Full-Bridge Active-Clamp Forward-Flyback Converter with an Integrated Transformer for High-Performance and Low Cost Low-Voltage DC Converter of Vehicle Applications

Abstract

This paper presents a full-bridge active-clamp forward-flyback (FBACFF) converter with an integrated transformer sharing a single primary winding. Compared to the conventional active-clamp-forward (ACF) converter, the proposed converter has low voltage stress on the primary switches due to its full-bridge active-clamp structure, which can leverage high performance Silicon- metal–oxide–semiconductor field-effect transistor (Si-MOSFET) of low voltage rating and low channel resistance. Integrating forward and flyback operations allows the proposed converter to have much lower primary root mean square (RMS) current than the conventional phase-shifted-full-bridge (PSFB) converter, while covering wide input/output voltage range with duty ratio over 0.5. The proposed integrated transformer reduces the transformer conduction loss and simplify the secondary structure of the proposed converter. As a result, the proposed converter has several advantages: (1) high heavy load efficiency, (2) wide input voltage range operation, (3) high power density with the integrated transformer, and (4) low cost. The proposed converter is a very promising candidate for applications with wide input voltage range and high power, such as the low-voltage DC (LDC) converter for eco-friendly vehicles.