K. ERENAY, M. YİLMAZ, B. FİNCAN, A. GOYNUSEN

Design and Optimization of a High Power Density and Efficiency Boost PFC

Nowadays electrical appliances have been becoming more and more popular every day in our life, and the systems that have more power density and that use energy efficiently and that improve the quality of the energy are required more. Especially with the decisions and regulation changes of the United States and the European Union in recent years, it has become compulsory to replace low efficiency electric motor drive systems with high efficiency permanent magnet electric motors and drivers, and as a result permanent magnet motors that have high efficient field orientation control algorithms technologies have begun to be chosen. Low cost uncontrolled rectifiers that have high power factor have become a necessity with the need for DC bus. In such systems with inherently nonlinear characteristics, the need for Power Factor Correction (PFC) circuit has been increasing, and Boost PFC (BPFC) which increase the input voltage are widely preferred for low/medium power applications. Therefore, distortion harmonics and high frequency noises are reduced according to standards such as CSRIP Class B – TS EN 61000-3-2 and also output voltage remains constant, becoming more than peak amount of the input grid voltage. In that study, it is designed that BPFC that has 1,150W output power level by increasing system's power density and efficiency. The system cost is reduced by decreasing the requirement of EMI filters and heatsink size, since using SiC (Silicon Carbide) diode and optimizing the system contribute increasing efficiency and power density. The most efficient Boost PFC design is realized at the lowest cost by performing detailed design, loss and cost analysis for each component used. The Boost PFC with full system efficiency of 95.5% at full load is obtained by model validation done by comparing the simulation results with the experimental results obtained by hardware implementation.

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