Multiphase High-Frequency Isolated DC–DC Converter for Industrial Applications

Abstract

Industrial applications such as welding, plasma cutting, and surface hardening require a large DC current at low voltage. In such applications, the rating of power supply varies from few kilowatts to hundreds of kilowatts. The power supply employs in such applications particularly in arc welding process is expected to operate from open-circuit (no-load) to short-circuit (when the electrode sticks to the workpiece for a short span of time) quickly. In this paper, high-frequency isolated multiphase DC-DC converter is proposed which is well suited for aforementioned applications. Based on mathematical analysis, a simulation study with 5 kW, 5 V/1,000 A proposed model is carried out using Simulink block set and Sim Power System tool box and its performances are evaluated under symmetrical control methods. To verify the simulation results, scaled prototype model of rating 1.5 V/100 A is developed and tested with aforementioned control method under different operating conditions. In comparison with conventional welding power supply employed in many industries, the performance of proposed converter is improved significantly in terms of size and weight, efficiency and dynamic response.