Dual Utility AC Line Voltage Operated Voltage Source and Soft Switching PWM DC-DC Converter with High Frequency Transformer Link for Arc Welding Equipment

  • Morimoto Keiki (Welding Engineering Department, DAIHEN Corporation) ;
  • Ahmed NabilA. (Welding Engineering Department, DAIHEN Corporation) ;
  • Lee Hyun-Woo (Electrical Energy Saving Research Center, The Graduate School of Electrical & Electronics Engineering Kyungnam University) ;
  • Nakaoka Mutsuo (Electrical Energy Saving Research Center, The Graduate School of Electrical & Electronics Engineering Kyungnam University)
  • Published : 2005.12.01

Abstract

This paper presents two new circuit topologies of the dc busline side active resonant snubber assisted voltage source high frequency link soft switching PWM full-bridge dc-dc power converters acceptable for either utility ac 200V-rms or ac 400V-rms input grid. These high frequency switching dc-dc converters proposed in this paper are composed of a typical voltage source-fed full-bridge PWM inverter, high frequency transformer with center tap, high frequency diode rectifier with inductor input filter and dc busline side series switches with the aid of a dc busline parallel capacitive lossless snubber. All the active switches in the full-bridge arms as well as dc busline snubber can achieve ZCS turn-on and ZVS turn-off transition commutation with the aid of a transformer leakage inductive component and consequently the total switching power losses can be effectively reduced. So that, a high switching frequency operation of IGBTs in the voltage source full bridge inverter can be actually designed more than about 20 kHz. It is confirmed that the more the switching frequency of full-bridge soft switching inverter increases, the more soft switching PWM dc-dc converter with a high frequency transformer link has remarkable advantages for its power conversion efficiency and power density implementations as compared with the conventional hard switching PWM inverter type dc-dc power converter. The effectiveness of these new dc-dc power converter topologies can be proved to be more suitable for low voltage and large current dc-dc power supply as arc welding equipment from a practical point of view.

References

  1. K. Morimoto, T. Doi, H. Manabe, H.W. Lee, M. Nakaoka, 'Advanced High Power DC-DC Converter using Novel Type Full-Bridge Soft-Switching PWM Inverter with High Frequency Transformer Link for Arc Welding Application,' Proc. of KIPE-ICPE, pp. 191-197, Oct. 2004
  2. K. Morimoto, T. Doi, H. Manabe, N.A. Ahmed, H.W. Lee, M. Nakaoka, 'Next Generation High Efficiency High Power DC-DC Converter incorporating Active Switch and Snubbing Capacitor Assisted Full-Bridge Soft-Switching PWM Inverter with High Frequency Transformer for Large Current Output,' Proc. of IEEE-APEC, pp. 1549-1555, March 2005 https://doi.org/10.1109/APEC.2005.1453242
  3. K. Morimoto, T. Doi, H. Manabe, N.A. Ahmed, H.W. Lee, M. Nakaoka, 'A Novel High-Frequency Transformer Linked Soft-Switching Pulse Modulation DC-DC Power Supply for Arc Welder,' Proc. of PCIM China, pp. 43-48, March 2005
  4. K. Morimoto, T. Doi, H. Manabe, T. Ahmed, E. Hiraki, N.A. Ahmed, H.W. Lee, M. Nakaoka, 'Advanced High Power DC-DC Converter using DC Bus Line Switch-Assisted Full-Bridge Soft-Switching PWM Inverter with High Frequency Transformer Link for Low Voltage and Large Current Output Application,' Proc. of IEEJ IPEC-Niigata, pp. 1561-1568, April 2005