High-frequency isolated soft-switching phase-shift PWM DC-DC power converter using tapped inductor filter

In this paper, a novel type of the step-up high frequency transformer linked full-bridge soft-switching phase-shift PWM DC-DC power converter with ZVS and ZCS bridge legs is proposed for small scale fuel cell power generation systems, automotive AC power supplies. A tapped inductor filter with a freewheeling diode is implemented in the proposed soft-switching DC-DC power converter to minimize the circulating current in the high-frequency step-up transformer primary side and high-frequency inverter stage. Using a tapped inductor filter with a freewheeling diode makes possible to reduce the circulating current without any active switches and theirs gate-drive circuits. The operating principle of the proposed DC-DC power converter with each operation mode during a half cycle of the steady state operation is explained. The optimum design of the tapped inductor turns ratio is described on the basis of the circuit simulation results. Developing 1 kW 100 kHz prototype with power MOSFETs and 36 V DC source verifies the practical effectiveness of the proposed soft-switching DC-DC power converter. The actual efficiency of the proposed DC-DC power converter is obtained 94% for the wide load and output voltage variation ranges.