Modeling and Optimization of a Zero-Voltage Switching Inverter for High Efficiency and Miniaturization

In a zero-voltage switching (ZVS) inverter, high conversion efficiency and miniaturization are expected since switching loss can be dramatically reduced with proper design. In order to realize ZVS condition, auxiliary components such as inductors, capacitors, and switches are embedded in the inverter to implement the function. Since the design of auxiliary components is critical to the ZVS inverter, it is impossible to realize maximum efficiency or minimum size by following the conventional design procedure. This paper introduces an optimized design methodology for a three-phase ZVS inverter with objectives of both high efficiency and miniaturization. Based on the loss models of different commercial IGBT modules under different ZVS conditions, as well as the loss models of auxiliary components and filter inductors, the issue of pursuing highest efficiency and power density is transformed into solving a constrained nonlinear multivariable problem. According to the proposed design methodology, all parameters that influence the efficiency and physical dimensions are considered simultaneously. Thus, the optimized selection of the IGBT module, the parameters of the auxiliary components and the filter inductors would be obtained. A 30-kW three-phase ZVS inverter prototype is built to verify the proposed design method. With proposed design method, the improved prototype has achieved both smaller passive components volume and higher efficiency compared to the former prototype.