A Bidirectional Three-Phase Push-Pull Converter with Hybrid PPS-DAPWM Switching Method for High Power and Wide Voltage Range Applications

High-power isolated bidirectional dc-dc converters with wide voltage range are attracting increasing attention in many applications. The bidirectional three-phase current-fed dc-dc converters are known to be suitable for wide voltage range applications compared to dual active bridge based converters, having advantages of reduced device current ratings and prevention of transformer saturation due to high impedance nature. However, when the duty cycle becomes lower than 0.33 or higher than 0.66, power transfer capability is limited, and the efficiency is significantly reduced due to increased circulating current, which has rarely been discussed so far. In this article, a hybrid dual-asymmetrical pulsewidth modulation (DAPWM) and pulsewidth modulation plus phase-shift (PPS) switching method is proposed for efficiency improvement of the bidirectional three-phase push-pull converter with very wide voltage range. A seamless mode change method between PPS and DAPWM is also proposed for minimizing the transient state. Further, through current waveform and power flow analysis, the leakage inductance along with transformer turn ratio are designed to minimize the root mean square (rms) current of devices, while having the capability of transferring the desired power and limiting the slew rate of transformer winding current under wide voltage range operation. Experimental results from a 22-kW prototype are provided to validate the proposed concept.