SEPIC-Boost-Based Unidirectional PFC Rectifier with Wide Output Voltage Range

A novel unidirectional hybrid PFC rectifier topology based on SEPIC and boost converters is proposed, which is applicable to various industrial applications such as electric vehicle charging stations, variable speed AC drives, and energy storage systems. Compared to other rectifiers, the proposed SEPIC-boost-based rectifier exhibits continuous current on the AC side, lower voltage stress on the active switches, a wider range of DC output voltage, no auxiliary DC-DC converters, and a high step-up static voltage gain operating with low input voltage and a low step-up static gain for the high-input-voltage operation. These traits allow the SEPIC-boost-based rectifier to utilize smaller input-side harmonic filtering inductors and adopt active switches with lower voltage ratings, resulting in reduced conduction losses. Additionally, the proposed rectifier features power factor correction and high boost/buck voltage-gain capabilities, simplifying control for electric vehicle charging and expanding its range of applications. In this paper, the operating principle of the novel topology is presented first, and then the mathematical model of the proposed rectifier is built. Based on this, the comparison between the proposed topology and conventional boost and SEPIC converters is given. Furthermore, the control strategy, including the high-power-factor control and the balancing control to the DC capacitor voltages, is discussed. Finally, to validate the accuracy of the proposed rectifier's theoretical research, a 500-W SEPIC-boost rectifier system has been constructed in the laboratory, generating a 200/120 Vdc output voltage from a 155 Vpk/50 Hz power source.