Abstract
A zero-voltage, zero-current switching (ZVZCS) PWM DC-DC power converter with secondary active rectifier tested as a dc current source for arc welding is described in this paper. The soft switching DC-DC converter consists of high frequency inverter, high frequency power transformer and controlled output rectifier with new secondary energy recovery turn-off snubber. Circulating current in the converter is reduced by using active rectifier and rms value of the current in secondary switches is decreased by utilizing a novel control algorithm. The experimental results of a 4.5 kW DC-DC converter working at switching frequency of 100 kHz are presented.
Highlights
Voltage-current characteristics of the arc welder depend generally on the type of welding
In the quest for smaller size and lighter weight of the power source it is necessary to operate the inverter at as high switching frequency as possible. This high frequency allows considerably reducing the size and weight of the transformer and it makes the filtering at the dc output of the DC-DC converter easier and cheaper
ZVZCS PWM DC-DC high power converter with active rectifier on the secondary side used as a current source is presented in this paper
Summary
Voltage-current characteristics of the arc welder depend generally on the type of welding. In the quest for smaller size and lighter weight of the power source it is necessary to operate the inverter at as high switching frequency as possible This high frequency allows considerably reducing the size and weight of the transformer and it makes the filtering at the dc output of the DC-DC converter easier and cheaper. Higher switching frequency results in increased switching losses in power semiconductor devices at turn-on and turn-off All these requirements can be met by welders consisting of a high frequency transformer fed by highfrequency soft-switching converter. The circulating energy is minimum compared with the resonant converters resulting in minimum conduction losses These converters are controlled either by traditional PWM or by phase shifted PWM method at constant switching frequency. ZVZCS PWM DC-DC high power converter with active rectifier on the secondary side used as a current source is presented in this paper. This is important for the converters operating at full load range - from no-load to short circuit, e. g. at converters for arc welding
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