Integrated methodology design to improve the efficiency and reduce volume of the CCM PFC boost converters with pre-sizing settings

This paper presents an optimization design methodology for CCM PFC Boost converters with volume and efficiency objectives. The optimization methodology, achieved by mathematical interactions, is based on the concept of the converter integrated design, in other words, all the main physical converter components are designed simultaneously in the function of a pair of overall variables. The integrated design provides for the reduction of cost and time of the project design of the system and also gives complete and matched solutions with the objective of the proposed optimization. The proposed methodology is evaluated with a PFC Boost converter including an input EMI filter (1000-W output power, 400-V DC output voltage and 220-V AC input voltage). In this case study, three different magnetic materials are used in both inductors designs (Boost and EMI filter) in order to demonstrate how technology affects the volume and efficiency results. To confirm the theoretical analysis that was carried out, the experimental mechanical, electrical and thermal measurements are presented.