Low-Volume PFC Rectifier Based on Nonsymmetric Multilevel Boost Converter

This paper introduces a digitally controlled single-phase rectifier with power factor correction (PFC) based on a modified three-level boost converter topology. In comparison with the conventional boost-based systems, the new PFC rectifier has about three times smaller inductor and significantly lower switching losses. The improvements are achieved by replacing the output capacitor of the boost converter with a nonsymmetric active capacitive divider, with a 3:1 division ratio, and by utilizing the downstream converter stage for the capacitive divider´s center-tap voltage regulation. The nonsymmetric voltage divider and applied switching sequence effectively provide four-level converter behavior using the same number of components as three-level converters. As a result, a 66% reduction of the inductor compared to the conventional boost-based PFC and a 33% compared to the standard three-level solutions operating at the same effective switching frequencies are also achieved. Experimental results obtained with a 400 W, 200 kHz, universal input voltage (85 V_rms-265 V_rms) PFC prototype demonstrate three times smaller inductor current ripple than that of the conventional boost converter allowing for the same inductor reduction. Efficiency improvements of up to a 6% are also demonstrated.