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Implementation of a Modular Full-Bridge DC/DC

Converter
B.R. Lin, Senior Member, IEEE, and Sheng-Zhi Zhang
Department of Electrical Engineering, National Yunlin University of Science and Technology, Yunlin 640, Taiwan

Abstract–In this paper, the modular multilevel dc/dc converters, byloss and low effective duty cycle. Therefore, the lower turns
integrating the full-bridge converters in series, are provided for ratio transformer must be used. The lower turns ratio
high power and high voltage dc-based systems. Each circuit module transformer will increase the primary conduction losses. To
includes a full-bridge converter and a half-bridge LLC resonant reduce the high circulating current losses, active components or
converter to implement the wide range of soft switching and low
conduction losses. The ZVS condition of the power switches at the
passive components [10] are adopted at the output side to reduce
leading leg is implemented by the energy stored on the output voltage overshoots and oscillations across the output diodes.
inductor. The ZVS condition of power switches at the lagging leg isTherefore, the primary current can be reduced to zero when the
implemented by the LLC resonant converter. Therefore, all converter is operated at freewheeling state.
switches can be turned on at ZVS from light load. A passive A modular multilevel dc/dc converter is presented to achieve
snubber is adopted on the secondary side of full-bridge converter low conduction loss and wide ZVS range. The proposed circuit
to reduce the conduction loss during the freewheeling interval topology is input-series and output-parallel of two circuit
especially at high input voltage and full load conditions. The modules with one flying capacitor. Thus, the voltage rating of
outputs of the full-bridge converter and resonant converter are power switches is reduced and low voltage rating switches can
series connection. Therefore, energy is transferred by both
converters at whole switching period. Two circuit modules are
be used in the proposed converter. One flying capacitor
connected input-series and output-parallel to effectively limit theconnected between two circuit modules can be used to balance
voltage rating of switches at Vin/2. Flying capacitor is adopted ininput capacitor voltages. In each circuit module, full-bridge
the proposed circuit to balance input voltages in each switching converter with LLC converter sharing the lagging-leg switches
cycle without the complexity control scheme. Finally, Experiments can achieve the wide ZVS range of all switches. The passive
with a 1920W prototype are provided to demonstrate the snubbers are used on the secondary side to decrease the primary
performance of the proposed circuit. current to zero. Thus, the high conduction loss in conventional
PS-PWM full-bridge circuit is improved. The output voltages of
Keywords—full-bridge converters; zero-voltage switching, LLC.. the LLC converter and the full-bridge converter are series
connection. Thus, energy can be delivered by both converters
I. INTRODUCTION
during the entire switching period. Finally, experiments with a
Multilevel converters for ac motor drivers [1], reactive laboratory circuit rated at 1920W are provided to show the
power compensators [2], high voltage dc distribution systems [3] performance of the proposed circuit.
and dc-based data storage systems [4] have been proposed and
studied for many years. The circuit topologies of multilevel II. CIRCUIT DIAGRAM
converters are based on the series-connected full-bridge circuits, Fig. 1 illustrates the circuit diagram of the modular three-
flying capacitor topologies or clamped diodes to reduce the level converter for high voltage dc-based applications such as
voltage stress of power semiconductors. For multilevel dc/dc dc-based distributions and dc-based data storage systems. The
converters, soft switching three-level pulse-width modulation circuit topology is based on the input-series and output-parallel
converters have presented in [5]-[7] to limit voltage stress of of two circuit modules with one flying capacitor connected
power semiconductors at Vin/2, decrease the switching losses between points a and d to autobalance input split capacitor
and increase the circuit efficiency. The phase shift pulse-width voltages v and v at V /2. Each circuit module delivers one
Cin1 Cin2 in
modulation (PS-PWM) is adopted to generate the gate signals of half of the rated power to the output load. The voltage rating of
power switches. The active switches at the leading leg can be power switch is limited at V /2. Therefore, the low voltage
in
easily turned on at zero voltage switching (ZVS) due to the rating switches can be used with the advantages of low turn-on
energy stored on the output inductor is reflected to the primary resistance and low conduction losses. Fig. 2 gives the main
side to discharge the output capacitance of switches. However, PWM waveforms of the modular dc-dc converter. Switches S
1x
the first shortcoming of the PS-PWM scheme is the narrow ZVS and S have the same time sequence, where x=1, 2, 3 and 4. The
2x
load range of the switches at the lagging leg switches due to the PS-PWM scheme is used to generate the necessary PWM
limited energy stored on the primary leakage inductor. The other waveforms of power switches S ~S . If switches S and S are
11 24 11 21
problem is the high conduction losses when the primary side is in the on state and S and S are both turned off as shown in
14 24
operated at freewheeling state. To extend the ZVS range, a large Fig. 3(a), then the flying capacitor voltage v =v
Cf Cin1 with time
leakage inductance or an external resonant inductance [8] or duration T /2. In the same manner, the flying capacitor voltage
s
half-bridge converter [9] can be used on the primary side. v =v
Cf Cin2 if S11 and S21 are in the off state and S14 and S24 are
However, the large inductance will results in high duty cycle

978-1-4673-8473-5/16$31.00 ©2016 IEEE


turned on with the time duration Tsw/2 as shown in Fig. 3(b). condition. Therefore, the primary fundamental current ip12 is
Therefore, it can obtain that vCin1=vCin2=vCf=Vin/2 and no lagging to the primary fundamental voltage vbc and the ZVS of
additional active component or the complex control loop is the lagging-leg switches S12 and S13 are easily achieved from
needed to balance the input spilt capacitor voltages. The light load. The passive snubber circuit including Cc1, Da1 and
advantages of the proposed modular multilevel dc/dc converter Db1 is adopted on the secondary side to reduce the primary
are low conduction losses due to low circulating current, wide current to zero at freewheeling state. When vab=0 (freewheeling
ZVS range due to resonant converter connected to the lagging- state), the diode Da1 conducts and the rectified voltage vr1=vCc1.
leg switches, less output inductor current ripple and voltage The reflected voltage n11vr1 is applied to Lr11 to decrease the
auto-balance ability. primary current ip11 to zero value. The output inductor voltage
vLo1=vCc1-vo11 instead of -vo11 in the conventional full-bridge
converter so that the size of the output inductor Lo1 is reduced.
Since the output voltages of the full-bridge converter and the
LLC converter are series connection, the resonant converter can
transferred energy for the entire switching period. Similarly,
module 2 has the same circuit characteristics as module 1.

(a) (b)
Fig. 1. Proposed modular multilevel dc/dc converter (a) circuit diagram.
Fig. 3. Voltage autobalance scheme (a) vCf=vCin1 (S11 and S21 on) (b) vCf=vCin2 (S14
and S24 on)

III. OPERATION PRINCIPLES


In the proposed modular multilevel converter, all
components in each circuit module are identical Lr11=Lr21,
Lr12=Lr22, Cr1=Cr2, Lo1=Lo2, n11=n21 and n12=n22. MOSFETs and
rectifier diodes are assumed ideal. The voltages across Co11~Co22
are constant. The output capacitances of switches
C11=….=C24=Coss. Based on the conduction states of power
switches and rectifier diodes, there are seven topological stages
in each half of switching cycle. Fig. 4 illustrates the equivalent
circuits for each stage at the first half switching cycle.
Stage 1 [t0 - t1]: Prior to t0, S11, S12, S21, S22, D11, D14, D21 and D24
conduct. The inductor currents ip11>0, ip12<0, ip21>0 and ip22<0.
S11 and S21 are turned off at time t0. ip11 (ip21) charges C11 (C21)
and discharges C14 (C24). The energy stored on Lo1 (Lo2) is used
Fig. 2. key PWM waveforms of the proposed converter in a switching cycle. to discharge C14 (C24) to zero voltage. Therefore, the ZVS
conditions of S14 and S24 are expressed in (1) and (2),
The circuit module 1 includes a full-bridge converter (S11-S14, respectively.
C11-C14, T11, Lr11, D11, D12, Lo1, Cc1, Da1, Db1 and Co11) and a LLC 2
( Lr11 + n11 Lo1 )i 2p11 (t0 ) ≥ 2Coss (Vin / 2) 2 = CossVin2 / 2 (1)
converter (S12, S13, C12, C13, Lr12, Cr1, T12, D13, D14 and Co12). (S11
2
and S14) and (S12 and S13) are in the leading-leg and lagging-leg, ( Lr 21 + n21 Lo 2 )i 2p 21 (t0 ) ≥ CossVin2 / 2 (2)
respectively. Half-bridge LLC converter is worked at the Since all components in circuit modules 1 and 2 are identical
constant duty cycle and constant switching frequency. Therefore, (L =L , i =i , L =L and n =n ), equation (1) and (2)
r11 r21 p11 p21 o1 o2 11 21
the output voltage Vo12 is un-regulated. The energy stored on the can be further expressed as (3) if the current ripple on L and
o1
output inductor Lo1 is used to achieve ZVS of the switches S11 L can be neglected.
o2
and S14 at the leading leg. The half-bridge LLC converter based 2
on the series resonant inductor Lr12, resonant capacitor Cr1 and ( Lr11 / n11 + Lo1 ) I o2 ≥ 2CossVin2 (3)
the magnetizing inductor Lm12 is operated at the inductive load
Stage 1 ends at t1 when vC14=vC24=0. The time duration at stage capacitor currents iCc1 and iCc2 to zero before S14 and S24 are
1 is given in (4). turned off. The rectified voltages vr1=vCc1+Vo11 and vr2=vCc2+Vo21.
C V 2n C V The primary currents ip11=-(iLo1+iCc1)/n11 and ip21=-(iLo2+iCc2)/n21
Δt01 = oss in ≈ 1 oss in (4) in this stage.
i p1 (t0 ) Io
Stage 7 [t6 - t7]: At time t6, ia1=iLo1 and ia2=iLo2 so that diodes Db1
The dead time between S11 (S21) and S14 (S24) must be greater and Db2 are both reverse biased. The rectified voltages
than Δt01 to achieve ZVS of S14 and S24. vr1≈Vin/(2n11)>vCc1 and vr2≈Vin/(2n21)>vCc2. Thus, diodes Da1 and
Stage 2 [t1 - t2]: Capacitors C14 and C24 are discharged to zero Da2 are reverse biased. The output inductor voltages
voltage at time t1. Therefore, vab=vde=0 and diodes Da1 and Da2 vLo1=Vin/(2n11)-Vo11>0 and vLo2=Vin/(2n21)-Vo21>0 so that iLo1 and
conduct. The inductor voltages vLo1=vCc1-Vo11<0 and vLo2=vCc2- iLo2 increase. At t7, S14 and S24 turn off and the circuit operation
Vo21<0 so that iLo1 and iLo2 decrease. Since ip11(t1) and ip21(t1) are for the first half switching period is ended.
both positive, the anti-parallel diodes of S14 and S24 conduct. D11 ia1 iLo1 Lo1 g Io
Therefore, the ZVS of S14 and S24 is achieved at t1. The reflected T11
+ + Db1
vr1 Cc1 +
Vo11
secondary windings voltages -n11vCc1 are applied to Lr11 and Lr21, module 1
- Da1 Co11
+
respectively and the primary currents ip11 and ip21 rapidly + D12 Vo
-
Ro
Vin S11 C11 S13 C13
decrease to zero at time t2. Thus, the conduction losses at T11
b
T12
D13 +
freewheeling state are removed. The time interval in this stage
+ a Lr11 Lm11 Lr12 Cr1 Co12 Vo12
Cin1 ip11 T12
2 ip12 h
is given as Δt12 = t2 − t1 ≈ Lr11 I o /( 2n11 vCc1 ) . The energy stored vCf + S14
Cf
C14 S12 L
C12 m12 D14
c
on capacitors Cc1 and Cc2 is transferred to the output load S21 C21T S23 C23
D21 ia2 iLo2 Lo2
T21 g
through (Lo1 and Da1) and (Lo2 and Da2), respectively. The LLC Cin2 +
21
e
+
vr2 Cc2
+ D
b2 +
Vo21
d Lr21 Lm21 Lr22 Cr2 - Da2 Co21
converters are still worked at resonant mode to delivered power. ip21 T22
ip22 D22
Stage 3 [t2 - t3]: At time t2, the rectified currents ia1 and ia2 -
S24 C24 S22 L
C22 m22
T22
decrease to zero. The capacitor currents iCc1=-iLo1 and iCc2=-iLo2. module 2 f D23 +
Co22 Vo22
The primary currents ip11=iLm11≈0 and ip21=iLm21≈0 in this stage. h
There is almost no circulating current loss in the primary side of D24
full-bridge converters. In this stage, vLo1=vCc1-Vo11<0 and (a)
vLo2=vCc2-Vo21<0 so that iLo1 and iLo2 are both decreasing.
Stage 4 [t3 - t4]: At t3, switches S12 and S22 turn off. Since ip12(t3)
and ip22(t3) are both negative, ip12 (ip22) charges C12 (C22) and
discharge C13 (C23). Since the LLC converters are working at the
inductive load, the primary currents ip12 and ip22 are lagging to
the input fundamental voltages vbc and vef. Therefore, the ZVS
turn-on of S13 and S23 are easily achieved at t4.
Stage 5 [t4 - t5]: At time t4, the capacitor voltages of C13 and C23
are decreased to zero. Since ip12(t4)-ip11(t4)<0 and ip22(t4)-
ip21(t4)<0, the output diodes of S13 and S23 conduct. Therefore,
the ZVS turn-on of S13 and S23 are achieved. The rectified
currents ia1 and ia2 increase. Since ia1<iLo1 and ia2<iLo2, the clamp
diodes Da1 and Da2 conduct. The primary inductor voltages
vLr11=n11vCc1-Vin/2<0 and vLr21=n21vCc2-Vin/2<0. The primary
currents ip11 and ip21 both decrease. The LLC converters are
resonant with vbc=vef=Vin/2. The primary side currents ip12 and (b)
ip22 increase in this stage. The primary currents ip11 and ip21
decrease until ip11=-iLo1/n11 and ip21=-iLo2/n21. The duration time
2
in this stage is give as Δt45 = t5 − t4 ≈ Lr11 I o /(n11Vin − 2n11 vCc1 ) .
In this stage, the primary voltages vab=vde=-Vin/2 in the full-
bridge converter and the rectified voltages vr1=vCc1 and vr2=vCc2.
The duty cycle loss at stage 5 is given as
2
δ 5 = Δt45 / Ts = Lr11 I o f s /( n11Vin − 2n11 vCc1 ) .
Stage 6 [t5 - t6]: At t5, the rectified currents ia1=iLo1 and ia2=iLo2
so that Da1 and Da2 are reverse biased. The reflected primary
inductance Lr11/(n11)2 and Cc1 are resonant with the resonant
frequency f R = n11 /(2π Lr11Cc1 ) . Therefore, diodes Db1 and
Db2 conduct in this stage and iLo1 and iLo2 increase. The half of a
resonant period 1/(2fR) should be less than the minimum
(c)
effective duty cycle time (δeff,minTs/2) in order to reduce the
IV. SYSTEM ANALYSIS
In the adopted modular converter, each circuit module
transfers one-half of the rated power to the output load by both
full-bridge converter and full-bridge resonant converter. LLC
resonant converter is controlled at the constant duty cycle
(δ=0.5) and constant switching frequency so that the output
voltages Vo12 and Vo22 are unregulated. Based on the
fundamental frequency analysis, the voltages
Vo12=Vo22≈Vin/(4n12)=Vin/(4n22). The operating switching
frequency fs is close to the series resonant frequency by Lr12 and
Cr1, f r1 = 1 / 2π Lr12 C r1 . Therefore, the primary current of the
resonant converter is reduced. Since the resonant converter is
(d) worked at the inductive load, the ZVS turn-on of the lagging-leg
switches S12, S13, S22 and S23 is easily achieved from light load.
The energy stored on Lo1 and Lo2 is used to achieve ZVS turn-on
of the leading-leg switches S11, S14, S21 and S24. The charge and
discharge time of S11-S24 can be neglected compared to the other
time intervals. Thus, modes 2, 3, 5, 6 and 7 are considered in the
following to discuss the circuit characteristics. In stage 6, the
average capacitor voltages VCc1=Vin/(2n11)-Vo11 and
VCc2=Vin/(2n21)-Vo21. Applying the flux balance on the output
inductors Lo1 and Lo2, the output voltages Vo11 and Vo21 are
obtained as
Vin Vin
Vo11 = Vo 21 = = (5)
4n11 (1 − δ + δ 5 ) 4n11 (1 − δ eff )
(e) where the effective duty cycle δeff=δ-δ5, and δ is the duty ratio
when S11 and S12 are in the on-state or S13 and S14 are in the on-
state. The output voltages Vo is given in (6).
Vin V
Vo = Vo11 + Vo12 = + in (6)
4n11 (1 − δ eff ) 4n12
From (6), the dc voltage gain of the proposed modular dc/dc
converter is derived in (7).
n12 + (1 − δ eff )n11
M dc = Vo / Vin = (7)
4n11n12 (1 − δ eff )
The respective output powers of full-bridge converter and half-
bridge resonant converter are expressed as
Vin I o
Pfull − bridg ≈ (8)
(f) 4n11 (1 − δ eff )
Vin I o
Phalf-bridge ≈ (9)
4n12
Based on the circuit configuration, the voltage rating of S11~S24
is limited at Vin/2. The output inductor current ripple ΔiLo1 and
ΔiLo2 can be obtained in (10).
Δi Lo1 = Δi Lo 2 = (Vo11 − VCc1 )(0.5 − δ eff )Ts / Lo1
Vin (10)
≈ (2Vo11 − )(0.5 − δ eff )Ts / Lo1
2n11
The output inductances Lo1 and Lo2 can be obtained if the ripple
currents ΔiLo1 and ΔiLo 2 are given.
(g) Vin
Fig. 4. Operation stages of the proposed converter in the first half of the Lo1 = Lo 2 ≥ (2Vo1 − )(0.5 − δ eff )Ts / ΔiLo1 (11)
switching cycle (a) stage 1 (b) stage 2 (c) stage 3 (d) stage 4 (e) stage 5 (f) stage 2n11
6 (g) stage 7.
Based on the main PWM waveforms in Fig. 2, the theoretical the electric specifications: Vin=750V~800V, Vo=48V,
average current and voltage stress of the rectifier diodes D11-D24 Io,max=40A, Po,rated=1920W, and fs=100kHz (switching
are frequency). The power ratings of the two half-bridge converters
iD11, av = ir12, av = iD 21, av = i D 22, av ≈ δI o / 2 (12) and two full-bridge converters are assumed as 800W and
iD13, av = iD14, av = iD 23, av = iD 24, av ≈ I o / 4 (13) 1200W, respectively. Thus, each resonant converter is rated at
400W and full-bridge converter is operated at 600W rated
v D11,stress = v D12,stress = v D 21,stress = v D 22,stress ≈ Vin / n11 (14) power. The output current of each resonant converter is
v D13,stress = v D14,stress = v D 23,stress = v D 24,stress ≈ 2Vo11 = Vin /(2n12 ) (15) Io/2=40/2=20A. Therefore, the output voltages Vo12 and Vo22 are
400W/20A=20V. Fig. 5 gives the experimental waveforms
The average current and voltage stresses of the diodes Da1-Db2
vS11,gs-vS14,gs for 100% loads. The gating signals of S21-S24 are
are expressed as
the same as the gating voltages of S11-S14. The experimental
iDa1, av = iDa 2, av = iDb1, av = iDb 2, av ≈ (1 − 2δ ) I o / 2 (16)
waveforms vS11,gs, vS11,ds, and iS11 at 30% load are illustrated in
Vin Fig. 6. Before switch S11 is turned on, the drain current is
v Da1,stress = .. = v Db 2,stress ≈ Vo11 = (17)
4n11 (1 − δ eff ) negative to discharge the output capacitor of S11. Thus, the drain
voltage can be decreased to zero before the gate voltage is high
voltage level. The ZVS turn-on of S11 is achieved from 30%
load to full load. Fig. 7 shows the experimental waveforms
vS12,gs, vS12,ds, and iS12 at 5% load. Since the LLC resonant
converter and full-bridge converter share the lagging-leg
switches, it is clear that the ZVS turn-on of S12 is achieved from
5% load to full load. Fig. 8 shows the measured waveforms vba,
vbc, vCr1, ved, vef, vCr2 and ip11~ip22 at full load. There are three
voltage levels on vba and ved and two voltage levels on vbc and
vef. At the freewheeling state, the primary currents ip11 and ip21
are decreased to zero. Thus, the conduction loss at freewheeling
state is removed. The primary currents ip12 and ip22 are the quasi-
sinusoidal currents. Fig. 9 shows the experimental voltage
waveforms vCin1, vCin2 and vCf. Based on the measured results,
three capacitor voltages vCin1, vCin2 and vCf are balanced. The
measured circuit efficiencies are 92.1%, 94.2%, 95.3% and
Fig. 5. Measured waveforms of the gating voltages of S11~S14 at full load. 93.5% at 480W (25% load), 960W (50% load), 1440W (75%
load) and 1920W (full load), respectively.

Fig. 6. Measured results of the leading-leg switch S11 at 30% load.

Fig. 7. Measured results of the leading-leg switch S12 at 5% load.

V. EXPERIMENTAL RESULTS
Experiments based on a laboratory prototype are presented to
show the performance and effectiveness of the proposed Fig. 8. Measured results of the ac side voltages and primary side currents at full
modular dc/dc converter. The prototype circuit is realized with load.
[6] Yilei Gu, Zhengyu Lu, Lijun Hang, Zhaoming Qian, and Guisong Huang,
“Three-level LLC series resonant DC/DC converter,” IEEE Trans. Power
Electron., vol. 20, no. 4, pp. 781-789, 2005.
[7] S.-K. Han, G.-W. Moon, and M.-J. Youn, “A voltage-balanced phase-shifted
three-level DC/DC converter operating from high-input voltage,” IEEE
Power Electron. Letters, vol. 1, no. 3, pp. 74-77, Sep. 2003.
[8] J.A. Sabate, V. Vlatkovic, R.B. Ridlry, F.C. Lee, and B.H. Cho, “Design
considerations for high-voltage high-power full-bridge zero-voltage-
switched PWM converter,” in Proc. of IEEE-APEC Conf., pp. 275-284,
1990.
[9] W. Yu, J.S. Lai, W.-H. Lai, and H. Wan, “Hybrid resonant and PWM
converter with high efficiency and full soft-switching range,” IEEE Trans.
Power Electron., vol. 27, no. 12, pp. 4925-4233, 2012.
[10] T. Mishima, K. Akamatsu, and M. Nakaoka, “A high frequency-link
secondary-side phase-shifted full-bridge soft-switching PWM DC-DC
converter with ZCS active rectifier for EV battery charger,” IEEE Trans.
Power Electron., vol. 28, no. 12, pp. 5758-5773, 2013.

Fig. 9. Measured results of the input split capacitor voltage and flying capacitor
voltage at full load.

VI. CONCLUSION
This paper studies a modular multilevel converter to have the
advantages of low voltage stress of switches, wide ZVS range of
all switches and low conduction losses at freewheeling state.
The series full-bridge converter is adopted at high voltage side
to limit the voltage stress of switches at Vin/2. Therefore, the low
turn-on resistance power MOSFETs are used to reduce the
conduction losses. LLC resonant converter and full-bridge
converter share the lagging-leg switch to extend the ZVS range
from low load to full load. The primary currents can be reduced
to zero at freewheeling state due to a passive snubber circuit is
used on the output side. The output voltages of LLC converter
and full-bridge converter are connected in series. Thus, the
output power can be transferred by both converters. The flying
capacitor is adopted on the primary side to balance input
voltages. Finally, experiments with a laboratory prototype rated
at 1920W are presented to show the performance of the proposed
circuit.

ACKNOWLEDGMENT
This project is partly supported by the National Science
Council of Taiwan under Grant NSC 102-2221-E-224-022-
MY3.

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