An Efficiency-Improved Single-Phase PFC Rectifier With Active Power Decoupling
An Efficiency-Improved Single-Phase PFC Rectifier With Active Power Decoupling
fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TPEL.2022.3160242, IEEE
Transactions on Power Electronics
Abstract- Active power decoupling (APD) technology is an increased to 1.3 times the original [8]. These basic cells are
effective solution to store the double-line frequency ripple power easy to control because they work independently with the
in the single-phase system and remove the bulky aluminum original circuit [9]-[11]. However, the extra power losses are
electrolytic capacitors (Al E-caps). However, APD introduces inevitably introduced due to the fact that additional active and
power loss because of adding extra switches operating at high
frequency, which hurts the system efficiency inevitably.
passive components are added. According to the normalized
Addressing this issue, this paper proposes an improved boost comparison results in [6], the efficiency penalty of the
power factor correction (PFC) rectifier with a buck-type APD independent basic APD cells is 3%. This hinders the course of
cell. An auxiliary circuit, composed of a resonant inductor and a industrialization.
diode, is added. With the developed modulation strategy, zero For reducing the power loss, some methods [12], [13] are
voltage switching (ZVS) of the switches both in the PFC and APD proposed to decrease the conduction loss of power devices and
circuits is achieved, which improves the system efficiency the inductor loss in basic APD cells. They are achieved by
significantly. This paper firstly describes operating modes and reducing the decoupling voltage. Based on this idea, a duty
then analyzes the soft-switching condition of each switch. Finally, ratio injection controller is proposed in [12] to generate a feed-
a 300 W prototype is built and the experimental result shows that
the efficiency is increased by 4%.1
forward to regulate the original duty ratio, then the efficiency
Index Terms- Active power decoupling, Power factor is increased by 1%. In [13], an adaptive voltage control
correction, Single-phase AC/DC converter, Zero voltage method is proposed to be applied for the boost-type APD cell.
switching. The minimum decoupling capacitor voltage is controlled to be
constant to reduce the voltage stress. Another way to reduce
I. INTRODUCTION power loss is to lessen the switching loss, by achieving soft
switching. In [14], a variable frequency control applying for
S INGLE-phase power factor correction (PFC) rectifiers
have been widely used in low and medium-power
applications [1]. Among them, the boost PFC converter is a
buck-type APD cell is proposed to make the current ripple of
the inductor large enough to fully discharge the junction
capacitance. Hence, zero voltage switching (ZVS) is achieved.
popular choice because of the simple circuit structure and The drawbacks are the complex control and filter design. To
effective shaping-current ability [2]. However, to store the avoid this, an active-filter controller is proposed in [15]. The
inherent double-line frequency ripple power, aluminum inductor current is controlled as a triangular shape, and the
electrolytic capacitors (Al E-caps) are needed [3]. They switches achieve ZVS at the peak and valley of the current. In
increase the volume and degrade the reliability of the system addition to modifying the control, soft switching can be
[4], which is not expected. achieved by adding auxiliary circuits. In [16], the active clamp
Active power decoupling (APD) is confirmed to be an circuit is used in the parallel PFC flyback converter, to achieve
effective method to cope with the double-line frequency ripple ZVS of the main switch and the auxiliary switch. Due to the
power and remove the Al E-caps from the system [5], [6]. In regulation of the output voltage by the clamp capacitor, the
[7], basic decoupling cells, like buck-type circuit, boost-type conduction loss will be reduced. Another method to reduce the
circuit, and buck-boost-type circuit, are introduced. They can conduction loss of the parallel PFC flyback converter is using
be connected into the single-phase AC/DC converters in series parallel-connected flyback converters [17]. But the negative
or parallel. And the power density of the converters will be impact of double-line frequency ripple power is not
considered. In [18], an APD auxiliary circuit (composed of
Manuscript received November 5, 2021; revised January 30, 2022; four switches and one capacitor) is proposed to connect to a
accepted March 3, 2022. This work was supported in part by the National single-phase flyback converter proposed in [19]. The auxiliary
Natural Science Foundation of China under Grant 61903381, in part by the capacitor is small enough to resonant with the parasitic
National Natural Science Foundation of China under Grant 52177205, and
inductor on the circuit. Each switch state of the auxiliary
Changsha City Science and Technology Plan Project under Grant kq2009007.
(Corresponding author: Yonglu Liu.) circuit is changed when the resonant current is zero. Therefore,
Y. Cui, H. Han, Y. Liu, G. Xu, M. Su, and S. Xie are with the School of zero current switching (ZCS) is achieved and the switching
Automation, Central South University and with Hunan Provincial Key loss reduces. In [20] and [21], the energy stored in the switch
Laboratory of Power Electronics Equipment and Gird, Changsha 410083,
junction capacitor is transferred into the added auxiliary
China. (email: [email protected]; [email protected];
[email protected]; [email protected]; [email protected]; circuit, which is in series with the DC-link. Then all switches
[email protected]). in the inverter and buck-type APD cell realize ZVS. However,
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this is accomplished at cost of increasing the voltage stresses A. Operating Region A (id>0)
of all switches by 10%. In this region id>0, S1 and S2 can achieve ZVS turn-on. Fig.
This paper presents a single-phase PFC rectifier with APD 3(a) shows the theoretical waveforms of the proposed circuit
and ZVS (shown in Fig. 1). By adding a resonant inductor and in region A. vgs1, vgs2, and vgs3 are the gate-source voltage of
a diode to the PFC rectifier with the buck-type APD cell, S1 the main switches. vD is the voltage across the diode D. ta1, ta2,
and S2 realize ZVS operation, S3 realizes ZVS turn-on in half and tb are the key periods to achieve ZVS. Iamax is the
of the grid period and the diodes D and Da realize ZCS turn- maximum value of ia. Fig. 4 shows the equivalent circuit of
off. Consequently, the system efficiency is improved each operation mode.
significantly without increasing the complexity of circuit Interval a1 [t0, t1]: S2 and D are turned on. vds1 and vds3
structure and control. The remainder of this paper is organized equal to Vdc. Da is reverse biased. ir and id decrease linearly. id
as follows: Section Ⅱ introduces the proposed rectifier and flows from the source to drain in S2. ir and id are expressed as
describes its operation modes. Section Ⅲ analyzes the ZVS
conditions. Section IV introduces design considerations. (1)
Section V analyzes the power loss and provides a comparison
result. Section VI depicts the controller design, and the
(2)
experimental results are presented in Section VII. Finally, the
conclusion is proposed in section VIII. This stage ends when S2 is turned off.
Boost PFC Buck-type APD
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ir L D ir L D ir L D ir L
C2 S2 C2 S2 C2 S2 C2
S2 CD CD
vds2 vds2 vds2 vds2 Cdc
id Cdc id Cdc id Cdc id
Ld Vdc R Vr ia La D a Ld Vdc R Vr ia L a Da Ld Vdc R Vr ia L a D a Ld Vdc R
Vr C1 S C3 C1 C3 C1 C3 C1 C3
S1 S1 C S1 Cd V S1 Cd V
vds1 3 Cd V d vds1 S3 vds3 d Vd vds1 S3 vds3 d vds1 S3 vds3 d
vds3
t0 ~ t1 t1 ~ t2 t2 ~ t3 t3 ~ t4
ir L D idc ir L D ir L D
C2 S2 C2 C2
S2 CD S2
vds2 vds2 vds2
id Cdc id Cdc id Cdc
Vr ia L a Da Ld Vdc R Vr ia L a Da Ld Vdc R Vr Ld Vdc R
S1 C1 C3 S1 C1 C3 S1 C1 C3
C C C
vds1 S3 vds3 d Vd vds1 S3 vds3 d Vd vds1 S3 vds3 d Vd
t4 ~ t5 t5 ~ t6 t6 ~ t7
Fig. 4. Equivalent circuits of each operation mode in region A.
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C2 C2
vds2 As analyzed in interval a4, t34 needs to be greater than tv1(as
vds2
id id expressed in (7)). Therefore, the limit of t34 is
Ld Vdc Ld Vdc
La Da ia L a Da (33)
Vdc Cd V C3 v Cd
C3 d ds3 Vd Inferred from (30)-(33), the range of tb is
(a) (b) (34)
Fig. 6. Equivalent circuits of intervals b2 and b6 in region B. (a) Interval b2,
(b) Interval b6. To avoid damaging the PF and the effect of APD, tb should
be as small as possible. Therefore, the ZVS condition of S1 is
III. ANALYSIS OF ZVS CONDITIONS (35)
According to section Ⅱ, ta1, ta2, and tb should be designed
elaborately to achieve the ZVS of S1, S2, and S3. In this section, where .
the steady-state analysis is carried out first to pave the way to
the analysis, then the ZVS conditions and design C. The ZVS condition for S2 and S3
considerations are analyzed. For S2, as described in interval a6 or b6, ta2 needs to be
larger than tv2 (as expressed in (11)). So, the ZVS condition of
A. Steady-state analysis
S2 is
The state-space average models are expressed as (36)
(20) For S3, as analyzed in interval a2, S3 cannot achieve ZVS in
region A. So, the ZVS condition of S3 is determined by region
B. In interval b2, ta1 should be smaller than ti1 (as expressed in
(21)
(16)) and larger than tv3 (as expressed in (14)). Hence, the
range of ta1 is
(22)
(37)
(23) and Id (t1) can be obtained from (2) and expressed as
The steady-state expressions of d1 and d3 are derived from (38)
(20) and (21) as
where t01 is approximate as
(24)
(39)
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B. Parameters selection
Following the above design guidelines, the selection of the
proposed converter parameters is as follow:
1) The basic parameters are selected as:
Input voltage: 110 V(RMS);
Output voltage: 250 V;
Rated power: 300 W;
Switching frequency: 20 kHz;
Current ripple factor: 0.4;
Maximum output voltage ripple: 5%×Vdc.
2) The theoretical voltage and current stresses are listed in
Fig. 7 . Decoupling capacitor design region.
TABLE II.
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V. POWER LOSS AND COMPARISION Fig. 9. Power loss comparison of PFC rectifier with APD and PFC rectifier
with APD and ZVS @ Po=300W.
A. Power loss
The power loss for the proposed converter mainly includes
switching loss and inductor loss. According to the datasheet of
semiconductor devices and the loss calculation method in [23],
the power loss of switches can be estimated. As for the
inductor power loss, they are composed of core loss and
copper loss. They can be estimated by adopting the method in
[24] and [25]. The calculation formulas of power loss are
listed in Table IV. The theoretically calculated results at 300
W are shown in Fig. 9. Compared with the PFC rectifier with
APD, the proposed circuit increases auxiliary branch loss by
2.6 W and reduces switching loss by 23.2 W. In contrast, the
switching loss of the proposed circuit was reduced by 80%. Fig. 10. Power loss and efficiency of PFC rectifier with APD and PFC
Fig. 10 shows the power loss and efficiency of the PFC rectifier with APD and ZVS at different output power.
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PS1
PS2
PS3
PD
PDa
PDr
PL
PLd
PLa
* PS1 is the loss of S1; PS2 is the loss of S2; PS3 is the loss of S3; PD is the loss of D; PDr is the loss of Dr; PDa is the loss of Da.
* PLa is the loss of La; PL is the loss of L; PLd is the loss of Ld.
*
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And the stability can be similarly proved. turn-on and turn-off of the diodes). It can be seen that the
PLL
currents of diodes have dropped to zero before their voltage
increase and the voltage and current of the diodes do not
Notch PI1 PI2 PWM overlap with each other, proving that D and Da achieve ZCS
turn-off.
Current loop 1 Fig. 14(k) shows the waveforms of the output voltage vdc,
Voltage loop 1
the decoupling capacitor voltage vd, the rectifier output voltage
PI3 PI4 PWM vr, and the rectifier output current ir. vdc is regulated at 250 V
with a small ripple voltage, which is lower than 5% of vdc. vd
fluctuates at the double-line frequency, the ripple voltage of vd
Voltage loop 2 Current loop 2
is 65 V, and the average value of vd is 200 V. ir is continuous
Fig. 11. Control diagram of the system. and in phase with vr. The PF is 0.996. Consequently, PFC and
APD are effective.
The experimental results at 10% load are shown in Fig. 15.
As can be seen, ZVS is also achieved at light load. According
(a) (b) to the analysis in Section III, when the circuit element
parameters, the output voltage Vdc and the average value of the
decoupling capacitor voltage are chosen, the ZVS
conditions are only related to Po. By substituting the Po under
(c) (d)
Fig. 12. Diagram of the control loops. (a) Voltage loop 1; (b) Current loop 1; different loads into (35), (36), and (41), the corresponding
(c) Voltage loop 2; (d) Current loop 2. intervals can be calculated to ensure the realization of ZVS.
Fig. 16 shows the dynamic experimental waveforms of the
proposed circuit. In Fig. 16(a), the output power decrease from
VII. EXPERIMENT RESULTS 300 W to 150 W. The output voltage Vdc tracks to 250 V
within 30 ms and the deviation is not obvious. The average
To verify the theoretical analysis, the laboratory prototype
decoupling capacitor voltage Vd tracks to 200 V within 60 ms.
was built, which is shown in Fig. 13.
No current spikes occur and the transient is smooth. Fig. 16(b)
shows the opposite transient process.
Fig. 17 shows the experimental results at 40 kHz. As seen,
S1 and S2 can achieve ZVS turn-on, S3 can achieve ZVS turn-
on in half of the output voltage cycle (region B), D and Da can
achieve ZCS turn-off.
Fig. 18 shows the efficiency curves of the PFC rectifier
with APD and the PFC rectifier with APD and ZVS at 10%-
100% load. It can be seen that the experiment efficiencies
Control agree with the theoretical value in Fig. 10. At 300 W, the
board
efficiency of the proposed rectifier is 95% and the PFC
rectifier with APD is 91%, the auxiliary branch helps to
Fig. 13. Photo of the prototype.
increase the efficiency by 4%.
Fig. 14 exhibits the experiment results at 20 kHz of the Figs. 19 and 20 show the power factor and THD under the
proposed converter. Figs. 14(a)-(f) show the gate-source condition of 10%-100% load. It can be seen that the power
voltages and the currents of S1, S2, and S3; the rectifier output factor and THD of the proposed circuit are almost the same as
current ir; and the decoupling inductor current id. As seen, the original circuit.
before iS1 and iS2 rise up, vds1 and vds2 have reached zero. As a
result, S1 and S2 achieve ZVS turn-on both in region A and
region B. Note that, in Fig. 14(c), iS2 and vds2 do not overlap
with each other, so the turn-off loss of S2 in region A equals
zero. For S3, since the voltage of the junction capacitor vds3
cannot drop to zero, S3 is hard-switching turned on in region A,
as shown in Fig. 14(e). Because of the hard-switching
operation, the current oscillation of ir and id occurs [27]. In
region B, vds3 drops to zero before iS3 rises, as shown in Fig. 14
(f). Hence, S3 achieves ZVS turn-on. In short, the ZVS
situations of S1, S2, and S3 are consistent with the theoretical
analysis in section Ⅱ.
Figs. 14(g)-(j) exhibit the voltage and current of the diode D Fig. 18 Efficiency curves of the PFC rectifier with APD and the PFC rectifier
and Da, the gate-source voltage of S1, and S3(To indicate the with APD and ZVS at 10%-100% load.
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ZVS on
ZVS on ZVS on
Time [4µs/div]
(j) (k)
Fig.14 The voltage and current waveforms at the switching transitions of all switches switch voltage and current. (a) ZVS situation of S1 in region A. (b) ZVS
situation of S1 in region B. (c) ZVS situation of S2 in region A. (d) ZVS situation of S2 in region B. (e) ZVS situation of S3 in region A. (f) ZVS situation of S3 in
region B. (g) ZCS situation of D in region A. (h) ZCS situation of D in region B. (i) ZCS situation of Da in region A. (j) ZCS situation of Da in region B. (k)
Steady-state waveforms.
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(a) (b)
Fig. 16 Dynamic experimental waveforms. (a) Step-down output power change from 300 W to 150 W; (b) Step-up output power change from 150 W to 300 W.
Fig. 19 Power factor of PFC rectifier with APD and the PFC rectifier with Fig. 20 THD of PFC rectifier with APD and PFC rectifier with APD and ZVS
APD and ZVS at 10%-100% output power. at 10%-100% output power.
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