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High-Efficiency High-Power-Density DC-DC Module, Based on Full Bridge Phase Shift Converter

High-Efficiency High-Power-Density DC-DC Module, Based on Full Bridge Phase Shift Converter. H. Pisani.

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High-Efficiency High-Power-Density DC-DC Module, Based on Full Bridge Phase Shift Converter

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  1. High-Efficiency High-Power-Density DC-DC Module, Based on Full Bridge Phase Shift Converter H. Pisani In order to develop a high-efficiency and high power density dc-dc module the CEI has created a methodology that takes into account the power losses and size of semiconductors and magnetic components to find the optimal design. This method helps during the design when it is necessary to make a trade-off between the efficiency and power density. The proposed method has been validated and the implemented converter has efficiency as high as 91.8% (in nominal conditions) and power density of 4.8 kW/dm3. Project sponsored by: Selected Architecture Objective and Specifications Full Bridge Phase Shift Substitute a commercial solution for a custom with the following specifications: • Nominal input voltage : 270V (180V-350V) • Nominal output voltage : 48V ( 39V – 55V) • Nominal output power : 600W • Constant switching frequency: 80 – 105 kHz • Possibility to put several modules in parallel • Limited volume : 12.2 x 4.7 x 2.16 cm3 • Good utilization of magnetic material in transformer • ZVS on the primary side Architecture Optimization • MOSFET voltage clamped to Vin Multi-objective Optimization System variables Important Design Issues • Magnetic design • Inductors • Transformer Non dissipative snubber • Capacitor design • Size and number • Recycling energy of PCB’s parasitics • Small components • Low voltage ratings Rectifierdiode’svoltage Primary Side Clamping Diodes 350V • Semiconductor design • Selection of MOSFETs and diodes • Number of MOSFETs and diodes in parallel The analysis leads to estimated volume, efficiency, electrical and thermal stress • Helps to obtain ZVS at low loads • Reduces oscillations at the secondary side Design of Additional Inductor • Helps to obtain ZVS Pareto Front • Fast current slope • High core losses High core temperature Complex design Maximum inductance hardly limited Experimental Results Designed Converter Commercial Converter Measured Efficiency Constant Switching Frequency Variable Switching Frequency Nominal Efficiency : 91.8 % Nominal Efficiency : 89 % Provide nominal power in full voltage range Output power limited by output voltage and current limit Power Density : 4.8kW/dm3 Power Density : 6 kW/dm3 CONCLUSIONS A commercial converter has been replaced by a highly optimized custom made converter. In order to design it, a multivariable optimization has been applied. The implemented converter operates at constant switching frequency, has higher efficiency than the commercial design and can provide nominal power in full range of output voltage (which the substituted commercial solution cannot do)

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