A Medium-Voltage Medium-Frequency Isolated DC–DC Converter Based on 15-kV SiC MOSFETs

Abstract

In this paper, a novel isolated dc-dc converter topology for medium-voltage (MV) applications is proposed by combining the advantages of resonant converters and dual active bridge (DAB) converters. In normal load scenario, this converter operates in an open loop resonant mode with a fixed switching frequency equals to the resonant frequency of the series resonant tank. Thus, zero voltage turn on at primary side and zero current turn off at secondary side are secured from zero to full load. When overload happens, the resonant capacitors will be clamped to the output voltage by the additional paralleled diodes. The proposed converter automatically switches to resonant and DAB mixed operation mode; therefore, the resonant current is naturedly limited. With zero to full load range soft switching and fast overload protection, the proposed topology is especially suitable for MV medium frequency applications utilizing high-voltage SiC MOSFETs. The converter operation modes are analyzed using time-domain waveforms and graphical state trajectory to derive the quantitative relationship between duty cycle, output voltage, and the overload current. Based on these relationships, a predictive duty cycle control is proposed to further limit the overload current of the resonant tank by sensing the output voltage. Combing the proposed topology and the predictive control, cycle-by-cycle overload and short-circuit protections are achieved. To fully utilize the capability of the 15-kV SiC MOSFET, magnetizing inductance, dead time, MV transformer, and resonant components are optimized with the operating range of 6-12 kV and 20-100 kHz. An experimental prototype running at 6 kV and 40 kHz is successfully tested with peak efficiency exceeding 98%. Test waveforms at no load and 10-kW full load validate the zero to full load range soft switching capability. Short circuit protection test demonstrates a 25-us overload protection speed.