IOP Conference Series: Materials Science and Engineering
PAPER • OPEN ACCESS
DESIGN AND SIMULATION OF PHASE SHIFTED DC-DC FULL
BRIDGE CONVERTER
To cite this article: Prarthiv Evan Poudyal et al 2019 IOP Conf. Ser.: Mater. Sci. Eng. 623 012021
View the article online for updates and enhancements.
This content was downloaded from IP address 1.38.162.13 on 25/07/2021 at 05:48
VCADPCA 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 623 (2019) 012021 doi:10.1088/1757-899X/623/1/012021
DESIGN AND SIMULATION OF PHASE SHIFTED
DC-DC FULL BRIDGE CONVERTER
Prarthiv Evan Poudyal1, V Vigneshwar1, N K Kumar1, V Indragandhi1,
A Nazar Ali2
1
School of Electrical Engineering, Vellore Institute of Technology, Vellore
2
Associate Professor, Department of EEE, Rajalakshmi College of Technology, Chennai
Abstract -Electric and hybrid electric vehicle (EV/HEV) architectures require a small DC-DC
converterto replace any conventional vehicle’s alternator. The DC-DC converter, also described as
the vehicle Auxiliary Power Module (APM), provides power flow between the vehicle high
voltage (HV) and low voltage (LV) DC bus. This abstract represents the phase shifted full bridge
DC-DC converter scheme to design, simulate DC/DC Converter for a power rating of 80W
intended for low power/ auxiliary applications in electric vehicles The proposed converter is very
beneficial as it can be used for 4 quadrant operation much adaptive to the unknown parameters in
the PV system and these unknown parameters are estimated through the adaptation laws in the
algorithm which guarantees maximum power extraction possible from the power converter for a
PV system. The converter supplies AC current as per requirement. The overall stability of the
converter output is analyzed by simulation. The results are compared with other existing converter
results for improving power quality even further. The proposed results indicate the robustness of
the proposed scheme.
Keywords: DC-DC Converter, Phase Shift Full Bridge, Hybrid vehicles.
1 INTRODUCTION
Electric vehicles (EVs) powered by batteries are the key to reducing global warming and rising fuel
cost.[1,2] A recent survey reported that EVs must be a good for most Americans' driving and commute
patterns, and 40% of the respondents indicated strong interests in purchasing EVs.
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd 1
VCADPCA 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 623 (2019) 012021 doi:10.1088/1757-899X/623/1/012021
Figure 1 Isolated Topology
[2]Despite the increasing popularity of EVs, they have not yet dominated the internal combustion vehicle
market for three reasons. First, EVs are expensive due mainly to the large number of battery cells required
to power them. [3]There have been various ongoing researches about reducing EV energy consumption in
the usage-phase that focuses on the vehicle side through, for an instance, optimization of the powertrain
system, upgrade to motor control strategies, and improvements in power density of the battery. [5,7] Most
of the modern-day electric cars struggle with range that they can provide to the user on a full charge of
these batteries
The possible ways to tackle this can be two:
(1) Increase the capacity of the battery
(2) Decrease the loads and improve the converter efficiency within the car.
Figure.2 Block Diagram
[4]The second way, Decrease the loads and improve the converter efficiency within the car. Main Power
Circuit (Motor and Drive Circuit). Auxiliary Power Circuit (Air Conditioning Unit, Audio System, GPS
and others)
2. Non-isolated converters
The non-isolated type converters are generally used wherever the voltage needs to be either stepped up or
down by a relatively small ratio (less than 4:1). [7,8,9] And whenever there is no problem with the output
and input having no dielectric isolation. There are five main types of converter in this non-isolated group,
usually called the buck, boost, buck-boost, [11,12] Cuk and charge-pump converters. The buck converter
is used for stepping down the voltage to the desired value, while the boost converter is used for stepping
up the voltage to the desired value. The buck-boost and Cuk converters can be used for either stepping-
2
VCADPCA 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 623 (2019) 012021 doi:10.1088/1757-899X/623/1/012021
down or stepping-up as per applications requirement. [13,14] The charge-pump converter is used for
either voltage step-up or voltage inversion, but only in relatively low power applications.
3. Related Works
X Mahindra e2o plus P8 Variant
Specifications:
High Voltage Battery = 72V
Low Voltage Battery = 12V
DC-DC Converter Topology = Full Bridge Phase Shifted
Power Rated (Po) = 80W
X Toyota Prius 2001 Hybrid Variant
Specifications:
High Voltage Battery = 300V
Low Voltage Battery = 42V
DC-DC Converter Topology = Full Bridge Isolated Boost
Power Rated (Po) = 80W
4. SIMULATION&SYSTEM MODELLING
Designing of Transformer. Filter capacitor & Load resistance
( )
() =
( )
Here,
( ) = 12,
( ) = 72
() =
12
() =
72
.
, = 1/6
[
( )]
( ) =
( )
Here,
( ) = 12,
( ) = 80
3
VCADPCA 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 623 (2019) 012021 doi:10.1088/1757-899X/623/1/012021
[12]
( ) =
80
.
, = 1.8
1 1
!
"
("!) = #1 + &
4 √2 × %%%%
!
Here,
(' )
%%%% ) =
!
( !
*-
( )
Here,
!
3
5() = 1009:;,
( ) = 1.8 ,
(' ) = 0.12, *-
( ) = 12
0.12
%%%% ) =
!
( ! = 0.01
12
1 1
!
"
("!) = #1 + &
4 √2 × %%%%
!
1 1
= #1 + &
4 × 100 × 10< × 1.8 √2 × 0.01
.
, "! = 100μ!
5. SPECIFICATION FOR MATLAB MODELLING.
Input Voltage (Vi)= 72V
Output Voltage (Vo) = 12V
Power Rated (Po) = 80W
Transformer Turns Ratio (P:S1:S2) = 6:1:1
Duty Cycle = 50%
Topology = Full Bridge Phase Shift Type
Output Filter Capacitor ("!) = 100μF
Load Resistance (R) = 1.8Ω
5.1 Steady State Results:
Input Voltage (Vi)= 72V
Input Current (Ii) = 1.21A
Input Power (Pi) = 87.12W
Output Voltage (Vo)= 12V
4
VCADPCA 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 623 (2019) 012021 doi:10.1088/1757-899X/623/1/012021
Output Current (Io) = 6.69
Output Power (Po) = 80.28W
Hence, we simulate a DC/DC Converter for a power rating of 80W intended for low power applications in
hybrid electric vehicles.
6. OPERATION
Figure.3 Circuit Diagram
A full bridge isolated phase shifted DC-DC converter is used. Full bridge refers to turning ON the switch
by pairing on two of the four switches (MOSFET) crossing diagonally to transfer electric power from
primary side to secondary side. Efficiency is improved with the phase shift type using soft switching. We
assume the breakdown voltage required for MOSFET with the full bridge converter to be:
When S1 & S4 are turned ON, ON-resistance of MOSFET is low and as a result, it can be
regarded as a short circuit between drain and the source. Therefore, the voltage Vin is applied between the
drain and the source of MOSFET, S2 & S3 are in the OFF state. When S2 & S3 are turned ON, Vin is also
applied to S1 & S4 that are in the OFF state. This is the measure of the breakdown voltage required for
MOSFET. In fact, a design with sufficient margin is required with surge voltage and derating taken into
consideration. Voltages of +Vin & -Vin are applied to the primary side of the transformer alternately by
switching the switches. This enables an effect equivalent to that of applying the power supply voltage
twice (Vin * 2) which allows supporting high power application. A device with high speed and low ON
resistance is required as a switching element. POWER MOSFET enables this demand. There is some loss
in MOSFET because of the flow of drain current Id under the application of voltage between drain and
the source. During switching transient period of MOSFET, drain current Id flows with voltage applied Vds,
causing a loss. Hence, soft-switching is used, switching when the current or voltage is zero, it is a counter
measure for the switching loss. A method to switch during zero voltage is called ZVS and that with zero
current is called ZCS. However, ZVS is more popular in the full bridge type power supply circuit using
MOSFETs.
6.1 PHASE SHIFTED TYPE FULL BRIDGE MODE 1 OPERATION
The timing to control each MOSFET differs. Timing is divided into 8 segments. In addition, a
dead time is applied while S1 & S2, and S3 & S4 (vertically connected switches) are NOT turned ON
simultaneously. Every MOSFET is turned OFF in the hard switch type, not every MOSFET is turned
OFF in the phase shift type. From t0 to t1, When S1 & S4 are turned ON, Vin is applied positively to the dot
end of the primary transformer. At this time, the dot end of the secondary side becomes positive and is
5
VCADPCA 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 623 (2019) 012021 doi:10.1088/1757-899X/623/1/012021
turned ON by forward biasing the diode D1. In addition, the capacitor Co is charged via the choke coil Ls.
t1 to t2, at the beginning of this period the voltage between the drain and the source is zero thus it starts
with soft switching. It doesn’t transit to OFF instantly. The freewheel current caused by the leakage
inductance Lp continues to flow even during transition period, the charge voltage finally reaches
equivalent to Vin.
Figure 4. Mode 1 Operation
6.2 BRIDGE MODE 2 OPERATION
When S2 & S3 are turned ON, the voltage between the drain and source of Q2 is zero, and during
transition from OFF to ON, the freewheel current of Lp continues to flow, soft switching is completed.
The non-dot side of both primary and secondary sides of the transformer becomes positive. D2 is turned
ON to charge Co via choke coil Ls. electric power is transferred from primary to secondary side. Phase-
shift type realizes soft switching by optimizing ON/OFF from S1 through S4.
Figure 5. Mode 2 Operation
7. SIMULATION RESULTS
6
VCADPCA 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 623 (2019) 012021 doi:10.1088/1757-899X/623/1/012021
7
VCADPCA 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 623 (2019) 012021 doi:10.1088/1757-899X/623/1/012021
8. CONCLUSION
This paper proposes a new active soft switching circuit for the PSFB DC-DC converter. The converter's
analysis is presented with the mathematical treatment required. The converter's equivalent steady-state
circuit model and dynamic model are presented. The converter's design guidelines will be discussed. A
design example is presented in accordance with the design guidelines. The designed converter is
simulated and for the specifications a prototype is developed. In order to validate the analysis, the circuit
simulations and experimental waveforms are presented. Experimental results are consistent with the
theory and simulations. Converter efficiency has been improved overall. This model of proposed are
validated experimentally.
9. REFERENCES
[1] K. Shi, D. Zhang, Z. Zhou, M. Zhang, D. Zhang and Y. Gu, “A Novel Phase-Shift Dual Full-
Bridge Converter With Full Soft-Switching Range and Wide Conversion Range,” IEEE
Transactions on Power Electronics, Vol. 31, No. 11, November 2016
[2] Mallikand A. Khaligh, “Variable-Switching-Frequency State-Feedback Control of a Phase-Shifted
Full-Bridge DC/DC Converter,” IEEE Transactions on Power Electronics, Vol. 32, No. 8, August
2017
[3] O. Lee, “Hybrid DC-DC Converter with Phase-Shift or Frequency Modulation for NEV Battery
Charger,” IEEE Transactions on Industrial Electronics, Vol. 63, No. 2, February 2016
[4] S. Kim, H. Cha, H. F. Ahmed, B. Choi, H. Kim, “ Isolated Double Step-down DC-DC Converter
with Improved ZVS Range and No Transformer Saturation Problem ,” IEEE Transactions on
Industrial Electronics, Vol. 32, No. 3, March 2017
[5] Y.Shen, X.Sun, W.Li, X.Wu, and B.Wang,“A Modified Dual Active Bridge Converter With
Hybrid Phase-Shift Control for Wide Input Voltage Range,” IEEE Transactions on Power
Electronics, Vol. 31, No. 10, October 2016
[6] J. Mason and P. K. Jain, "New Phase Shift Modulated ZVS Full Bridge DC/DC Converter with
Minimized Auxiliary Current for Medium Power Fuel Cell Application," in Proc. Power
Electronics Specialists Conference, 2005, pp. 244-249, June 2005.
[7] Y. Jang and M. M. Jovanovic, "A New Family of Full-Bridge ZVS Converter," IEEE Transactions
on Power Electronics, vol. 19, no. 3, May 2004.
[8] Z. Chen, B. Ji, F. Ji, and 1. Shi, "Analysis and Design Considerations of An Improved ZVS Full-
Bridge DC-DC Converter," in Proc. Applied Power Electronics Conference and Exposition, 2010,
pp. 1471-1476.
[9] B. Yang, 1. 1. Duarte, W. Li, K. Yin, X. He, and Y. Deng, "Phase Shifted Full Bridge Converter
Featuring ZVS over the Full Load Range," in Proc. 36th Annual Conference on IEEE industrial
Electronics Society, 2010, pp. 644-649.
[10] X. Zhou, M. Donati, 1. Amoroso, and F. C. Lee, "Improved Light-Load Efficiency for Synchronous
Rectifier Voltage Regulator Module," IEEE Transactions on Power Electronics, vol. 15, no. 5, May
8
VCADPCA 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 623 (2019) 012021 doi:10.1088/1757-899X/623/1/012021
2000.
[11] Texas Instruments, "Green Phase-Shifted Full-Bridge Controller with Synchronous Rectification,"
Datasheet SLUSAI6, Mar. 2010.
[12] R. Ramachandran and M. Nymand, “Design and analysis of an ultra-high efficiency phase shifted
full bridge GaN converter,” in Proc. IEEE Applied Power Electronics Conference and Exposition,
Charlotte, NC, Mar. 2015, pp. 2011-2016.
[13] B. Y. Chen and Y. S. Lai, “Novel Dual Mode Operation of Phase-Shifted Full Bridge Converter to
Improve Efficiency under Light Load Condition,” in Proc. IEEE Energy Conversion Congress and
Exposition, San Jose, CA, Sept. 2009, pp. 1367-1374.
[14] J.W. Kim, D.Y. Kim, C.E. Kim, M.Y. Kim et. al. “Switching control method for light load
efficiency improvement in phase shifted full bridge converter,” in Proc. IEEE Energy Conversion
Congress and Exposition Asia, Melbourne, Jun. 2013, pp. 165-169.
