Optimizing Single-Stage Power Factor Correction

by Steven M. Sandler, Program Engineer, Acme Aerospace Division, an Actuant Co., Tempe, Ariz.; Charles Hymowitz, Managing Director, AEi Systems, Los Angeles; Harold Eicher, Vice President-Engineering, Champs-Technologies, East Setauket, N.Y., Power Electronics Technology, Mar 01 2006

Focus:
The boost topology is popular for implementing power factor correction because it offers high efficiency, but it has drawbacks such as the need for a dc-dc converter to step down the boost converter's output and provide isolation. This second stage reduces overall efficiency and increases the components count. For some applications it's preferable to design a single-stage PFC converter. This article presents four topologies capable of converting a single-phase, 115-Vac 400-Hz input to a 28-Vdc 200-W output using a single-stage PFC design. The topologies are isolated SEPIC (critical-conduction and continuous-conduction versions) and voltage-mode flyback (single- and multi-phase versions). After a brief comparison of these topologies, the design of a two-phase voltage-mode flyback to generate the 28-V output is discussed in detail, including design of the flyback transformer and output capacitor selection. The performance of this converter is simulated and verified experimentally.

What you’ll learn:

• How to design a single-stage PFC converter that generates 200 W of 28-Vdc output
• How to understand tradeoffs in choosing a topology for single-stage PFC converter design

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