Design methodology for universal line input boost power factor correction magnetics

This study presents a design methodology for inductors employed in single-phase power factor correction (PFC) boost converters operating in continuous conduction mode (CCM). A simulation tool based on the proposed design methodology performs an automatic selection of magnetic core taking into account the standard limits for conducted electromagnetic interference (EMI), single- or multi-layer winding pattern and the limit of temperature rise on the inductor core. Through a sweep simulation, the algorithm chooses the switching frequency and the input current ripple that minimise the magnetic volume of boost inductor considering the characteristics of some powder cores (sendust, molypermalloy and high-flux). The design methodology is confirmed by experimental results obtained from a 650 W universal line input PFC prototype, considering a switching frequency of 70 kHz and an input current ripple of 40%.