated in a complete switching cycle. "> Figure 7
Conceptual waveforms of the proposed full-bridge converter with dual-input sources over a switching cycle. "> Figure 8
Conceptual waveforms of the proposed full-bridge converter operated in the boundaries of DCM and CCM. "> Figure 9
Schematic diagram of the proposed full-bridge converter. "> Figure 10
Conceptual waveforms of the key component currents in the proposed full-bridge converter. "> Figure 11
Block diagram of the control circuit of the proposed DC distribution system. "> Figure 12
Measured waveforms of switch voltage and current under 30% of full-load conditions for the full-bridge converter operated in a hard-switching manner: (a) switch voltage VDC1 and current IDS1, and (b) switch voltage VDS2 and current IDS2. "> Figure 13
Measured waveforms of switch voltage and current under 30% of full-load conditions for the full-bridge converter operated in asoft-switching manner: (a) switch voltage VDC1 and current IDS1, and (b) switch voltage VDS2 and current IDS2. "> Figure 14
Measured output voltage VDC1 and current IDC1 waveforms under step-load change between 10% of full-load conditions and full-load conditions. "> Figure 15
Efficiency comparison between the proposed full-bridge converter and the conventional one from a light load to a heavy load. "> Figure 16
Core loss (mW/cm3) curves of transformer Tr, manufactured by PC 40 material of TDK. "> Figure 17
Core loss (mW/cm3) curves of inductor L1, manufactured by PC 40 material of TDK. "> Figure 18
Block diagram of the proposed DC distribution system with multipleinput power sources. "> Figure 19
Measured currents IDC1, IDC21, and IDC22 and voltage VDC2 waveforms when <math display="inline"><semantics> <mrow> <mn>0</mn> <mo><</mo> <msub> <mi>P</mi> <mrow> <mn>24</mn> <mo> </mo> <mi>V</mi> </mrow> </msub> <mo>+</mo> <msub> <mi>P</mi> <mrow> <mn>48</mn> <mo> </mo> <mi>V</mi> </mrow> </msub> <mo>≤</mo> <msub> <mi>P</mi> <mrow> <mi>P</mi> <mi>V</mi> <mrow> <mo stretchy="false">(</mo> <mrow> <mi>m</mi> <mi>a</mi> <mi>x</mi> </mrow> <mo stretchy="false">)</mo> </mrow> </mrow> </msub> </mrow> </semantics></math>. "> Figure 20
Measured currents IDC1, IDC21, and IDC22 and voltage VDC2 waveforms when <math display="inline"><semantics> <mrow> <msub> <mi>P</mi> <mrow> <mi>P</mi> <mi>V</mi> <mrow> <mo stretchy="false">(</mo> <mrow> <mi>m</mi> <mi>a</mi> <mi>x</mi> </mrow> <mo stretchy="false">)</mo> </mrow> </mrow> </msub> <mo><</mo> <msub> <mi>P</mi> <mrow> <mn>24</mn> <mtext> </mtext> <mi>V</mi> </mrow> </msub> <mo>+</mo> <msub> <mi>P</mi> <mrow> <mn>48</mn> <mtext> </mtext> <mi>V</mi> </mrow> </msub> <mo>≤</mo> <msub> <mi>P</mi> <mrow> <mi>P</mi> <mi>V</mi> <mrow> <mo stretchy="false">(</mo> <mrow> <mi>m</mi> <mi>a</mi> <mi>x</mi> </mrow> <mo stretchy="false">)</mo> </mrow> </mrow> </msub> <mo>+</mo> <msub> <mi>P</mi> <mrow> <mi>ac</mi> <mrow> <mo stretchy="false">(</mo> <mrow> <mi>m</mi> <mi>a</mi> <mi>x</mi> </mrow> <mo stretchy="false">)</mo> </mrow> </mrow> </msub> </mrow> </semantics></math>. "> Figure 21
Measured currents IDC1, IDC21, and IDC22 and voltage VDC2 when Pac(max) + PBS(max) < P24 V + P48 V. ">

Versions Notes

Abstract

Due to the advantages of power supply systems using the DC distribution method, such as a conversion efficiency increase of about 5–10%, a cost reduction of about 15–20%, etc., AC power distribution systems will be replaced by DC power distribution systems in the future. This paper adopts different converters to generate DC distribution system: DC/DC converter with PV arrays, power factor correction with utility line and full-bridge converter with multiple input sources. With this approach, the proposed full-bridge converter with soft-switching features for generating a desired voltage level in order to transfer energy to the proposed DC distribution system. In addition, the proposed soft-switching full-bridge converter is used to generate the DC voltage and is applied to balance power between the PV arrays and the utility line. Due to soft-switching features, the proposed full-bridge converter can be operated with zero-voltage switching (ZVS) at the turn-on transition to increase conversion efficiency. Finally, a prototype of the proposed full-bridge converter under an input voltage of DC 48 V, an output voltage of 24 V, a maximum output current of 21 A and a maximum output power of 500 W was implemented to prove its feasibility. From experimental results, it can be found that its maximum conversion efficiency is 92% under 50% of full-load conditions. It was shown to be suitable for DC distribution applications.

Keywords:

multiple input power sources; DC distribution system and full-bridge converter

1. Introduction

In general, power distribution systems are divided into AC distribution systems and DC distribution systems. In the past century, AC distribution systems have always been used for human environments. The overuse of fossil fuels has caused environmental pollution, leading to serious greenhouse effects. This has disturbed the balance of the global climate. In particular, effluent gas emissions and increases in CO₂ levels in the atmosphere have affected global surface temperatures, which have increased at a rate of 0.6 °C/century [1,2]. To save energy, a multiple energy source policy has been widely adopted in regard to power distribution systems. Compared to AC distribution systems, power systems using a DC distribution method have many advantages, such as a conversion efficiency increase of about 5–10%, a cost reduction of about 15–20% etc. Therefore, AC power distribution systems will be replaced by DC power distribution systems [3].The DC system is a popular distribution system. For the DC distribution system, a power processor with a high conversion efficiency is adopted to transfer power to load. In addition, to implement carbon reductions, zero-emissions renewable energy approaches have been rapidly applied to power processors, in applications such as power generation for grid connections, DC/DC converters, electric vehicle construction, battery charge/discharger development, satellite power systems, etc.

In renewable systems, the technologies of PV arrays and wind turbines, which are devices used to transfer renewable energy into electrical power, are important developments [4,5]. When renewable energy is used in cities, PV arrays have fewer limitations compared with those of wind turbines. Therefore, PV arrays are widely used to transfer power to load. Due to the unstable generation of electrical power by PV arrays, power supplied by a utility line can be adopted to balance power between PV arrays and DC loads. This is shown in Figure 1. In Figure 1, it can be observed that the voltage V_s of the utility line varies from AC 90 V to 264 V. In order to generate a proper voltage level (about DC 48 V) to be supplied to a full-bridge converter, a high step-down converter is required, such as push-pull, full-bridge, half-bridge, forward, or fly-back converters [6,7,8]. Due to a simple circuit structure and low cost, a flyback converter can be chosen to generate the DC voltage from the utility line to the DC load, and is used to achieve power factor correction (PFC). Due to the flyback converter adopted in the proposed DC distribution system [9,10,11], a soft switching circuit is required to increase its conversion efficiency, as shown in Figure 2. In Figure 2, it can be seen that an active clamp circuit is introduced into the flyback converter to recover energy stored in the leakage inductor. When the energy stored in the leakage inductor is recovered, the conversion efficiency of the flyback converter can be increased. In addition, the current of the leakage inductor can eliminate the effect of the parasitic capacitor on switches, allowingswitches M₁–M₄ to be operated with zero-voltage switching (ZVS) at the turn-on transition.

When a DC/DC converter uses PV arrays as its input power source, it needs a step-up converter to generate a desired DC voltage level due to the lower voltage output of PV arrays, such as boost, buck-boost, Cuk, Zeta, or SEPIC converter. In order to generate the desired voltage, a boost converter can be adopted, as shown in Figure 3. When a boost converter is used in the proposed DC power system, an interleaving circuit structure is applied to the DC/DC converter in order to generate a higher output power to DC loads. In Figure 3, the active single-capacitor snubber can store energy in the capacitor to smooth out the switch voltage. As a result, switches M₁ and M₂ can be operated with zero-voltage transition (ZVT) features at the turn-on transition. In order to operate the maximum power point of the PV arrays, there are many methods to implement maximum power point tracking (MPPT) of PV arrays, such as power matching [12,13], curve-fitting [14,15], perturb-and-observe [16,17], and incremental conductance [18,19] methods. When MPPT is implemented using the power matching method, a specific insolation condition or load is required, resulting in application limitations. If the curve-fitting technique is adopted to achieve MPPT, a prior establishment characteristic curve of PV arrays is required. It cannot predict the characteristics including other factors, such as aging, temperature, and the possible breakdown of individual cells. Since the incremental conductance technique requires an accurate mathematical operation, it leads to more complexity and higher costs. Due to the simpler control and lower cost of implementing the perturb-and-observe method for PV array applications, the DC power system proposed herein adopts the perturb-and-observe method to implement MPPT.

The proposed DC distribution system is applied to a DC load. In order to generate a specific output voltage (about DC 24 V) with safety considerations, a DC/DC converter with galvanic isolation is required. Since the output voltage V_DC1 is less than the input voltage V_DC2, the power processor needs a step-down converter. As mentioned above, flyback, forward, half-bridge, full-bridge or push-pull converters can be used. Due to the lower power level processing capability of flyback and forward converters, half-bridge, full-bridge, or push-pull converters can be applied to the proposed DC distribution system. When the proposed power system using a half-bridge or push-pull converter generates the desired output voltage, it will result in an unbalanced operation of the transformer. To avoid the unbalanced operation of the transformer, a full-bridge converter is adopted in the proposed power system. In this paper, we will focus on the power management of the proposed DC distribution system and the design of the full-bridge converter. In addition, all the acronyms and abbreviations used herein are listed in Table 1.

2. Related Work

As a full-bridge converter has been selected for the proposed DC power system, one needs a transformer to transfer power from the input source to the load, as shown in Figure 4. Due to the leakage inductance of the transformer, the energy stored in leakage inductance will induce a serious spike voltage across switches when switches are in the off state. There are many methods to solve this problem. One of these methods, an asymmetrical pulse-width modulation technique, was introduced in [20]. Its gate signal is shown in Figure 5a. Although this has many advantages, such as ZVS features, no extra conduction loss, and fixed operational frequency, its chief drawback is that the maximum duty ratio is limited to 0.5 and the transfer ratio is lower under the same turns ratio of the transformer.

In order to reduce switching losses, the full-bridge converter can use a snubber to help switches to achieve soft-switching features. Its gate signal can be generated by a general PWM IC, as shown in Figure 5b. Snubbers can be divided into two types—active and passive snubbers. In passive snubbers [20,21,22,23,24,25], the full-bridge converter uses a capacitor, inductor, or diode to achieve soft-switching features, such as ZVS, zero-current switching (ZCS), zero-current transition (ZCT), and ZVT. In [20,21,22,23,24], the snubber circuit is placed in the primary winding side of the transformer. It is inserted into the primary and secondary winding sides of the transformer [25]. When a passive snubber is used, the cost and volume of the full-bridge converter are increased. Its design becomes more complex. Another approach has been proposed—to add active components onto the primary winding side or the secondary side of transformer. For the active snubber [26,27,28], when the active snubber is added into the full-bridge converter, it generates an extra current to discharge the output capacitances of the switches. As a result, the switches in the full-bridge converter can be operated with ZVS at the turn-on transition. In addition, the switches can be operated with ZCS features, reducing switching losses. Although the active snubber can reduce switching losses, it will result in a higher cost, a more complex driving circuit, and a larger volume.

In general, the full-bridge converter adopts the phase-shift control method to achieve soft-switching features. With this approach, the duty ratio of the PWM control IC is limited to 0.5. In addition, the PWM control IC selection in the full-bridge converter is also restricted by the phase-shift algorithm control function, resulting in a lower transfer ratio under the same turns ratio of the transformer. Due to the advanced technology of semiconductor manufacturing, the conduction resistance of the switch is extremely low during switching under turn-on conditions. This can substantially reduce the conduction losses of switches. Therefore, when the switches of the full-bridge converter are operated with ZVS features to induce a circulating current, flowing through the primary winding of the transformer, the effect of conduction losses on the circulating current will be reduced significantly. In this paper, the switches of the proposed full-bridge converter are divided into two legs—left leg and right leg switches, as shown in Figure 4. The left leg switches include switches M₁ and M₂, where as the right leg ones include switches M₃ and M₄. In order to achieve ZVS features, switches M₁ and M₂ are operated in a complementary fashion. The operation of switches M₃ and M₄ is the same as that of switches M₁ and M₂. In addition, switches M₁ and M₃ are operated at 180° out of phase. The gate signal is shown in Figure 5c. Using this approach, switches M₁—M₄ can be operated in ZVS at the turn-on transition to increase the conversion efficiency. The duty ratios of the switches can be varied to achieve various transfer ratios for the proposed system. The proposed system only adds two inverters in the control circuit to implement soft-switching features. Although the proposed system will induce a circulating current to increase the conduction losses of the switches, this will be significantly reduced due to the extremely low conduction resistance of the switches. As mentioned above, the proposed full-bridge converter adopts the gate signal control method to achieve ZVS features and to increase conversion efficiency.

3. Topology and Operational Method of the Proposed DC Distribution Power

The proposed DC distribution power includes three converters: DC/DC converter with PV arrays, power factor correction (PFC) with utility line and the proposed full-bridge converter with multi-input sources. The power management of the proposed DC distribution power and soft-switching features of the proposed full-bridge converter are focus in this paper. In order to implement power management and soft-switching features, topology of the proposed DC distribution one and operational method of the proposed full-bridge converter are described as follows.

3.1. Topology of the Proposed DC Distribution System

The proposed DC distribution system is used in a multi-input power source system. The input power sources include a utility line and PV arrays. Therefore, the utility line and PV arrays can separately adopt the converter to transfer power into a desired voltage level. When the desired voltage level is generated, the proposed full-bridge converter uses the desired voltage level to supply power for the DC loads. Therefore, the proposed DC distribution system consists of power factor correction (PFC) with the utility line as the input source, a DC/DC converter with PV arrays as the input source and the full-bridge converter with multi-input sources to generate the DC voltage supplied to DC loads, as shown in Figure 4.

When the proposed DC distribution system is in the working state, it requires a proper control method to supply power for DC loads. Since this paper focuses on the design and implementation of the proposed full-bridge converter, power management among converters in the proposed DC distribution system is adopted to implement the control method for the proposed system. In addition, the measured results of the proposed full-bridge converter include switch waveforms, dynamic load variation, and conversion efficiency, which are used to verify the feasibility of the proposed full-bridge converter. This will be shown in the Measured Results and Discussion sections.

3.2. Operational Method of the Proposed Full-Bridge Converter

In general, when the load is greater than 20–30% of the full-load condition, the full-bridge converter is designed to operate in continuous conduction mode (CCM). This paper only describes the operational method for CCM in the proposed full-bridge converter. To achieve a higher conversion efficiency, the operator of the proposed full-bridge converter must adopt a different operational method to control the switches in the proposed system. According to the operational method of the proposed converter, its operational modes are divided into 14 modes, as shown in Figure 6, and their key waveforms are illustrated in Figure 7. Since the operational modes between t₀–t₇ are similar to those modes between t₇–t₁₄, except that the operational main switch changes from M₁ to M₃, each operational mode during half of one switching cycle is briefly described as follows.

Mode 1 (Figure 6b: t₀ ≤ t < t₁):Before t₀, the current I_DS1 of switch M₁ has a negative value. The body diode D_M1 of switch M₁ is forwardly biased. Switches M₁, M₂, and M₃ are in the off state, whereasswitch M₄ is in the turn-on state. Diodes D₁–D₄ are in the forward biased state, as shown in Figure 6a. When t = t₀, switch M₁ is turned on and switch M₁ is operated with ZVS at the turn-on transition, as shown in Figure 6b. Switch M₄ is kept in the turn-on state, whereas M₂ and M₃ are still in the turn-off state. Within this time interval, diodes D₁–D₄ are in a freewheeling state by inductor L₁. Current I_DS1 abruptly increases from a negative value to an initial value, which is the initial value of inductor current I_L1, reflected in the secondary winding to the primary winding of the transformer T_r when the proposed system is operated in CCM. Inductor current I_L1 linearly decreases.

Mode2 (Figure 6c: t₁ ≤ t < t₂): At t₁, the current I_DS1 reaches the initial value. Diodes D₁ and D₄ are kept in the forward biased state, whereas D₂ and D₃ change their operated states from the forward biased state to the reverse biased state. Current I_DS1 increases in a linear manner. On the secondary side of transformer T_r, inductor current I_L1 linearly increases.

Mode 3 (Figure 6d: t₂ ≤ t < t₃): when t = t₂, the current I_DS1 reaches the maximum value. Switch M₁ is turned off, whereasswitches M₂ and M₃ are in the turn-off state and M₄ is in the turn-on state. The energy trapped in the leakage inductor L_K is released by parasitic capacitors C_M1 and C_M2. Therefore, voltage V_DS2 is changed from V_DC to 0 V, whereasvoltage V_DS₁ is varied from 0 V to V_DC. Diodes D₁ and D₄ are in the forward biased state, and D₂ and D₃ are in the reverse biased state. Inductor current I_L1 linearly increases.

Mode 4 (Figure 6e: t₃ ≤ t < t₄): When t = t₃, voltage V_DS1 reaches V_DC and voltage V_DS2 is down to 0 V. At that moment, body diode D_M2 is forwardly biased. The primary winding of transformer T_r is in a short-circuit state. Current I_LK is kept at a fixed value. Since inductor current I_L1 needs to remain in the continuous conduction state, diodes D₁–D₄ are in a freewheeling state by inductor L₁. Inductor current L₁ linearly decreases.

Mode 5 (Figure 6f: t₄ ≤ t < t₅): At t₄, body diode D_M2 is in a forward biased state. At that moment, switch M₂ is turned on. Switch M₂ is operated with ZVS at the turn-on transition. Diodes D₁–D₄ are kept in the forward biased state. Inductor current I_L1 is reduced ina linear manner.

Mode 6 (Figure 6g: t₅ ≤ t < t₆): At t₅, switch M₄ is turned off. The energy stored in leakage L_K is released by parasitic capacitors C_M3 and C_M4. Voltage V_DS3 across capacitor C_M4 is increased from 0 V to V_DC. Diodes D₁–D₄ are kept in a forward biased state. Inductor current I_L1 linearly decreases.

Mode 7 (Figure 6h: t₆ ≤ t < t₇): when t = t₆, voltage V_DS3 reaches 0 V and voltage V_DS4 varies to V_DC. The body diode D_M3 is forwardly biased. Current I_DS3 abruptly changes from a negative value to an initial value. During this interval, diodes D₁–D₄ are in the forward biased state. Inductor current I_L1 linearly decreases. When switch M₃ is turned on at the end of mode 7, the other half of one switching cycle starts.

4. Design Method of Full-Bridge Converter with Multiple Input Sources

In the proposed full-bridge converter, component design and selection are very important. Therefore, component design and selection are derived as follows:

4.1. Component Design of the Proposed Full-Bridge Converter

For the design of the proposed full-bridge converter with dual input sources, the determination of the duty ratio D, turns ratio N of transformer T_r, inductance L₁, and capacitance C_DC1 are important. Their designs are analyzed briefly as follows.

(a): Duty ratio D

When deriving the duty ratio D of the proposed full-bridge converter, the input to output voltage transfer ratio M must be first obtained. According to the volt-second balance of inductor L₁, the following equation can be obtained:

(N V_{D C 2} - V_{D C 1}) D T_{s} + (- V_{D C 1}) (\frac{1}{2} - D) T_{s} = 0

(1)

where T_s is the switching period and N is the turns ratio of the transformer T_r. From (1), it can be found that transfer ratio M can be expressed as

M = \frac{V_{D C 1}}{V_{D C 2}} = 2 N D

(2)

According to (2), the duty ratio D can be rewritten as

D = \frac{V_{D C 1}}{{2 N V}_{D C 2}}

(3)

According to the operational principle of the proposed full-bridge converter with dual input sources, a larger duty ratio D corresponds to a smaller turns ratio N of transformer T_r. As a result, less current stress is imposed on switches M₁–M₄ and diodesD₁–D₄. However, in order to accommodate for the variations of the load, line voltage and component value, it is better to select an operating range of D = 0.35–0.4.

(b): Turns ratio N of Transformer T_r

When the duty ratio D is specified, turns ratios N of transformer T_r can be determined by (3), which is expressed as

N = \frac{V_{D C 1}}{2 D V_{D C 2}}

(4)

In addition, the magnetizing inductor L_m must be much greater than L₁/N². It needs to satisfy the inequality, which yields

L_{m} \geq \frac{10 L_{1}}{N^{2}}

(5)

According to the inequality listed in (5), the magnetizing current of transformer T_r can be neglected.

(c): Inductor L₁

Figure 8 shows the conceptual waveforms of the proposed full-bridge converter operated within the boundaries of discontinuous-conduction mode (DCM) and CCM. When the proposed converter is operated in these boundaries, the output current I_DC1 can be determined by

I_{D C 1} = \frac{Δ I_{L 1 (m a x)}}{2}

(6)

where ΔI_L1(max) representsthe maximum variation value. In general, ΔI_L1(max) can be expressed by

Δ I_{L 1 (m a x)} = \frac{(N V_{D C 2} - V_{D C 1}) D T_{s}}{L_{1 B}}

(7)

where L_1B is the inductance operated at the boundary of DCM and CCM. In the design consideration of I_DC1 from (6), it is equal to KI_DC1(max), where I_DC1(max) is the maximum output current. Note that the K value ranges from 0 to 1. According to (6) and (7), the inductance L₁ can be determined by

L_{1} = L_{1 B} = \frac{(N V_{D C 2} - V_{D C 1}) D T_{s}}{2 K I_{D C 1 (m a x)}}

(8)

(d): Output capacitor C_DC1

In order to reduce the ripple of the output voltage V_DC1, the output capacitor C_DC1 must be large enough. The ripple voltage across output capacitor C_DC1 is expressed as follows:

Δ V_{r} = \frac{Δ T_{L 1 (m a x)}}{L_{D C 1}} (\frac{1}{16 f_{s}} + C_{D C 1} \times E S R)

(9)

where ESR is the equivalent series resistance of the output capacitor C_DC1. For aluminum electrolytic capacitors, the product of (C_DC1 × ESR) is much less than (1/16f_s) and it can be neglected. Thus, capacitor C_DC1 is selected as

C_{D C 1} = \frac{Δ I_{L 1 (m a x)}}{16 f_{s} Δ V_{r}}

(10)

4.2. Component Selection of the Proposed Full-Bridge Converter

To select the semiconductors for the proposed full-bridge converter, the voltage and current stresses of the switches and diodes are very important. Figure 9 illustrates a schematic diagram of the proposed full-bridge converter. The maximum voltage stress

V_{D S 1 (m a x)}

V_{D S 2 (m a x)}

V_{D S 3 (m a x)}

V_{D S 4 (m a x)}

) of switch

M_{1}

can be determined by

V_{D S 1 (m a x)} {= V}_{D C 2}

(11)

The maximum voltage stress

V_{D 1 (m a x)}

V_{D 2 (m a x)}

V_{D 3 (m a x)}

V_{D 4 (m a x)}

) of diode

D_{1}

can be expressed as

V_{D 1 (m a x)} {= N V}_{D C 2}

(12)

The conceptual waveforms of the component currents are shown in Figure 10. According to the conceptual current waveforms of switch

M_{1}

, its maximum rms current

I_{D S 1 (r m s)}

I_{D S 3 (r m s)}

) is expressed as

I_{D S 1 (r m s)} = \sqrt{{(I}_{D (m a x)}^{2} {+ I}_{P (m a x)}^{2} {+ I}_{D (m a x)} I_{P (m a x)}) \frac{D}{3}}

(13)

where

I_{D (m a x)}

is the initial current of inductor

L_{1}

from secondary winding, reflected to primary winding when the proposed converter is operated in CCM and the output current

I_{o}

is under full-bridge conditions. In addition, the maximum rms current

I_{D S 2 (r m s)}

I_{D S 4 (r m s)}

) can be expressed as

I_{D S 2 (r m s)} = \sqrt{I_{P (m a x)}^{2} {(1 - 2 D) + (I}_{D (m a x)}^{2} {+ I}_{P (m a x)}^{2} {+ I}_{D (m a x)} I_{P (m a x)}) \frac{D}{3}}

(14)

In Figure 10, according to current waveform of diode

D_{1}

, the maximum rms current

I_{D S 1 (r m s)}

I_{D S 2 (r m s)}

I_{D S 3 (r m s)}

I_{D S 4 (r m s)}

) can be derived by

I_{D 1 (r m s)} = \frac{1}{N} \sqrt{(\frac{10 D - 1}{24} {) (I}_{D (m a x)}^{2} {+ I}_{P (m a x)}^{2} {+ I}_{D (m a x)} I_{P (m a x)})}

(15)

5. Power Loss Analysis of the Proposed Full-Bridge Converter

Due to soft-switching features, conversion efficiency of the proposed full-bridge converter is higher than that of the counterpart with hard-switching method. In order to verify the measured conversion efficiency of the proposed one, its power analysis is very important. The proposed full-bridge converter is shown in Figure 9. Its key component current waveforms are illustrated in Figure 10. According to the current waveforms, the power losses of the proposed system include losses from the switches, diode, transformer core, and inductor core. In the following, a power loss analysis is conducted.

5.1. Losses of Switches

Figure 11 shows the conceptual waveforms of switching losses for switches

M_{1}

M_{2}

M_{3}

, and

M_{4}

. Switches

M_{1} - M_{4}

are operated in ZVS at the turn-off transition of the switches. Therefore, switching losses

P_{S o f f}

of switches

M_{1} - M_{4}

can be derived as

P_{S o f f} = \frac{1}{{2 T}_{S}} V_{D S 1 (m a x)} {(t}_{S o f f} I_{P})

(16)

where

t_{S o f f}

is the falling time of switch

M_{1}

. In addition, the conduction loss of switch

M_{1}

can be determined by

P_{C D} {= I}_{D S 1 (m a x)}^{2} R_{D S (o n)}

(17)

where

R_{D S (o n)}

is a resistance of the switch during the turn-on interval.

5.2. Losses of Diodes

When diodes

D_{1} - D_{4}

are in the forward biased state, the forward drop

V_{F}

of the diode will induce diode loss. This can be expressed as

P_{D 1} {= I}_{D 1 (r m s)} V_{F}

(18)

5.3. Losses of Transformer $T_{r}$ and Inductor $L_{1}$

The losses of the transformer

T_{r}

and inductor

L_{1}

include core loss and copper losses. In the following, core loss and copper loss of transformer

T_{r}

and inductor

L_{1}

are respectively derived.

(a): Transformer $T_{r}$

The core loss of transformer

T_{r}

is derived based on the maximum flux density

B_{m}

. The maximum flux density

B_{m}

can be determined as

B_{m} = \frac{u_{o} u_{r} N_{1} I_{L m (P)}}{l_{e 1}}

(19)

where

μ_{0} {= 4 π \times 10}^{- 7} \frac{H}{m}

μ_{r}

is permeability,

N_{1}

indicates the turns of primary winding,

I_{L m (P)}

represents the peak current of magnetizing inductance, and

l_{e 1}

expresses the effective magnetic path length. When

B_{m}

is determined, the core loss coefficient

C_{P 1}

can be obtained based on the core loss curve. The core loss

P_{{C 1 (T}_{r})}

is derived by

P_{{C 1 (T}_{r})} {= C}_{P 1} V_{e 1}

(20)

where

V_{e 1}

is the effective core volume of the transformer core. In addition, copper loss

P_{{C P (T}_{r})}

can be determined as

P_{{C P (T}_{r})} {= I}_{L K (r m s)}^{2} R_{{D C 1 (T}_{r})} {+ I}_{N S (r m s)}^{2} R_{{D C 2 (T}_{r})}

(21)

Where

R_{{D C 1 (T}_{r})}

is the resistance of primary winding and

R_{{D C 2 (T}_{r})}

represents that of secondary winding. Their values are listed in Table 2. In order to determine the copper loss of transformer

T_{r}

, the magnetizing current

I_{L K (r m s)}

can be determined by

I_{L K (r m s)} = \sqrt{{(I}_{D}^{2} {+ I}_{P}^{2} {+ I}_{D} I_{P}) (\frac{2 D}{3} {) + I}_{P}^{2} (1 - 2 D)}

(22)

Moreover, the secondary current

I_{N S (r m s)}

can be derived as

I_{N S (r m s)} = \frac{1}{N} \sqrt{{(I}_{D}^{2} {+ I}_{P}^{2} {+ I}_{D} I_{P}) \frac{2 D}{3}}

(23)

(b): Inductor $L_{1}$

The core loss of inductor

L_{1}

is derived based on the maximum flux density

B_{{m (L}_{1})}

. The maximum flux density

B_{{m (L}_{1})}

can be determined as

B_{{m (L}_{1})} = \frac{u_{o} u_{r} N_{3} I_{P}}{{N (l}_{e 2} {+ u}_{r} l_{g})}

(24)

where

N_{3}

is the turns of inductor

L_{1}

, N expresses the turns ratio of transformer,

l_{e 2}

indicates the effective magnetic path length, and

l_{g}

represents the air gap length. When

B_{{m (L}_{1})}

is obtained, the core loss coefficient

C_{P 2}

can be obtained through the core loss curve of the inductor core. The core loss

C_{{P 2 (L}_{1})}

is derived by

C_{{P 2 (L}_{1})} {= C}_{P 2} V_{e 2}

(25)

where

V_{e 2}

is the effective magnetic path length. To calculate the copper loss

C_{{C P (L}_{1})}

, the rms current

I_{L 1 (r m s)}

must be determined. The current

I_{L 1 (r m s)}

can be derived by

I_{L 1 (r m s)} = \frac{1}{N} \sqrt{\frac{1}{3} {(I}_{D}^{2} {+ I}_{P}^{2} {+ I}_{D} I_{P})}

(26)

When the current

I_{L 1 (r m s)}

is obtained, the copper loss

P_{{C P (L}_{1})}

is expressed as

P_{{C P (L}_{1})} {= I}_{L 1 (r m s)}^{2} R_{D C 3 (L 1)}

(27)

The

R_{D C 3 (L 1)}

is illustrated in Table 2.

6. Power Management of the Proposed DC Distribution System

The proposed DC distribution system adopts a utility line and PV arrays to supply power to DC loads. There are three power processors, which are the PFC, DC/DC converter, and the full-bridge converter with multiple input sources, as shown in Figure 11. The PFC supplies power from the utility line (AC90 V–264 V) to DC 48 V, where as the DC/DC converter supplies power from the PV arrays (DC 34 V–43 V) to DC 48 V. The two power supplies provide power to the full-bridge converter with multiple input sources. In order to operate the proposed DC distribution system, each power processor must be operated at the appropriate power level, which is limited by the maximum output power of each power processor. In the following, the control algorithm and power management of the proposed DC distribution system are briefly described.

6.1. Control Algorithm of the Proposed DC Distribution System

The proposed DC distribution system includes three power processors. The circuit topology of the proposed system is divided into two parts: the power stage and the control stage. The power stage consists of three power processors, where the control stage consists of the control circuit. The control circuit consists of the PFC unit, MPPT unit, PWM control unit, power calculation unit, and protection unit. The PFC unit helps the PFC with utility line as its input source to achieve power factor correction, ensuring that the input voltage V_S and current I_S are controlled in this phase. According to the relationships between P_PV and P_L, in which P_PV is the power supplied by the PV arrays and P_L is the consumption power of the loads, the MPPT unit can control the operating states of the DC/DC converter with the PV arrays as the input source. There are two operating states: MPPT and regulation voltage states. When P_PV ≥ P_L, the signal C_PL changes from a low level to a high level. This can enable the regulation voltage to generate the reference voltage V_ref2 and disable MPPT control. Therefore, reference voltage V_ref3 is equal to voltage V_ref2. PWM generator #2 can generate PWM signals M₂₁ and M₂₂ by voltage V_ref3. The DC/DC converter, using PV arrays as its input source, is operated in the regulation voltage mode. If P_PV < P_L, C_PL varies from a high level to a low level. MPPT control is enabled by the signal C_PL, whereas the regulation voltage is disabled. Thus, reference voltage V_ref3 equals I_ref1. PWM generator #2 can generate signals M₂₁ and M₂₂ to control the DC/DC converter by voltage V_ref3. The DC/DC converter is operated in MPPT mode.

The proposed full-bridge converter can regulate the output voltage V_DC1 by means of the PWM control unit. When the protection unit generates a signal C_P, which is a high level, PWM generator #1, PWM generator #2, and PWM generator #3 are disabled by signal C_P. Signal C_P varies from a low level to a high level when voltages V_DC1 and V_DC2 are in the under-voltage state or currents I_DC1 and I_DC2 are in the overload state. Signal C_P is generated by the protection unit. The control algorithm of the proposed DC distribution system was described previously.

6.2. Power Management of the Proposed DC Distribution System

The maximum output power of the PFC is set at P_ac(max), whereas that of the DC/DC converter is specified by P_PV(max). In addition, the maximum power of the proposed full-bridge converter with dual input sources is limited at P_24SV(max). In the proposed DC distribution system, it can supply two different voltage levels to DC loads: DC 48 V and DC 24 V, respectively. Therefore, load powers can be indicated by P_{24 V} and P_{48 V}, separately. According to the power management of the proposed DC power system, there are three operational states

0 \leq P_{24 V} + P_{48 V} < P_{P V (m a x)}

P_{P V (m a x)} \leq P_{24 V} + P_{48 V} < P_{P V (m a x)} + P_{a c (m a x)}

, and

P_{24 V} + P_{48 V} > P_{P V (m a x)} + P_{a c (m a x)}

. Its operational states are illustrated in Table 1. Note that the DC 24 V load and DC 48 V load are simultaneously turned on or turned off since some loads require powers of DC 24 V and 48 V at the same time.

As shown in Table 3, when the operational state of the proposed DC distribution system is in the

0 \leq P_{24 V} + P_{48 V} < P_{P V (m a x)}

state, the PFC is shut down, and the DC/DC converter is working, which is operated at

P_{PV} = P_{24 V} + P_{48 V}

. The proposed DC distribution system supplies power to load #1 (DC 24 V) and load #2 (DC 48 V). If operational state is kept at

P_{P V (m a x)} \leq P_{24 V} + P_{48 V} < P_{P V (m a x)} + P_{a c (m a x)}

, the PV arrays are operated at P_PV(max), where as the PFC supplies power at

P_{a c} = P_{24 V} + P_{48 V} - P_{P V (m a x)}

. Therefore, three power processors in the proposed DC distribution system are in the working state. When

P_{24 V} + P_{48 V} > P_{P V (m a x)} + P_{a c (m a x)}

, the proposed DC power system is shut down since the generation power of the proposed system is not enough to supply load #1 and load #2. According to operational state mentioned above, the proposed DC distribution system can meet the requirements of a DC power distribution system.

7. Measured Results and Discussion

In order to verify the performances of the proposed full-bridge converter, a prototype with the following specifications was implemented.

Input voltage V_DC2: DC 48 V,
Switching frequency f_s: 50 kHz,
Output voltage V_DC1: DC 24 V,
Maximum output current I_DC1(max): 21 A,
Maximum output power P_24SV(max): 500 W.

According to the previously outlined specifications and design of the proposed full-bridge converter with dual input sources, the duty ratio D = 0.35 and turns ratio N = 0.8 were determined. When k = 0.1, as illustrated in Equation (8), the proposed full-bridge converter is operated in the boundaries of DCM and CCM. Therefore, inductance L₁ is specified and its value is equal to 38.7 μH. The other components of the power stage in the proposed full-bridge converter were determined as follows:

Switches M₁~M₄: AoW2918,
Transformer core: EE-55,
Diodes D₁~D₄: STPS41H100CT,
Capacitor C_DC1: 3300 μF/35 V,
Leakage inductor L_K: 3.8 μH,
Magnetizing inductor L_m: 1.72 mH.

According to the specifications and component selection of the proposed full-bridge converter, its key component parameters are listed in Table 2.

Figure 12 shows the measured waveforms of switch voltage V_DS and current I_DS under 30% of full-load conditions for the full-bridge converter operated in a hard-switching manner. Figure 12a shows those waveforms of voltage V_DS1 and I_DS1, whereas Figure 12b illustrates those waveforms of voltage V_DS2 and I_DS2. Figure 13 shows those waveforms for the proposed full-bridge converter under 30% of full-load conditions, in which the waveforms exhibit soft-switching features. In Figure 13, it can be observed that the proposed full-bridge converter was operated with approximately ZVS at the turn-on transition, reducing switching losses and increasing conversion efficiency. Figure 14 illustratesthe measured output voltage V_DC1 and current I_DC1 waveforms under a step-load change between 10% of full-load conditions and full-load conditions, in which it can be observed that the regulation of output voltage V_DC1 was within ±1% and the dynamic load variation of the proposed full-bridge system was able to meet its power rating.

An efficiency comparison between the proposed full-bridge converter and a conventional system from a light load to a heavy load is shown in Figure 15. The components and parameter values of the conventional system were the same as the proposed full-bridge converter, except the soft-switching features were not the same as those of the proposed system. As shown in Figure 15, the maximum conversion efficiency was located at 50% of the full load and its value was about 92%. Its conversion efficiency was higher than that of its counterpart with the hard-switching manner. In order to prove this conversion efficiency, as shown in Figure 15, a power loss analysis of the proposed full-bridge converter was derived. Table 4 lists the semiconductor losses of the proposed full-bridge converter under different load conditions. Since switches

M_{1} - M_{4}

are operated with ZVS at the turn-on transition, their switching loss was calculated based on that of the turn-off transition. In order to calculate the switch loss and diode loss, the key component peaks and rms currents under different loads are listed in Table 5. Table 6 illustrates the parameters of core material and core loss analysis for the proposed full-bridge converter. Power loss analyses of the proposed full-bridge converter at core loss efficiencies of transformer

T_{r}

and inductor

L_{1}

are respectively provided in Figure 16 and Figure 17. A power loss analysis of the proposed full-bridge converter under different loads is provided in Table 7. In Table 7, it can be seenthat the calculation efficiency

η_{c}

was higher than 0.6–3.7% of the practical efficiency

η_{p}

. When the load was under 30% and below 30% of full-load conditions, the leakage inductor current

I_{L K}

did not eliminate the energy stored in the parasitic capacitor of the switches. Its switching loss at turn-on transition was approximately0.5% of the input power of the proposed converter under different loads. In addition, the stray loss of the proposed converter was about 0.6–3.5% under different loads. Particularly, when the load was increased, the stray loss also increased. When the proposed full-bridge converter adopted the proposed gate signal control method to drive switches M₁–M₄, the power loss increases due to the circulating current flowing through switches M₂ and M₄ and the primary winding side of the transformer. The extra loss in switches M₂ and M₄ are equal to 2(P_c2-P_c1). In the primary winding side of the transformer, I_LK_(rmsp) is the reflected current from the secondary winding side to the primary winding side, where I_LK_(rmsp) = NI_NS_(rms). The increase in copper loss of transformer for the circulating current is equal to P_C_(Trl) =

{(I}_{L K (r m s)}^{2} - I_{L K (r m s p)}^{2}) R_{d c 1 (T r)}

. When the proposed full-bridge converter is operated under full-load conditions, the extra loss is equal to 2(P_C2−P_C1) + P_C_(Trl) = 2.674 W. This reduces conversion efficiency by 0.49%. Therefore, the extra power loss for the circulating current is very low in the proposed full-bridge converter.

In order to demonstrate the power management of the proposed DC distribution system, a block diagram of the proposed system is shown in Figure 18. Concerning the contents of Figure 18, the DC/DC converter with PV arrays was previously shown in Figure 2, where as the power factor correction was illustrated in Figure 3. In addition, the proposed full-bridge converter with dual-input sources was plotted in Figure 4. The proposed DC distribution includes three converters: theDC/DC converter with PV arrays, the power factor correction system, and the proposed full-bridge converter. Figure 11 shows a block diagram of control circuit of the proposed DC distribution system. Since the DC/DC converter with PV arrays and power factor correction are connected in parallel, they will supply power to load #1 and load #2, where load #1 is the output load of DC 24 V and load #2 is the output load of DC 48 V. The total maximum power of the DC/DC converter with PV arrays and power factor correction is greater than or equal to the sum of the maximum power of load #1 and load #2. Since the maximum processing power of the proposed full-bridge converter is equal to 500 W and its conversion efficiency is 88%, the maximum input power of the proposed full-bridge converter is limited by 568 W. Therefore, the total maximum power requirement is equal to 1928 W at the DC 48 V terminal. This is close to 1920 W, which is the sum of 1200 W for the maximum output power of the DC/DC converter with PV arrays and 720 W for that of the power factor correction system. The maximum output power of each converter is listed in Table 8. Because the proposed DC distribution system is designed using power factor correction, the DC/DC converter with PV arrays, and the proposed full-bridge converter, its power management is divided into three states, as listed in Table 3. The output power of load #1 is at the DC 24 V terminal, where as that of load #2 is at the DC 48 V terminal. In order to calculate the total load power,

P_{24 V}

must be transferred from the DC 24 V terminal and reflected to the DC 48 V terminal. Therefore,

P_{24 V}

, divided by η where η is the conversion efficiency of the proposed full-bridge converter, as shown in Figure 15, can be equivalent to the DC 48 V terminal. When the proposed DC distribution power is operated in state 1, its current and voltage waveforms are as shown in Figure 19. In Figure 19, before t_o,

P_{24 V} {= P}_{48 V} = 0 W

. At t =

t_{0}

P_{48 V}

varies from 0 W to 300 W. Since

P_{P V (m a x)} = 600 W

P_{P V (m a x)}

P_{24 V} {+ P}_{48 V}

and the operational condition is in the state 1 condition. When t =

t_{1}

P_{24 V}

changes from 0 W to 240 W. The total load power is equal to 560 W (= (240/η(=0.9)) + 300 = 560 W). Therefore,

P_{P V (m a x)}

P_{24 V} {+ P}_{48 V}

and the proposed system is still operated in the state 1 conditions. When

P_{P V (m a x)}

= 550 W,

P_{ac (m a x)}

= 720 W,

P_{48 V}

= 480 W and

P_{24 V}

= 480 W. Its measured waveform is illustrated in Figure 20. As shown in Figure 20, before t_o,

P_{24 V}

P_{48 V}

P_{ac}

= 0 W. When t =

t_{0}

P_{24 V}

P_{48 V}

= 480 W. The total load power is equal to 1030 W (= (480/η(=0.88)) + 480 = 1030 W). Since

P_{P V (m a x)}

= 550 W and

P_{ac}

= (P_{24 V}/η) +

P_{48 V}

−

P_{P V (m a x)}

P_{ac}

= 480 W. Therefore,

P_{P V (m a x)}

P_{24 V} {+ P}_{48 V}

P_{P V (m a x)}

P_{ac (m a x)}

. The proposed systemis operated in the state 2 condition. When

P_{P V (m a x)}

= 600 W,

P_{ac (m a x)}

= 720 W,

P_{24 V}

= 500 W, and

P_{48 V}

= 480 W, the waveforms are as shown in Figure 21. As seen in Figure 21, before t_o,

P_{24 V}

P_{48 V}

P_{ac}

= 0 W. At t =

t_{0}

P_{48 V}

= 960 W and

P_{24 V}

= 500 W. The total load power is equal to 1528 W (= 960 + (500/η(=0.88)) = 1528 W). Since

P_{P V (m a x)}

P_{ac (m a x)}

= 1320 W,

P_{P V (m a x)}

P_{ac (m a x)}

P_{24 V} {+ P}_{48 V}

. This will result in a linear drop of voltage at the DC48 V terminal. When t =

t_{1}

, voltage

V_{D C 2}

(DC 48 V terminal) is less than the minimum set value of output voltage at the DC 48 V terminal. The proposed DC distribution power is shut down, and load#1 and load #2 are turned off. In that moment, the DC/DC converter with PV arrays and power factor correction are turned on again. After 10 s, load #1 and load #2 are turned on again. The proposed DC distribution system is shut down again until itis operated in state 1 or state 2 conditions. As mentioned above, the proposed DC distribution system can use a single chip to achieve power management. Its operational states meet the desired operational states listed in Table 3.

8. Conclusions

In this paper, the proposed full-bridge converter with dual input sources is applied to a DC power distribution system. The topology and control method of the proposed DC distribution system are proposed in this paper. In addition, the operational method, design, and power loss analysis of the proposed full-bridge converter are described in detail. The measured results verified that the proposed full-bridge converter can be applied to DC distribution applications. Based on the power loss analysis and experimental results, it can be seen that the calculation efficiency

η_{c}

is higher than 0.6–3.7% of the practical efficiency

η_{p}

. The reason for this is that the stray loss of the proposed converter induces the different value. In addition, the extra power loss caused by the circulating current reduces the conversion efficiency by 0.49% in the proposed full-bridge converter. This does not affect the conversion efficiency of the proposed converter significantly. Its maximum conversion efficiency is 92% under 50% of full-load conditions. In particular, the measured results have proven that different operational states among the converters in the proposed DC distribution system can be implemented. Therefore, the proposed full-bridge converter with multiple input sources is suitable for DC distribution applications.

Author Contributions

Writing—original draft, S.-Y.T.; Writing—review & editing, J.-H.F. Both authors have read and agreed to the published version of the manuscript.

Funding

This research was funded by Ministry of Science and Technology (MOST) in Taiwan grant number MOST 109-2622-E-182-003-cc3.

Institutional Review Board Statement

Not applicable.

Informed Consent Statement

Not applicable.

Data Availability Statement

Not applicable.

Conflicts of Interest

The authors declare no conflict of interest.

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Figure 1. Block diagram of the proposed DC distribution system with multipleinput power sources.

Figure 2. Schematic diagram of power factor correction (PFC) inthe proposed DC distribution system for generating power from the utility line.

Figure 3. Schematic diagram of DC/DC converter with PV arrays ofthe proposed DC distribution system for generating power from PV arrays.

Figure 4. Schematic diagram of the proposed DC distribution system.

Figure 5. Conceptual gate signal waveforms of switches M₁–M₄ for full-bridge converter: (a) phase-shift control method, (b) the conventional PWM control method, and (c) the proposed PWM control method.

Figure 6. Equivalent circuit of the proposed full-bridge converter with dual-input sources operated in a complete switching cycle.

Figure 7. Conceptual waveforms of the proposed full-bridge converter with dual-input sources over a switching cycle.

Figure 8. Conceptual waveforms of the proposed full-bridge converter operated in the boundaries of DCM and CCM.

Figure 9. Schematic diagram of the proposed full-bridge converter.

Figure 10. Conceptual waveforms of the key component currents in the proposed full-bridge converter.

Figure 11. Block diagram of the control circuit of the proposed DC distribution system.

Figure 12. Measured waveforms of switch voltage and current under 30% of full-load conditions for the full-bridge converter operated in a hard-switching manner: (a) switch voltage V_DC1 and current I_DS1, and (b) switch voltage V_DS₂ and current I_DS₂.

Figure 13. Measured waveforms of switch voltage and current under 30% of full-load conditions for the full-bridge converter operated in asoft-switching manner: (a) switch voltage V_DC1 and current I_DS1, and (b) switch voltage V_DS₂ and current I_DS₂.

Figure 14. Measured output voltage V_DC1 and current I_DC1 waveforms under step-load change between 10% of full-load conditions and full-load conditions.

Figure 15. Efficiency comparison between the proposed full-bridge converter and the conventional one from a light load to a heavy load.

Figure 16. Core loss (mW/cm³) curves of transformer T_r, manufactured by PC 40 material of TDK.

Figure 17. Core loss (mW/cm³) curves of inductor L₁, manufactured by PC 40 material of TDK.

Figure 18. Block diagram of the proposed DC distribution system with multipleinput power sources.

Figure 19. Measured currents I_DC1, I_DC21, and I_DC22 and voltage V_DC2 waveforms when

0 < P_{24 V} + P_{48 V} \leq P_{P V (m a x)}

Figure 19. Measured currents I_DC1, I_DC21, and I_DC22 and voltage V_DC2 waveforms when

0 < P_{24 V} + P_{48 V} \leq P_{P V (m a x)}

Figure 20. Measured currents I_DC1, I_DC21, and I_DC22 and voltage V_DC2 waveforms when

P_{P V (m a x)} < P_{24 V} + P_{48 V} \leq P_{P V (m a x)} + P_{ac (m a x)}

Figure 20. Measured currents I_DC1, I_DC21, and I_DC22 and voltage V_DC2 waveforms when

P_{P V (m a x)} < P_{24 V} + P_{48 V} \leq P_{P V (m a x)} + P_{ac (m a x)}

Figure 21. Measured currents I_DC1, I_DC21, and I_DC22 and voltage V_DC2 when P_ac(max) + P_BS(max) < P_{24 V} + P_{48 V}.

Table 1. Acronyms and abbreviations.

Acronyms/ Abbreviations	Parameter/Definition
ZVS	Zero-voltage switching
PFC	Power factor correction
ZCS	Zero-current switching
ZCT	Zero-current transition
ZVT	Zero-voltage transition
IC	Integrated circuit
PWM	Pulse-width modulation
PV	Photovoltaic
MPPT	Maximum power point tracking
CCM	Continuous conduction mode
DCM	Discontinuous conduction mode

Table 2. Key component parameters of the proposed full-bridge converter.

Component	Part Number	Voltage/Current Ratings or Formula	Features
Component	Part Number	Voltage/Current Ratings or Formula	Symbol	Parameter	Values
Switches $M_{1}$ , $M_{2}$ , $M_{3}$ , $M_{4}$	AOW2918	100 V/90 A	$R_{D S (o n)}$	Drain-source on resistance	<7 mΩ
			$t_{o n}$	Turn-on transition time	41 ns
			$t_{o f f}$	Turn-off transition time	51 ns
Diodes $D_{1}$ ~ $D_{4}$	STPS41H100CT	100 V/40 A	$V_{F (m a x)}$	Maximum forward voltage	0.67 V
Transformer $T_{r}$	EE-55Core (PC 40, manufactured by TDK)	$B_{m} = \frac{u_{o} u_{r} N_{1} I_{L m (P)}}{l_{e 1}}$ (T) $u_{o}$ : 4π× $10^{- 7} H / m$ $I_{L m (P)}$ : Peak Current of magnetizing inductor for primary winding $R_{D C 1 (T r)} = \frac{R_{D C (28)} N_{1} l_{m 1 (T r)} {* 10}^{- 6}}{40}$ (Ω) $R_{D C 2 (T r)} = \frac{R_{D C (28)} N_{2} l_{m 2 (T r)} {* 10}^{- 6}}{80}$ (Ω)	$u_{r}$	Permeability	2300
			$l_{e 1}$	Effective Magnetic Path length	123 mm
			$V_{e 1}$	Effective core volume	43.7 ${cm}^{3}$
			$l_{m 1 (T r)}$	Approximate mean length of turn for primary winding	92.2 mm
			$l_{m 2 (T r)}$	Approximate mean length of turn for secondary winding	100.6 mm
			$R_{D C 1 (T r)}$	Resistance using 40 strands of AWG#28 for primary winding	8.37 mΩ
			$R_{D C 2 (T r)}$	Resistance using 80 strands of AWG#28 for secondary winding	3.71 mΩ
			$N_{1}$	Turn of primary winding	16 T
			$N_{2}$	Turn of secondary winding	13 T
			$R_{D C (28)}$	Resistance of AWG#28	227 $\frac{m Ω}{m}$
Inductor $L_{1}$	EE-55Core (PC 40 manufactured by TDK)	$B_{m (L 1)} = \frac{u_{o} u_{r} N_{3} I_{L 1 (P)}}{l_{e 2} {+ u}_{r} l_{g}}$ (T) $I_{L 1 (P)}$ : Peak Current of inductor $L_{1}$ $R_{D C 3 (L 1)} = \frac{R_{D C (28)} N_{3} l_{m 3 (L 1)} {* 10}^{- 6}}{80}$ (Ω)	$u_{r}$	permeability	2300
			$l_{e 2}$	Effective Magnetic Path length	123 mm
			$V_{e 2}$	Effective core volume	43.7 ${cm}^{3}$
			$l_{m 3 (L 1)}$	Approximate mean length of turn	96.4 mm
			$R_{D C 3 (L 1)}$	Resistance using 80 strands of AWG#28	4.38 mΩ
			$l_{g}$	Air gap	3.08 mm
			$N_{3}$	Turn of inductor $l_{1}$	16 T

Table 3. Power management of the proposed DC distribution system.

	State 1	State 2	State 3
Power System	$0 < P_{24 V} + P_{48 V}$ $\leq P_{P V (\max)}$	$P_{P V (\max)} <$ $P_{24 V} + P_{48 V}$ $\leq P_{P V (\max)} + P_{a c (\max)}$	$P_{P V (\max)} + P_{a c (\max)} <$ $P_{24 V} + P_{48 V}$
Power factor correction (utility line) P_ac(max)	shutdown	working	shutdown
DC/DC converter with PV arrays (MPPT) P_PV(max)	working	working	shutdown
The proposed full-bridge converter (with multiple input sources) $P_{24 V (m a x)}$	working	working	shutdown
Load#1 $P_{24 V}$	ON	ON	OFF
Load#2 $P_{48 V}$	ON	ON	OFF

Table 4. Semiconductor loss analysis of the proposed full-bridge converter under different load conditions.

Load (%)	$Switch M_{1}$ $or M_{3} Loss$		$Switch M_{2}$ $or M_{4}$		$Diodes D_{1} - D_{4}$
Load (%)	Switch Loss $P_{s o f f 1} = \frac{1}{{2 T}_{s}} V_{D S}$ ${(t}_{s o f f} I_{P}) (W)$	Conduction Loss $P_{c 1}$ $= I_{D S 1 (r m s)}^{2}$ $R_{d s (o n)} (W)$	Switching Loss $P_{s o f f 2} = \frac{1}{{2 T}_{s}} V_{D S}$ ${(t}_{s o f f} I_{P}) (W)$	Conduction Loss $P_{c 2}$ $= I_{D S 2 (r m s)}^{2}$ $R_{d s (o n)} (W)$	Forward Drop $Voltage Loss P_{D 1}$ $= I_{D 1 (r m s)} V_{F} (W)$
10	160 m	7 m	160 m	25 m	0.76
20	263 m	25 m	263 m	36 m	1.47
30	365 m	56 m	365 m	150 m	2.19
40	468 m	99 m	468 m	253 m	2.91
50	571 m	155 m	571 m	384 m	3.63
60	674 m	223 m	674 m	541 m	4.36
70	777 m	303 m	777 m	726 m	5.08
80	880 m	396 m	880 m	938 m	5.81
90	982 m	501 m	982 m	1.18	6.53
100	1.085	618 m	1.085	1.44	7.26

Table 5. Key component currents of the proposed full-bridge converter under different load conditions.

Load (%)	$I_{o}$ (A)	$I_{D}$ (A)	$I_{P}$ (A)	$I_{D S 1 (r m s)}$ $= I_{D S 3 (r m s)}$	$I_{D S 2 (r m s)}$ $= I_{D S 4 (r m s)}$	$I_{L K (r m s)}$	$I_{N S (r m s)}$	$I_{D 1 (r m s)}$ $= I_{D 2 (r m s)}$ $= I_{D 3 (r m s)}$ $= I_{D 4 (r m s)}$	$I_{L 1 (r m s)}$	Operational Condition
10	2.1	0.75	2.611	0.986	1.879	2.122	1.743	1.136	2.205	$V_{D C 2} = 48 V$ , $V_{o} = 24 V$ , $I_{o (m a x)} = 21 A$ , $N = 0.8$ , $D = 0.3125$ , $T_{s} = 20 μ S$ , $L_{1} = 38.7 μ H$ , ${Δ I}_{L 1} = \frac{({N V}_{D C 2} - V_{o})}{L_{1}} \times {D T}_{S} = 2.326 A$ $I_{D} N = I_{o} - \frac{Δ I_{L 1}}{2}$ , $I_{P} {= I}_{D} {+ Δ I}_{L 1}$ , and $I_{L m (P)} = \frac{V_{D C 2}}{L_{m}} {D T}_{s}$ = 0.174 A
20	4.2	2.43	4.291	1.902	2.269	3.76	3.362	2.192	4.253
30	6.3	4.11	5.971	2.834	4.626	5.425	5.01	3.266	6.337
40	8.4	5.79	7.651	3.769	6.013	7.097	6.663	4.344	8.428
50	10.5	7.47	9.331	4.706	7.402	8.772	8.319	5.423	10.523
60	12.6	9.15	11.011	5.643	8.793	11.448	9.976	6.563	12.618
70	14.7	10.83	12.691	6.581	10.184	12.125	11.634	7.584	14.716
80	16.8	12.51	14.371	7.519	11.575	13.803	13.292	8.665	16.813
90	18.9	14.19	16.051	8.458	12.967	15.482	14.952	9.747	18.913
100	21	15.87	17.731	9.397	14.36	17.161	16.612	10.829	21.012

Table 6. Core parameters and core loss analysis for the proposed full-bridge converter.

Load (%)	Core Loss and Core Parameters
	$Transformer T_{r}$				$Inductor L_{1}$
	Maximum Flux Density $B_{m} = \frac{u_{o} u_{r} N_{1} I_{L m (P)}}{l_{e 1}} (mT)$	Core Loss Efficiency $C_{P 1}$ $(\frac{mw}{{c m}^{3}})$	Core Loss $P_{C 1 (T r)}$ $(V_{e 1} = 43.7 {c m}^{3})$ (W)	Copper Loss $P_{C P (T r)} (W)$	Maximum Flux Density $B_{m} = \frac{u_{o} u_{r} N_{1} I_{L m (P)}}{l_{e 2} {+ u}_{r} l_{g}} (mT)$	Core Loss Efficiency $C_{P 2}$ $(\frac{m w}{{c m}^{3}})$	Core Loss $P_{{C 2 (L}_{1})}$ $(V_{e 2} = 43.7 {c m}^{3})$ (W)	Copper Loss $P_{{C P (L}_{1})} (W)$
10	65.3	7	306 m	49 m	20.9	2	87 m	21 m
20	65.3	7	306 m	160 m	34.4	2.8	122 m	79 m
30	65.3	7	306 m	339 m	47.9	4	175 m	176 m
40	65.3	7	306 m	586 m	61.3	7	360 m	311 m
50	65.3	7	306 m	900 m	74.8	8	350 m	485 m
60	65.3	7	306 m	1.47	88.2	20	874 m	697 m
70	65.3	7	306 m	1.73	101.7	32	1.40	949 m
80	65.3	7	306 m	2.25	115.2	40	1.75	1.24
90	65.3	7	306 m	2.84	128.6	60	2.62	1.57
100	65.3	7	306 m	3.49	142.1	70	3.06	1.93

Table 7. Power loss analysis for the proposed full-bridge converter under different load conditions.

Load (%)	Practical Efficiency $η_{p}$ (%)	Switch Losses		Diode Losses	Total Core Losses $P_{T C} = P_{C 1 (T r)} + P_{C P (T r)} + P_{C 2 (L 1)} + P_{C P (L 1)} (W)$	Total Power Losses $P_{l o s s} (W)$	Calculation Efficiency $η_{c} (%)$
Load (%)	Practical Efficiency $η_{p}$ (%)	Switching Losses $P_{T S 1} {= 2 P}_{s o n 1} + {2 P}_{s o n 2} (W)$	Conduction Loss $P_{T C} {= 2 P}_{C 1} {+ 2 P}_{C 2} (W)$	$P_{T D} {= 4 P}_{D 1} (W)$		Total Power Losses $P_{l o s s} (W)$	Calculation Efficiency $η_{c} (%)$
10	88.5	640 m	64 m	3.04	463 m	4.21	92.2
20	90.5	1.05	122 m	5.88	667 m	7.72	92.8
30	90.4	1.46	412 m	8.76	996 m	11.63	92.8
40	91	1.87	704 m	11.64	1.56	15.77	92.7
50	92	2.28	1.08	14.52	2.04	19.92	92.6
60	91	2.70	1.53	17.44	3.35	25.02	92.3
70	91	3.11	2.06	20.32	4.39	29.88	92.1
80	90	3.52	2.67	23.24	5.55	34.98	91.9
90	89	3.93	3.36	26.12	7.34	40.75	91.7
100	88	4.34	4.11	29.04	8.79	46.28	91.5

Table 8. Power rating of each power processor in the proposed DC distribution system.

Power Sources	Symbol	Definition	Value
Utility line (using power factor correction(PFC))	P_ac	output power of utility line at present
Utility line (using power factor correction(PFC))	P_ac(max)	maximum output power of utility line	720 W
PV arrays (using DC/DC converter with PV arrays)	P_PV	output power of PV arrays
PV arrays (using DC/DC converter with PV arrays)	P_PV(max)	maximum output power of PV arrays	1200 W
Load	P_{24 V}	consumption power at present (Load#1)	P_{24 V(max)} = 500 W
	P_{48 V}	consumption power at present (Load#2)	P_{48 V(max)} = 1360 W
	P_24SV	output power of the proposed full-bridge converter
	P_24SV(max)	maximum output power of the proposed full-bridge converter	500 W

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Tseng, S.-Y.; Fan, J.-H. Soft-Switching Full-Bridge Converter with Multiple-Input Sources for DC Distribution Applications. Symmetry 2021, 13, 775. https://doi.org/10.3390/sym13050775

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Tseng S-Y, Fan J-H. Soft-Switching Full-Bridge Converter with Multiple-Input Sources for DC Distribution Applications. Symmetry. 2021; 13(5):775. https://doi.org/10.3390/sym13050775

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Tseng, S.-Y., & Fan, J.-H. (2021). Soft-Switching Full-Bridge Converter with Multiple-Input Sources for DC Distribution Applications. Symmetry, 13(5), 775. https://doi.org/10.3390/sym13050775

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Soft-Switching Full-Bridge Converter with Multiple-Input Sources for DC Distribution Applications

Abstract

1. Introduction

2. Related Work

3. Topology and Operational Method of the Proposed DC Distribution Power

3.1. Topology of the Proposed DC Distribution System

3.2. Operational Method of the Proposed Full-Bridge Converter

4. Design Method of Full-Bridge Converter with Multiple Input Sources

4.1. Component Design of the Proposed Full-Bridge Converter

4.2. Component Selection of the Proposed Full-Bridge Converter

5. Power Loss Analysis of the Proposed Full-Bridge Converter

5.1. Losses of Switches

5.2. Losses of Diodes

5.3. Losses of Transformer $T_{r}$ and Inductor $L_{1}$

6. Power Management of the Proposed DC Distribution System

6.1. Control Algorithm of the Proposed DC Distribution System

6.2. Power Management of the Proposed DC Distribution System

7. Measured Results and Discussion

8. Conclusions

Author Contributions

Funding

Institutional Review Board Statement

Informed Consent Statement

Data Availability Statement

Conflicts of Interest

References

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Article Menu

Soft-Switching Full-Bridge Converter with Multiple-Input Sources for DC Distribution Applications

Abstract

1. Introduction

2. Related Work

3. Topology and Operational Method of the Proposed DC Distribution Power

3.1. Topology of the Proposed DC Distribution System

3.2. Operational Method of the Proposed Full-Bridge Converter

4. Design Method of Full-Bridge Converter with Multiple Input Sources

4.1. Component Design of the Proposed Full-Bridge Converter

4.2. Component Selection of the Proposed Full-Bridge Converter

5. Power Loss Analysis of the Proposed Full-Bridge Converter

5.1. Losses of Switches

5.2. Losses of Diodes

5.3. Losses of Transformer T r and Inductor L 1

6. Power Management of the Proposed DC Distribution System

6.1. Control Algorithm of the Proposed DC Distribution System

6.2. Power Management of the Proposed DC Distribution System

7. Measured Results and Discussion

8. Conclusions

Author Contributions

Funding

Institutional Review Board Statement

Informed Consent Statement

Data Availability Statement

Conflicts of Interest

References

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5.3. Losses of Transformer $T_{r}$ and Inductor $L_{1}$