International Journal of Control and Automation

Vol.7, No.4 (2014), pp.267-278

http://dx.doi.org/10.14257/ijca.2014.7.4.23

High Power Full-Bridge DC-DC Converter using a Center-Tapped

Transformer and a Full-Wave Type Rectifier
Min-Gi Kim, Geun-Yong Park, Doo-HeeYoo and Gang-YoulJeong
Department of Electronic Information Engineering, Soonchunhyang University
22 Soonchunhyang-Ro, Shinchang-Myun, Asan-Si, Choongnam, South Korea
[email protected]
Abstract
This paper proposes a high power full-bridge DC-DC converter, using a center-tapped
transformer and a full-wave type rectifier. The proposed converter realizes unipolar primary
voltage switching, using the unipolar pulse-width modulation (PWM) technique. Also, the
proposed converter reduces the freewheeling conduction loss, using the unipolar PWM
technique and a resonant circuit, composed of a clamp capacitor and resonant inductor in the
primary, and thus achieves high efficiency. However, because the proposed converter uses
only a full-bridge circuit, center-tapped transformer, and full-wave type rectifier, the
structure of the proposed converter is simple. In this paper, the operational principle of the
proposed converter is described in detail, and a design example of a proposed converter
prototype is shown. Finally, experimental results of the prototype are shown, to verify the
feasibility of the proposed converter.
Keywords: Full-bridge DC-DC converter, Center-tapped transformer, Full-wave type
rectifier, unipolar PWM technique, Resonant circuit

1. Introduction
Recently, according to the increase of power capacity of electric/electronic devices, many
high power DC-DC power converters have been proposed [1-15]. Among these power
converters, conventional ZVS (Zero Voltage Switching) unipolar PWM full-bridge converters
are a popular topology for medium/high power applications, offering desirable features, such
as ZVS operation, and high efficiency.
However, the conventional ZVS full-bridge DC-DC converter has a serious disadvantage:
that of the narrow ZVS range of the lagging leg. During the lagging leg transition under light
load operation, the primary current decreases, and finally changes its polarity; but the energy
available for charging or discharging the switch output capacitor is insufficient, which
unfortunately results in hard switching conditions. However,because this also increases the
circulating current under normal load, itresults in increase of the total conduction loss of the
converter and the voltage/current stress of each switch.
Therefore, many research results have been proposed, to extend the ZVS range down to a
light load [3-6]. But there are some disadvantages: in [3] and [4], the effective duty ratio
should be reduced, and in [5] and [6], excessive conduction losses occur,due to an increased
auxiliary resonant current.Also, it causes problems, such as the thermal problem and
increased cost. Because of these problems, ZVS full-bridge DC-DC converters were proposed
that use two transformers. But, this proposal cannot solve the bulky system problem. Half-

ISSN: 2005-4297 IJCA

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International Journal of Control and Automation

Vol.7, No.4 (2014)

bridge DC-DC converters with other methods [7-11] are proposed, but their output power was
not large.
In this paper, a high power DC-DC converter using a center-tapped transformer and fullwave type rectifier is presented. A clamp capacitor and resonant inductance are used as a
resonant circuit for the soft-switching of the converter primary, with the unipolar PWM
technique. The proposed converter reducesfreewheeling conduction loss with the unipolar
PWM technique, and a simple resonant circuit, composed of a clamp capacitor and resonant
inductor. The proposed converter utilizes the unipolar PWM technique like the conventional
full-bridge DC-DC converter, so its modification from the conventional converter circuit is
easy. Thus, the proposed converter achieves high efficiency. Also,because the proposed
converter is composed of only a full-bridge circuit, center-tapped transformer, and full-wave
type rectifier, the structure of the proposed converter becomes simple. In this paper,
theoperational principle is explained in detail, and a design example of a prototype of the
proposed converter is shown. Experimental results based on the prototype are shown, to
confirm the validity of the proposed converter.

2. Operational Principles
DS1 CS1

DS4 CS4
iDr1

S1
Cin
Vin

S4

Np

Cc

ip

A
v Cc

S3

Ns1

vLr

Ns2
Lm
iDr2

iS2

VDr1

Co

Vo

Vp

Lr

S2
DS3CS3

Dr1

DS2 CS2

VDr2

Dr2

Figure 1. A circuit diagram of the proposed converter

Figure 1 shows a circuit diagram of the proposed full-bridge DC-DC converter. The
proposed converter is composed of the primary, the center-tapped transformer, and the
secondary. The primary part of the proposed converter is composed of a DC input source
,
the main switches
of the full-bridge circuit, a clamp capacitor , and a resonant
inductor . The secondary part of the proposed converter is composed of a full-wave type
rectifier
and
, output filter capacitor , and load . The configuration of the proposed
converter is basically similar to that of the conventional full bridge DC-DC converter, except
for the center-tapped transformer, and resonant circuit, composed of a clamp capacitor and
resonant inductor.
Figure 2 shows the key part waveforms of the proposed converter in steadystate. The
proposed converter operatesbased onthe gate-source voltages
of the main
switches.The converter operation can be divided into six modes or three categories: power
delivery interval, freewheeling interval, and commutation interval.

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VGS1,3
VGS1

VGS3

VGS1

VGS2,4
VGS2

VGS4

VGS2

DTs
Ts=T/2

VAB
DeTs

DTs

T
T

VAB-vLr

Vp

t
vLr

vCc

VCc,max

t
Mode 2

Mode 5

ip

t0

t1
Mode 1

t2

t3

Mode 3

t4

t5

t6

Mode 6
Mode 4

Figure 2. The key part waveforms of the proposed converter in steadystate

Figure 3 showsthe equivalent circuits of each mode of the proposed converter, where the
bold lines denotepaths that conduct currents, andthe dotted lines denote paths that do not
conduct current.
To illustrate the steady state operation, the following appropriate items are assumed:
1) The power switches
parasitic capacitors.

are ideal, except for their anti-parallel diodes and

2) The magnetizing inductance

is of very large value, and
and
(
) are the primary and the secondary turn numbers of the transformer,
respectively.
3) The output voltage

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is constant.

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DS1 CS1

DS4 CS4
iDr1

S1
Cin
Vin

S4

Np

Cc

ip

A
v Cc

S3

Ns1

VDr1

Co

Vo

Co

Vo

Co

Vo

Co

Vo

Vp

Lr
vLr

Ns2
Lm

S2

iDr2
DS2 CS2

DS3CS3

Dr1

VDr2

Dr2

(a) Mode 1
DS1 CS1

DS4 CS4
iDr1

S1
Cin
Vin

S4

Np

Cc

ip

A
v Cc

S3

Ns1

VDr1

Vp

Lr
vLr

Ns2
Lm

S2

iDr2
DS2CS2

DS3CS3

Dr1

VDr2

Dr2

(b) Mode 2
DS1 CS1

DS4 CS4
iDr1

S1
Cin
Vin

S4

Np

Cc

ip

A
v Cc

S3

Ns1

Dr1
VDr1

Vp

Lr
vLr

Ns2

VDr2

Lm

S2

iDr2
DS2 CS2

DS3CS3

Dr2

(c) Mode 3

DS1 CS1

DS4 CS4
iDr1

S1
Cin
Vin

S4

Np

Cc

ip

A
v Cc

S3

Ns1

VDr1

Vp

Lr
vLr

Ns2

VDr2

Lm

S2

iDr2
DS3CS3

Dr1

DS2 CS2

Dr2

(d) Mode 4

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Vol.7, No.4 (2014)

S1

S1

DS4 CS4
iDr1

Cin
Vin

Np

Cc

ip

A
v Cc

S3

Ns1

VDr1

Co

Vo

Co

Vo

Vp

Lr
vLr

Ns2
Lm

S2

VDr2

iDr2

Dr2

iDr1

Dr1

DS2 CS2

DS3CS3

Dr1

(e) Mode 5
DS1 CS1

DS4 CS4

S1
Cin
Vin

S4

Np

Cc

ip

A
v Cc

S3

Ns1
Vp

Lr
vLr

Ns2
Lm

S2

iDr2
DS3CS3

VDr1

DS2 CS2

VDr2

Dr2

(f) Mode 6

Figure 3. The equivalent circuits of each mode of the proposed converter

Mode 1(
): In this mode, the power is delivered from the primary to the secondary.
This is the power delivery interval. The secondary diodes
and
are turned on and off,
respectively. At this time, the primary current increases almost linearly, as follows:

(1)
Then, the resonant inductor voltage
respectively, as follows:

and the clamp capacitor voltage

are expressed,

(2)
(3)
The slope of the primary current is changed more rapidly by the clamp capacitor voltage
, compared with the conventional full-bridge DC-DC converter.
Mode 2(
: Mode 2 begins when the switch
is the freewheeling interval. The primary current

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is turned off at time

. This mode
charges and discharges the parasitic

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capacitors
and
of the switches
can be expressed as follows:

and

, respectively. At this time, the primary current

(4)
The anti-parallel diode

of switch

conducts, and thus the ZVS of

is achieved.

Mode 3(
: Mode 3 begins when the switch is turned off at time
,. During
mode 3, the direction of primary current is changed, which is different from modes 1 and 2.
The primary current is expressed by the following equation:

(5)

At time
, the commutation between secondary diode
this mode ends.

and

is completed, and

Since from mode 4, the mode operations are symmetric in the current conducting paths and
components, as shown in Figures 2 and 3, the explanation of the next three modes, modes
4~6, can convenientlybe omitted.

3. Design Examples
In order to verifythe performance of the proposed converter, a prototype of the proposed
converteris designed and implemented, based on the following Table 1:
Table 1. Design specifications of theprototype converter
Item

Symbol

Value

Input DC voltage

380V

Output DC voltage

24V

Max output power

960W

Switching frequency

100kHz

Effectiveduty ratio

0.5

Based on the structure and operation of the proposed converter, the main center-tapped
transformer turn ratio (=
) is calculated by the following equation:
(6)

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where,
is the effective duty ratio of the converter primary voltage applied to the bridge
points A-B. Thus, based on the design specifications of Table 1, the turn ratio is set as
.
At modes 1 and 3, the clamp capacitance
at mode 3, and the maximum voltage
clamp capacitor from equation (3), as follows:

is calculated by its maximum voltage

is calculated by the ripple voltage of the

(7)
where, is the load current at maximum output power
capacitance is given by the following equation:

.From equation (7), the clamp

(8)
In order that the slope of the primary current becomes positive, the following relation should
be satisfied:
(9)
Therefore, the clamp capacitance
follows:

can be calculated using equations (8) and(9), as

(10)
From equation (9), the maximum value
of the clamp capacitor voltage should be
less than
. Here, the design margin of the maximum value
is considered,
whichis set to about 10% of thevoltage
. Therefore, the clamp capacitance
was
selected as an approximated value of =0.33F. Thus,by equation (7), the maximumclamp
capacitor voltage
is modified to
.
In order to achieve the ZVS of the primary full-bridge circuit,normally the lagging-leg
switches and
must operate as the ZVS at the turn-off condition. This means that the
following relation should be satisfied:
(11)
where, theleft side
is the energy stored in at mode 1,and the right side
is the double margin value of the energy comingout from the resonant inductor
, whichthe parasitic capacitors of the lagging-leg switches
and should charge or
discharge.So the peak value
of the primary current can beapproximately calculated by
the following equation:

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(12)
where,
is the effective on-duty time, which can be approximated as the time of mode
1.Therefore, the resonant inductance can be calculated using equations (11) and(12), as
follows:
(13)

where,the parasitic capacitance

of the MOSFET switches is selected as
=2200pF,
according to the specification of the MOSFET used, FQA24N50. Thus, the resonant
inductance is selectedas
.

4. Experimental Results
To verify the effectiveness of the proposed converter, a prototype of the proposed
converter is implemented, with the specifications of Table 1 in Section 3.
Figure 4 shows the experimental waveforms of the gate-source driving voltages of the
upper MOSFET switches and
, and the bridge voltage
of the primary full-bridge
MOSFET circuit. From this, it can be known that the control and driving circuit operations of
the proposed converter are good, and the full-bridge circuit is well operated by the operations
of the control and driving circuits.
Figure 5 shows the experimental waveforms of the primary voltages and currents of the
primary full-bridge circuit, which let us know that the full-bridge circuit is well designed and
operated, because the experimental waveforms coincide with the theoretical waveforms of
Figure 2.
Figure 6 shows the experimental waveforms of the secondary output voltage, and current
of the proposed converter. This shows that the proposed converter operates well and stably, as
a high power DC-DC converter.

Figure 4. Experimental waveforms of the gate-source driving voltages of the

upper switches, and the bridge voltage of the primary full-bridge circuit

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Vol.7, No.4 (2014)

Figure 5. Experimental waveforms of the primary voltages, and

current of the full-bridge circuit

Figure 6. Experimental waveforms of the secondary output voltage,

and current of the proposed converter

5. Conclusion
In this paper, a high power DC-DC converter is proposed, using a center-tapped
transformer and full-wave type rectifier. A simple resonant circuit, composed of a clamp
capacitor and resonant inductor, is used for soft-switching of the converter primary, with the
unipolar PWM technique. The proposed converter reduces freewheeling conduction
loss,using the unipolar PWM technique, and a simple resonant circuit. Thus, the proposed
converter achieves high efficiency. However, the proposed converter utilizes the unipolar
PWM technique, like the conventional full-bridge DC-DC converter. Because the proposed
converter is composed of a full-bridge circuit, center-tapped transformer, and full-wave type
rectifier, the structure of the proposed converter is simple. In this paper, the operational
principle is explained in detail,according to each operation mode; and a design example of a
prototype of the proposed converter is shown. Experimental results based on the implemented

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Vol.7, No.4 (2014)

prototype are shown, to confirm the validity of the proposed converter. The proposed
converter shows good performance as a high power DC-DC converter.

Acknowledgements
This work was supported by the Soonchunhyang University Research Fund.

References
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Authors
Min-Gi Kim
Min-Gi Kim received his B.S. degree in Electronic Information
Engineering in 2013 from Soonchunhyang University, Korea, where
he is currently working toward the M.S. degree. His research
interests include DC-DC power converter, AC-DC high frequency
inverter, and power conversion for the renewable energy.

Geun-Yong Park
Geun-Yong Park received his B.S. degree in Electronic
Information Engineering in 2013 from Soonchunhyang University,
Korea, where he is currently working toward the M.S. degree. His
research interests include DC-DC power converter, AC-DC high
frequency inverter, and power conversion for the renewable energy.

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Vol.7, No.4 (2014)

Doo-HeeYoo
Doo-HeeYooreceived his B.S. and M.S. degrees in Electronic
Information Engineering from Soonchunhyang University, Korea, in
2007 and2009, respectively, where he is currently working toward
the Ph.D. degree. His research interests include DC-DC power
converter, AC-DC high frequency inverter, and power conversion
for the renewable energy.

Gang-YoulJeong
Gang-YoulJeong received his B.S. degree in Electrical
Engineering from Yeungnam University, Korea, in 1997, and his
M.S. and Ph.D. degrees in Electronic and Electrical Engineering
from POSTECH (Pohang University of Science and Technology),
Korea, in 1999 and 2002, respectively. He has been an associate
professor in Department of Electronic Information Engineering,
SoonchunhyangUniversity, Korea. His research interests include
DC-DC power converter, AC-DC high frequency inverter, and
power conversion for the renewable energy.

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