CCM PFC Inductor Design with Powder Core.pptVIP

CCM Power Factor Correction Inductor Design with Powder Core  By Jacki_wang  Power Factor Definition Power Factor (PF) is a term describing the input characteristic of an electrical appliance that is powered by alternating current (ac). It is the ratio of “real power” to “apparent power” or: Where v and i are instantaneous values of voltage and current. RMS indicates the root-mean-squared value of the voltage or current. The apparent power (Vrms x Irms), in effect, limits the available output power. Power Factor Correction Here’s the input current of a power supply without PFC. The current is concentrated at the peak of the voltage waveform, where the input rectifier conducts to charge the input energy-storage capacitor. In this case the harmonics are huge, because much of the power is concentrated in a short period of time in each cycle. Why Choose Powder Core Normally, because of the low loss coefficient, we use the ferrite core for the PFC inductor. However, the space for PFC components is smaller and smaller due to the slim requirement of power supply. The powder core have higher saturate flux, can conduct the same energy with smaller size core vs ferrite. CCM Inductor in PFC Circuit Normally, a boost circuit will be used for the power factor correction, inductor in active PFC circuit is a really choke, and it is very significant because the energy is carry by the choke from input to output circuit. The key point of designing PFC choke is: 1. Will not saturate at maximum peak current. 2. The loss can be accepted accordance to the temperature rise. Inductor Current calculation We use a 90~264Vac input and 5V 60A single output power for the design example. Set the PFC output voltage 380Vdc, the efficiency of the dc-dc circuit is 90%, and 95% efficiency for PFC circuit, than PFC output power should be 330W . Set the operation frequency 70KHz, then: The RMS value of two signals is t