Development Of High-efficiency And High-power DC Power Supply Module With High-voltage Input

With the rapid development of science and technology,module power supply plays an increasingly important role in modern industrial system and national defense construction.However,there is still a big gap in development level between domestic and foreign,and it needs to be improved in module power supply with high-voltage input,high-efficiency and high-power especially.In addition,advanced module power supply products are extremely dependent on imports,while domestic module power supply with high-voltage input,high-efficiency and high-power is an urgent demand.Therefore,it has important practical significance to research.Firstly,based on the analysis of the common topological characteristics in module power supply with high-voltage and high-power,and combined with the specific requirements,the phase-shifted full-bridge converter is adopted as the power circuit,and suppress the voltage spike of the secondary side rectifier by adding clamping diodes on the primary side.In order to reduce the voltage stress of the rectifier and improve the conversion efficiency,a full-bridge synchronous rectifier is used on the secondary side.Then,the principle of phase-shifted full-bridge converter and the control sequence of synchronous rectifier under different loads are analyzed,and the parameters of power circuit,including magnetic components,filter capacitors and the type of power devices,are designed.Aiming at the optimization of efficiency in the converter under full load range,dead time adaptive adjustment,dynamic synchronous rectification technology and the control of ultra-light-load Burst are adopted to improve the conversion efficiency of the module power supply under wide load current.Secondly,in order to solve the magnetic bias problem of transformer in phase-shifted full-bridge converter and improve the dynamic response of module power supply effectively,the peak current control mode is adopted.For the operation with duty cycle greater than 50%,slope compensation is used to eliminate subharmonic oscillation.According to the basic modeling method,the small-signal model of phase-shifted full-bridge converter is built,and the accurate model under peak current control is further established based on the average value equation of the inductor current.According to the number and distribution of zeros and poles of the transfer function of the equivalent power stage,a type IV compensator is designed to correct the converter control system.Then,the auxiliary unit circuit of the module power supply is designed,including the peripheral circuit of the controller,the driving circuit,the protection circuit and the auxiliary power supply circuit.And select the domestic components to improve the localization proportion.Moreover,the PCB layout and structure design of the module power supply are completed.Finally,based on the above scheme,a high-efficiency full-brick DC module power supply experimental prototype with input voltage of 180V-425 V and rated output of 28V/1008 W is built,and the efficiency up to 94.4%.