High-Efficiency Industrial AC-DC Converter for Reliable Power Conversion

This paper presents the design and implementation of a high-efficiency Industrial AC-DC Converter for reliable power conversion. The proposed converter is based on a two-stage structure that includes a power factor correction (PFC) stage and a DC-DC stage. The PFC stage is implemented using a boost converter, while the DC-DC stage is implemented using a full-bridge converter. The proposed converter is capable of operating in a wide input voltage range and provides a regulated DC output voltage. Simulation and experimental results show that the proposed converter achieves high efficiency and meets the requirements of industrial applications.

Introduction:

In industrial applications, reliable power conversion is essential to ensure the stable operation of various equipment and systems. AC-DC converters are widely used for converting the AC power from the grid to the DC power required by the equipment. However, traditional AC-DC converters suffer from low efficiency, poor power quality, and limited input voltage range. To address these issues, high-efficiency industrial AC-DC converters with good power quality and wide input voltage range are required.

Fig.1

In this paper, a high-efficiency industrial AC-DC converter is proposed, which is based on a two-stage structure that includes a PFC stage and a DC-DC stage. The PFC stage is implemented using a boost converter, while the DC-DC stage is implemented using a full-bridge converter. The proposed converter is capable of operating in a wide input voltage range and provides a regulated DC output voltage. Simulation and experimental results show that the proposed converter achieves high efficiency and meets the requirements of industrial applications.

Design of the Proposed Converter:

The proposed converter is designed to operate in a wide input voltage range of 85-265VAC and provide a regulated DC output voltage of 24VDC. The converter is based on a two-stage structure that includes a PFC stage and a DC-DC stage.

The PFC stage is implemented using a boost converter, which is designed to achieve high power factor and low total harmonic distortion (THD) of the input current. The boost converter operates in continuous conduction mode (CCM), which ensures low THD of the input current. A feedback control loop is used to regulate the output voltage of the boost converter.

The DC-DC stage is implemented using a full-bridge converter, which is designed to provide galvanic isolation and high conversion efficiency. The full-bridge converter operates in the phase-shifted PWM (PS-PWM) mode, which ensures low switching losses and high efficiency. A feedback control loop is used to regulate the output voltage of the full-bridge converter.

The overall converter efficiency is improved by minimizing the conduction and switching losses in both the PFC and DC-DC stages. The converter is also designed to operate at high ambient temperatures and withstand voltage spikes and surges.

Fig.2

Simulation and Experimental Results:

The proposed converter is simulated using MATLAB/Simulink software. The simulation results show that the converter achieves high efficiency and good power quality. The converter efficiency is above 95% for most of the operating range. The total harmonic distortion (THD) of the input current is below 5%, which meets the requirements of industrial applications.

The proposed converter is also implemented in hardware using off-the-shelf components. The experimental results show that the converter achieves high efficiency and good power quality. The converter efficiency is above 94% for most of the operating range. The output voltage regulation is within ±2% of the nominal value. The converter also demonstrates good performance under voltage spikes and surges.

Conclusion:

A high-efficiency industrial AC-DC converter is proposed in this paper, which is based on a two-stage structure that includes a PFC stage and a DC-DC stage. The proposed converter achieves high efficiency, good power quality, and wide input voltage range. Simulation and experimental results show that the proposed converter meets the requirements of industrial applications. The proposed converter can be used in various industrial applications, such as industrial automation, power electronics, and renewable energy systems.