Analysis, estimation and minimization of power loss in CCM operated PSFB converter

Phase Shifted Full Bridge (PSFB) converters are widely accepted for high and medium power DC-DC conversion. These converters have features such as ZVS operation and reduced EMI operations, which leads to higher efficiency. In the traditional power loss calculation methods, only the fundamental component of switching frequency is considered. This paper describes more detailed power loss analysis of a PSFB converter under continuous conduction mode (CCM). Actual current waveforms are taken into consideration for the power loss analysis. The skin effect and proximity effect under non sinusoidal excitation on power loss are considered. The conduction and switching losses of devices and magnetic losses of the converter are analyzed theoretically. The major parameters that influence the power losses of the system are determined and thereby minimized the power losses for maximum efficiency. A 23kW prototype converter is realized for the validation of the analysis.