Solid-state switch-mode rectification converters have reached a matured level for improving power quality in terms of power-factor correction (PFC), reduced total harmonic distortion at input AC mains and precisely regulated DC output in buck, boost, buck-boost and multilevel modes with unidirectional and bidirectional power flow. This paper deals with a comprehensive review of improved power quality converters (IPQCs) configurations, control approaches, design features, selection of components, other related considerations, and their suitability and selection for specific applications. It is targeted to provide a wide spectrum on the status of IPQC technology to researchers, designers and application engineers working on switched-mode AC-DC converters. A classified list of more than 450 research publications on the state of art of IPQC is also given for a quick reference.

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A review of single-phase improved power quality AC-DC converters

High-frequency-link (HFL) power conversion systems (PCSs) are attracting more and more attentions in academia and industry for high power density, reduced weight, and low noise without compromising efficiency, cost, and reliability. In HFL PCSs, dual-active-bridge (DAB) isolated bidirectional dc-dc converter (IBDC) serves as the core circuit. This paper gives an overview of DAB-IBDC for HFL PCSs. First, the research necessity and development history are introduced. Second, the research subjects about basic characterization, control strategy, soft-switching solution and variant, as well as hardware design and optimization are reviewed and analyzed. On this basis, several typical application schemes of DAB-IBDC for HPL PCSs are presented in a worldwide scope. Finally, design recommendations and future trends are presented. As the core circuit of HFL PCSs, DAB-IBDC has wide prospects. The large-scale practical application of DAB-IBDC for HFL PCSs is expected with the recent advances in solid-state semiconductors, magnetic and capacitive materials, and microelectronic technologies.

Overview of Dual-Active-Bridge Isolated Bidirectional DC–DC Converter for High-Frequency-Link Power-Conversion System

Similar to the efforts to move toward electric vehicles, much research has focused on the idea of a more electric aircraft (MEA). The motivations for this research are similar to that for vehicles and include goals to reduce emissions and decrease fuel consumption. In traditional aircraft, multiple systems may use one type or a combination of types of energy, including electrical, hydraulic, mechanical, and pneumatic energy. However, all energy types have different drawbacks, including the sacrifice of total engine efficiency in the process of harvesting a particular energy, as with hydraulic and pneumatic systems. The goal for future aircraft is to replace most of the major systems currently utilizing nonelectric power, such as environmental controls and engine start, with new electrical systems to improve a variety of aircraft characteristics, such as efficiency, emissions, reliability, and maintenance costs. This paper provides an in-depth look into how the systems have—or will be—changed. Future aircraft capabilities such as electric taxi and gas–electric propulsion for aircraft are also included for discussion. Most recent commercial transport aircrafts are described as the current state-of-the-art electric aircraft system. Future goals, including those of NASA, are presented for future advances in MEA.

More Electric Aircraft: Review, Challenges, and Opportunities for Commercial Transport Aircraft

In the first part of this paper, three-phase power factor correction (PFC) rectifier topologies with sinusoidal input currents and controlled output voltage are derived from known single-phase PFC rectifier systems and/or passive three-phase diode rectifiers. The systems are classified into hybrid and fully active pulsewidth modulation boost-type or buck-type rectifiers, and their functionality and basic control concepts are briefly described. This facilitates the understanding of the operating principle of three-phase PFC rectifiers starting from single-phase systems, and organizes and completes the knowledge base with a new hybrid three-phase buck-type PFC rectifier topology denominated as Swiss Rectifier. Finally, core topics of future research on three-phase PFC rectifier systems are discussed, such as the analysis of novel hybrid buck-type PFC rectifier topologies, the direct input current control of buck-type systems, and the multi-objective optimization of PFC rectifier systems. The second part of this paper is dedicated to a comparative evaluation of four rectifier systems offering a high potential for industrial applications based on simple and demonstrative performance metrics concerning the semiconductor stresses, the loading and volume of the main passive components, the differential mode and common mode electromagnetic interference noise level, and ultimately the achievable converter efficiency and power density. The results are substantiated with selected examples of hardware prototypes that are optimized for efficiency and/or power density.

The Essence of Three-Phase PFC Rectifier Systems—Part II

With the number of electric vehicles (EVs) on the rise, there is a need for an adequate charging infrastructure to serve these vehicles. The emerging extreme fast-charging (XFC) technology has the potential to provide a refueling experience similar to that of gasoline vehicles. In this article, we review the state-of-the-art EV charging infrastructure and focus on the XFC technology, which will be necessary to support the current and future EV refueling needs. We present the design considerations of the XFC stations and review the typical power electronics converter topologies suitable to deliver XFC. We consider the benefits of using the solid-state transformers (SSTs) in the XFC stations to replace the conventional line-frequency transformers and further provide a comprehensive review of the medium-voltage SST designs for the XFC application.

Extreme Fast Charging of Electric Vehicles: A Technology Overview

A passive 12-pulse rectifier system, a two-level, and a three-level active three-phase pulsewidth-modulation (PWM) rectifier system are analyzed for supplying the dc-voltage link of a 5-kW variable-speed hydraulic pump drive of an electro-hydrostatic actuator to be employed in future More Electric Aircraft. Weight, volume, and efficiency of the concepts are compared for an input phase voltage range of 98-132 V and an input frequency range of 400-800 Hz. The 12-pulse system shows advantages concerning volume, efficiency, and complexity but is characterized by a high system weight. Accordingly, the three-level PWM rectifier is identified as the most advantageous solution. Finally, a novel extension of the 12-pulse rectifier system by turn-off power semiconductors is proposed which allows a control of the output voltage and, therefore, eliminates the dependency on the mains and load condition which constitutes a main drawback of the passive concept.

Comparative evaluation of three-phase high-power-factor AC-DC converter concepts for application in future More Electric Aircraft

In telecom applications, the vision for a total power conversion efficiency from the mains to the output of point-of-load (PoL) converters of 95% demands optimization of every conversion step, i.e., the power factor correction (PFC) rectifier front-end should show an outstanding efficiency in the range of 99%. For recently discussed 400-V dc distribution bus voltages, a buck-type PFC rectifier is a logical solution. In this paper, an efficiency-optimized, 98.8% efficient, 5-kW three-phase buck-type PFC rectifier with 400-V output is presented. Methods for calculating losses of all components are described and are used to optimize the converter design for efficiency at full load. Special attention is paid to semiconductor losses, which are shown to be dominant, with the parasitic device capacitance losses being a significant component. The calculation of these parasitic capacitance losses is treated in detail, and the charge-balance approach used is verified. A prototype of the proposed rectifier is constructed which verifies the accuracy of the models used for loss calculation and optimization.

Towards a 99% Efficient Three-Phase Buck-Type PFC Rectifier for 400-V DC Distribution Systems

Up to now, in the development of power electronics systems, the reduction of the initial costs or the increase of the power density have been of primary concern. However, with increasing energy costs also the power conversion efficiency is gaining higher and higher importance. Accordingly, while maintaining high power density, an efficiency as high as possible must be obtained. In this paper the maximum attainable efficiency and the dependency of the efficiency limit on technological parameters is determined for single-phase PFC boost rectifiers. In a first step basic PFC boost rectifier topologies are briefly compared with regard to high efficiency and a dual-boost PFC rectifier with integral common-mode filtering is selected as basis for the investigations. Next, simple approximations of the technological limits of the system performance are calculated in the efficiencypower density plane. With this, the Feasible Performance Space and the reduction in power density which has to be accepted for increasing the efficiency are clarified, and the trade-off limit curve (Pareto Front) of a multi-objective, i.e. efficiency and power density design optimization is determined. Furthermore, a comprehensive numerical efficiency optimization is carried out which identifies an efficiency limit of 99.2% for a 3.2kW system. The theoretical considerations are verified by experimental results from a laboratory prototype of the ultra-high efficiency system achieving 99.1% efficiency at a power density of 1.1kW/din3, as well as those firom an ultra-compact dual-boost PFC rectifier (95.8%, 5.5kW/dn3) and a very low switching freluency (3kHz) conventional PFC boost rectifier (96.7%, 2kW/din3). Finally, the sensitivity of the efficiency optimum with regard to various technological parameters is analyzed and an outlook on the further course of the research is given.

Exploring the pareto front of multi-objective single-phase PFC rectifier design optimization - 99.2% efficiency vs. 7kW/din 3 power density

In this paper a generalized description and an overview of degrees of freedom and selected measures for efficiency improvement of power electronics converters is given. The background of all considerations is formed by single-phase PFC rectifier systems, but the concepts shown are fundamental and fully applicable for other converter systems. First, the influence of the main components of the losses of a converter on the efficiency characteristic over the output power is discussed. Subsequently, a detailed analysis of the possibilities, of minimizing the semiconductor losses, the losses of the passive components including the EMI filter, and the power requirements of auxiliary systems in the course of the design process are given. In this context also the technological boundaries that limit the maximum efficiency of a converter are clarified and the compromise that always has to be made between efficiency and power density is highlighted. Furthermore, a control procedure is discussed to maximize the efficiency in the partial load range and a resonant transition mode ZVS converter system is presented that allows to attain efficiencies significantly over 99% without the use of SiC semiconductors. In addition the accuracy of the input and output power measurements required for measuring highest efficiencies is clarified, whereby the advantage of a direct loss measurement by means of a calorimeter becomes immediately clear. Finally, results of measurements on a demonstrator of a CCM single-phase PFC rectifier system with 99.1% max. efficiency and η > 99% above half rated power, and on a resonant transition mode PFC rectifier system with ηmax = 99.3% and η > 99% above 15% rated power are presented.

Extreme efficiency power electronics

In telecom applications, the vision for a total power conversion efficiency from the mains to the output of PoL converters of 95% demands for an optimization of every conversion step, i.e. the PFC rectifier front-end should show an outstanding efficiency in the range of 99%. For recently discussed 400 V DC distribution bus voltages a buck-type PFC rectifier is a logical solution. In this paper, an efficiency-optimized, nearly 99% efficient, 5 kW three-phase buck-type PFC rectifier with 400 V output is presented. Methods for calculating losses of all components are described, and are used to optimize the converter design for efficiency at full load. Special attention is paid to semiconductor losses, which are shown to be dominant, with the parasitic device capacitance losses being a significant component. A prototype of the proposed rectifier is constructed which verifies the accuracy of the models used for loss calculation and optimization.

J. Minibock

Papers

Comparative evaluation of three-phase high-power-factor AC-DC converter concepts for application in future More Electric Aircraft

Towards a 99% Efficient Three-Phase Buck-Type PFC Rectifier for 400-V DC Distribution Systems

Exploring the pareto front of multi-objective single-phase PFC rectifier design optimization - 99.2% efficiency vs. 7kW/din 3 power density

Extreme efficiency power electronics

Towards a 99% efficient three-phase buck-type PFC rectifier for 400 V DC distribution systems