Isolated Single-Stage Interleave Resonant PFC Rectifier with Active and Novel Passive Output Ripple Cancellation Circuit

Abstract: With the increasing demand for fast, cheaper, and efficient power converters come the need for a single-stage power factor correction (PFC) converter. Various single-stage PFC converter proposed in the literature has the drawback of high DC bus voltage at the input side and together with the shift to wide bandgap switches like GaN drives the converter cost higher. However, an interleaved topology with high-frequency isolation was proposed in this research work due to the drastic reduction in the DC bus voltage and extremely low input current ripple thereby making the need for an EMI filter circuit optional.   Meanwhile, this research work focuses on adapting the proposed topology for a high voltage low current application (EV charger - 400V, 7KW) and low voltage high current application (telecom power supply - 58V,  58A) owing to cost benefits. However, all single-stage PFC are faced with the drawback of second-order (100Hz) output harmonic ripple. Therefore, the design and simulation presented a huge peak to peak ripple of about 50V/3A and 26V/26A for the EV charger and telecom power supply case, respectively. This created the need for the design of a ripple cancellation circuit as the research required a peak to peak ripple of 8V and 200mV for the EV - charger and telecom power supply, respectively.   A novel output passive ripple cancellation technique was developed for the EV charger case due to the ease it offers in terms of control, circuit complexity and extremely low THDi when compared with the active cancellation approach. The ripple circuit reduced the 50V ripple to 431mV with the use of a total of 2.2mF capacitance at the output stage.   Despite designing the passive technique, an active ripple cancellation circuit was designed using a buck converter circuit for the telecom power supply. The active approach was chosen because the passive has a slow response and incurs more loss at a high current level. Adding the active ripple cancellation circuit led to a quasi-single stage LLC PFC converter topology. A novel duty-ratio feedforward control was added to synchronize the PFC control of the input side with the buck topology ripple cancellation circuit. The addition of the ripple circuit with the feedforward control offered a peak to peak ripple of 6.7mV and a reduced resonant inductor current by half.   After analysis, an extremely low THDi of 0.47%, PF of 99.99% and a peak efficiency of 97.1% was obtained for the EV charger case. The telecom power supply offered a THDi of 2.3%, PF of 99.96% with a peak efficiency of 95%.