A novel soft-commutating isolated boost full-bridge ZVS-PWM DC-DC converter for bidirectional high power applications

A soft-commutating method and control scheme for an isolated boost full bridge converter is proposed in this paper to implement dual operation of the well-known soft-switching full bridge dc/dc buck converter for bidirectional high power applications. It provides a unique commutation logic to minimize a mismatch between current in the current-fed inductor and current in the leakage inductance of the transformer when commutation takes place, significantly reducing the power rating for a voltage clamping snubber and enabling use of a simple passive clamped snubber. To minimize the mismatch, the method and control scheme utilizes the resonant tank and freewheeling path in the existing full bridge inverter at the voltage-fed side to preset the current in the leakage inductance of the transformer in a resonant manner. Zero-voltage-switching is also achieved for all the switches at the voltage-fed side inverter in boost mode operation. The proposed soft-commutating method is verified through boost mode operation of a 3-kW bidirectional isolated full bridge dc/dc converter developed for fuel cell electric vehicle applications. The tested result verified the isolated boost converter can operate at an input voltage of 8.5-15 V and an output voltage of 250-420 V with a peak efficiency of 93% and an average efficiency of 88% at 55-kHz switching frequency with 72 degrees C automotive coolant.