Design and Experimental Validation of a High-Boost Full-Bridge Converter with Extended ZVS Range and Stable Efficiency Under Wide Load Variations

Edris Noei Jirandeh; Alireza Zarei; Farhad Shahnia; Mohammad Mohammadi; Meghdad Taheri

doi:10.3390/en18215807

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Design and Experimental Validation of a High-Boost Full-Bridge Converter with Extended ZVS Range and Stable Efficiency Under Wide Load Variations

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Design and Experimental Validation of a High-Boost Full-Bridge Converter with Extended ZVS Range and Stable Efficiency Under Wide Load Variations

Edris Noei Jirandeh, Alireza Zarei, Farhad Shahnia, Mohammad Mohammadi and Meghdad Taheri

Energies (Basel), Vol.18(21), 5807

2025

DOI: https://doi.org/10.3390/en18215807

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Abstract

high-voltage power supplies (HVPS)

phase-shift full-bridge (PSFB)

high-power converters

ZVS

ZCS

This paper introduces a new four-switch, high-voltage, high-step-up converter employing two transformers. The topology enables Zero-Voltage Switching (ZVS) across all primary switches for operating conditions ranging from no load to full load. A voltage-quadrupler and a voltage-doubler rectifier are used on the secondary sides of the transformers, enabling reduced turn-off current for the voltage-quadrupler diodes and Zero-Current Switching (ZCS) turn-off for the voltage-doubler diodes, thereby ensuring high efficiency across diverse load levels. Notably, the voltage stress experienced by the voltage-multiplier diodes is significantly lower than the output voltage, thereby rendering the converter exceptionally suitable for high-voltage applications such as electron beam welding (EBW). The voltage gain surpasses that of the conventional phase-shift full-bridge (PSFB) converter, permitting a lower transformer turns ratio and thus reducing winding resistivity. The removal of the substantial output inductor leads to a lighter and more compact design, eliminating insulation concerns associated with inductor windings. This paper details the operation of the proposed converter, supported by experimental results from a 500-W prototype with a 150-V input and 2-kV output, which confirm its high performance and operational advantages.

Details

Title: Design and Experimental Validation of a High-Boost Full-Bridge Converter with Extended ZVS Range and Stable Efficiency Under Wide Load Variations
Authors/Creators: Edris Noei Jirandeh
Alireza Zarei - Imam Khomeini International University
Farhad Shahnia - Murdoch University, Centre for Water, Energy and Waste
Mohammad Mohammadi - Amirkabir University of Technology
Meghdad Taheri - Amirkabir University of Technology
Publication Details: Energies (Basel), Vol.18(21), 5807
Publisher: MDPI
Number of pages: 24
Identifiers: 991005830347107891
Murdoch Affiliation: School of Engineering and Energy; Centre for Water, Energy and Waste
Language: English
Resource Type: Journal article

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Collaboration types: Domestic collaboration; International collaboration
Citation topics: 4 Electrical Engineering, Electronics & Computer Science; 4.18 Power Systems & Electric Vehicles; 4.18.334 Converter Technologies
Web Of Science research areas: Energy & Fuels
ESI research areas: Engineering