Design and Experimental Validation of a High-Boost Full-Bridge Converter with Extended ZVS Range and Stable Efficiency Under Wide Load Variations

Edris Noei Jirandeh, Alireza Zarei (), Farhad Shahnia (), Mohammad Mohammadi and Meghdad Taheri
Additional contact information
Edris Noei Jirandeh: Department of Electrical Engineering, Amirkabir University of Technology, 424 Hafez Avenue, Tehran P.O. Box 15875-4413, Iran
Alireza Zarei: Faculty of Technical and Engineering, Imam Khomeini International University, Qazvin P.O. Box 34148-96818, Iran
Farhad Shahnia: School of Engineering and Energy, Murdoch University, Perth, WA 6150, Australia
Mohammad Mohammadi: Department of Electrical Engineering, Amirkabir University of Technology, 424 Hafez Avenue, Tehran P.O. Box 15875-4413, Iran
Meghdad Taheri: Department of Electrical Engineering, Amirkabir University of Technology, 424 Hafez Avenue, Tehran P.O. Box 15875-4413, Iran

Energies, 2025, vol. 18, issue 21, 1-24

Abstract: This paper introduces a new four-switch, high-voltage, high-step-up converter employing two transformers. The topology enables Zero-Voltage Switching (ZVS) across all primary switches for operating conditions ranging from no load to full load. A voltage-quadrupler and a voltage-doubler rectifier are used on the secondary sides of the transformers, enabling reduced turn-off current for the voltage-quadrupler diodes and Zero-Current Switching (ZCS) turn-off for the voltage-doubler diodes, thereby ensuring high efficiency across diverse load levels. Notably, the voltage stress experienced by the voltage-multiplier diodes is significantly lower than the output voltage, thereby rendering the converter exceptionally suitable for high-voltage applications such as electron beam welding (EBW). The voltage gain surpasses that of the conventional phase-shift full-bridge (PSFB) converter, permitting a lower transformer turns ratio and thus reducing winding resistivity. The removal of the substantial output inductor leads to a lighter and more compact design, eliminating insulation concerns associated with inductor windings. This paper details the operation of the proposed converter, supported by experimental results from a 500-W prototype with a 150-V input and 2-kV output, which confirm its high performance and operational advantages.

Keywords: high-voltage power supplies (HVPS); phase-shift full-bridge (PSFB); high-power converters; ZVS; ZCS (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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