Design and Implementation of a Power Semiconductor-Based Switching Mode Laser Diode Driver

Fiber lasers are commonly used in many industrial applications, such as cutting, welding, marking, and additive manufacturing. In a fiber laser system, the driver of a pumping source using a laser diode (LD) module and its dynamic control capability directly affect the performance of the fiber laser system. The commercial design of pumping source drivers for high-power fiber lasers is mainly based on a linear-type DC power supply, which has two major drawbacks, i.e., lower efficiency and bulk. In this regard, this paper proposes for the first time a new design approach with a programmable switching mode laser diode driver using a power semiconductor device (PSD)-based full-bridge phase-shifted (FB-PS) DC-DC converter for driving a 200 W optical power laser diode module. In this paper, the characteristics of a laser diode module and the system configuration of the proposed laser diode driver are first introduced. Then, a current control scheme using the concept of phase angle shifting to achieve a fast dynamic current tracking feature is explained. The proposed current control technique with a fully digital control scheme is then addressed. Next, dynamic mathematical models of the laser diode driver system and controllers are derived, and the quantitative design detail of the controller is presented. To confirm the correctness of the proposed control scheme, a simulation study on a typical control case is performed in PSIM 9.1 software environment. To verify the effectiveness of the proposed LD driver, a digital signal processor is then used as the control core to construct a hardware prototype implementation for performing experimental tests. Results obtained from simulation and hardware tests show highly satisfactory driving performances in the laser diode's output current command tracking control.