Design and Experimental Validation of a High-Boost Full-Bridge Converter with Extended ZVS Range and Stable Efficiency Under Wide Load Variations

This paper introduces a new four-switch, high-voltage, high-step-up converter employing two transformers. The topology enables Zero-Voltage Switching (ZVS) across all primary switches for operating conditions ranging from no load to full load. A voltage-quadrupler and a voltage-doubler rectifier are used on the secondary sides of the transformers, enabling reduced turn-off current for the voltage-quadrupler diodes and Zero-Current Switching (ZCS) turn-off for the voltage-doubler diodes, thereby ensuring high efficiency across diverse load levels. Notably, the voltage stress experienced by the voltage-multiplier diodes is significantly lower than the output voltage, thereby rendering the converter exceptionally suitable for high-voltage applications such as electron beam welding (EBW). The voltage gain surpasses that of the conventional phase-shift full-bridge (PSFB) converter, permitting a lower transformer turns ratio and thus reducing winding resistivity. The removal of the substantial output inductor leads to a lighter and more compact design, eliminating insulation concerns associated with inductor windings. This paper details the operation of the proposed converter, supported by experimental results from a 500-W prototype with a 150-V input and 2-kV output, which confirm its high performance and operational advantages.