LCC resonant converter with inductive filter operating in discontinuous current mode (DCM) can achieve zero-current switching (ZCS) for both the power switches and rectifier diodes. Therefore, it is suitable for high-power, low-voltage, high-current power supplies. The DCM LCC resonant converter with inductive filter might operate in different operating modes when input voltage or load changes, which challenges the design. This paper derives a mode boundary map, from which the operating mode of the converter can be easily determined. Based on the mode boundary map, a generalized optimal design procedure is proposed and a set of optimal and normalized converter parameters is determined, which can be easily converted into real parameters according to the converter specification. Three 5 kW prototypes with different converter parameters are fabricated and tested in the lab, and the experimental results show that with the set of optimal parameters, the converter can achieve the highest efficiency over the entire input voltage and load range.Index Terms-Discontinuous current mode (DCM), LCC resonant converter, mode boundary map, optimal design, zero-current switching (ZCS). Series resonant capacitor.The maximum switching frequency.Peak value of i L r . I LrNk Abbreviation of i LrN (α k ) (k = 1, 2, 3). I LrN rms RMS value of i LrN . I LrN pk Peak value of i L r N . I * Lr rms Normalized I Lr rms with respect to I o max V o / V in min . I * Lr pkNormalized I Lr pk with respect toOutput current at full load.
I oNNormalized form of I o /n, I oN = I o Z r /(nV in ).
L fOutput filter inductor. L r Sum of the resonant inductor and the leakage inductor of the transformer. n Primary to secondary turns ratio of the transformer.Characteristic impedance of the resonant tank,Normalized form of time t, α = ω r t. α 12 Abbreviation of α 2 − α 1 . α 23 Abbreviation of α 3 − α 2 . α k Normalized form of t k (k = 0, 1, 2, 3). 0885-8993 © 2014 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See http://www.ieee.org/publications standards/publications/rights/index.html for more information. TAN AND RUAN: OPTIMAL DESIGN OF DCM LCC RESONANT CONVERTER WITH INDUCTIVE FILTER BASED ON MODE BOUNDARY MAP 4145 λ Capacitor ratio, λ = C p /C s . ω rResonant angular frequency, ω r = 2πf r .