A three-phase current-fed dc/dc converter with a three-leg high frequency transformer for fuel cells

Abstract

In this paper, a three-phase current-fed dc/dc converter with an active clamp is introduced, and a new three-phase three-leg high frequency transformer is proposed for the converter. The three-phase dc/dc converter transfers power through transformer leakage inductances in the discontinuous current mode; a single common active clamp branch is employed for zero-voltage switching (ZVS) in all active switches. Further, the converter's three-phase power configuration increases power transfer, and it reduces the rms current per phase, thus reduces conduction losses. Moreover, a delta–delta connection on the three-phase transformer provides parallel current paths and reduces conduction losses in the transformer windings. A three-phase transformer can be constructed by connecting three discrete single-phase transformers, but this process results in a higher volume and higher material costs. Therefore, a new three-phase three-leg high frequency transformer is designed with three discrete cores integrated into a single transformer core. The proposed transformer is analyzed according to the several operating modes of the converter, and its design rules are determined. Experimental results are obtained on a 500-W prototype unit; the design is fully verified and analyzed.