Evaluation of an optimal design for a single-phase boost PFC converter (CCM) considering different magnetic materials core

In power factor correctors converters (PFCs), magnetic elements as inductors and transformers have a strong influence on volume, power density, cost and performance, becoming the main elements in these systems. Thus, the optimized design of these components is extremely necessary. However, reducing the inductor volume with maximum efficiency, on equipment and systems, result in a high cost, making the optimized design a great challenge for engineers. With the inductor optimization purpose, this paper presents a comparative inductor design for a single-phase boost PFC converter operating in the continuous conduction mode (CCM) for different input power levels (500 W, 750 W and 1000 W). The design is developed using different operation points (Δi @ fs) and magnetic materials technologies (Molipermalloy (MPP), High Flux (HF) and KoolMμ), which will show different volumes, costs and efficiency for each operation point of design. Thereby, the results will point the technology that presents the better cost/benefit relationship for each power range.