An All-SiC Three-Phase Buck Rectifier for High-Efficiency Data Center Power Supplies

Abstract

The low power losses of silicon carbide (SiC) devices provide new opportunities to implement an ultra high-efficiency front-end rectifier for data center power supplies based on a 400- <formula formulatype="inline" xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex Notation="TeX"> ${\rm V}_{\rm dc}$</tex></formula> power distribution architecture, which requires high conversion efficiency in each power conversion stage. This paper presents a 7.5-kW high-efficiency three-phase buck rectifier with 480- <formula formulatype="inline" xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex Notation="TeX">$\hbox{V}_{{\rm ac}, {\rm rms}}$</tex></formula> input line-to-line voltage and 400- <formula formulatype="inline" xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex Notation="TeX">${\rm V}_{\rm dc}$</tex></formula> output voltage using SiC MOSFETs and Schottky diodes. To estimate power devices' losses, which are the dominant portion of total loss, the method of device evaluation and loss calculation is proposed based on a current source topology. This method simulates the current commutation process and estimates devices' losses during switching transients considering devices with and without switching actions in buck rectifier operation. Moreover, the power losses of buck rectifiers based on different combinations of 1200-V power devices are compared. The investigation and comparison demonstrate the benefits of each combination, and the lowest total loss in the all-SiC rectifier is clearly shown. A 7.5-kW prototype of the all-SiC three-phase buck rectifier using liquid cooling is fabricated and tested, with filter design and switching frequency chosen based on loss minimization. A full-load efficiency value greater than 98.5% is achieved.