Optimal design of a compact 99.3% efficient single-phase PFC rectifier

Due to rising energy costs the efficiency of power electronics converter systems is of higher and higher importance, especially for applications with continuous operation as e.g. server power supplies. For designing such supplies numerous parameters like the switching frequency and the characteristic values and the geometry of magnetic components must be determined. In this paper, an optimisation procedure, which automatically determines the parameter values of a single-phase bridgeless PFC rectifier for maximum efficiency is presented. There, continuous and discontinuous operation mode, as well as a concept for magnetic integration of the CM and DM filter inductors is included. For verifying the considerations, a prototype with 99.3% efficiency and a power density of 1.35 kW/dm³ is presented.