99.3% Efficient Three-Phase Buck-Type All-SiC SWISS Rectifier for DC Distribution Systems

Abstract

DC power distribution systems for data centers, industrial applications, and residential areas are expected to provide higher efficiency, higher reliability, and lower cost compared to ac systems and have been an important research topic in recent years. In these applications, an efficient power factor correction (PFC) rectifier, supplying the dc distribution bus from the conventional three-phase ac mains, is typically required. This paper analyzes the three-phase, buck-type, unity power factor SWISS Rectifier for the realization of an ultrahigh-efficiency PFC rectifier stage with a 400-V rms line-to-line ac input voltage and a 400-V dc output voltage. It is shown that the mains current total harmonic distortion of the rectifier can be improved significantly by interleaving two converter output stages. Furthermore, the dc output filter is implemented using a current-compensated integrated common-mode coupled inductor, which ensures equal current sharing between the interleaved half bridges and provides common-mode electromagnetic interference (EMI) filter inductance. Based on a theoretical analysis of the coupled inductor's magnetic properties, the necessary equations and the design procedure for selecting semiconductors, magnetic cores, the number of turns, and the EMI filter are discussed. Based on these results, an ultrahigh-efficient 8-kW 4-kW $\cdot$ dm $^{-3}$ (66-W $\cdot$ in $^{-3}$ ) laboratory-scale prototype converter using 1.2-kV SiC MOSFETs is designed. Measurements taken on the prototype confirm a full power efficiency of $\text{{99.16}{\%}}$ and a peak efficiency of $\text{{99.26}{\%,}}$ as well as the compliance to CISPR 11 Class B conducted emission limits.