DC Voltage Sensorless Predictive Control of a High-Efficiency PFC Single-Phase Rectifier Based on the Versatile Buck-Boost Converter

Many electronic power distribution systems have strong needs for highly efficient AC-DC conversion that can be satisfied by using a buck-boost converter at the core of the power factor correction (PFC) stage. These converters can regulate the input voltage in a wide range with reduced efforts compared to other solutions. As a result, buck-boost converters could potentially improve the efficiency in applications requiring DC voltages lower than the peak grid voltage. This paper compares SEPIC, noninverting, and versatile buck-boost converters as PFC single-phase rectifiers. The converters are designed for an output voltage of 200 V and an rms input voltage of 220 V at 3.2 kW. The PFC uses an inner discrete-time predictive current control loop with an output voltage regulator based on a sensorless strategy. A PLECS thermal simulation is performed to obtain the power conversion efficiency results for the buck-boost converters considered. Thermal simulations show that the versatile buck-boost (VBB) converter, currently unexplored for this application, can provide higher power conversion efficiency than SEPIC and non-inverting buck-boost converters. Finally, a hardware-in-the-loop (HIL) real-time simulation for the VBB converter is performed using a PLECS RT Box 1 device. At the same time, the proposed controller is built and then flashed to a low-cost digital signal controller (DSC), which corresponds to the Texas Instruments LAUNCHXL-F28069M evaluation board. The HIL real-time results verify the correctness of the theoretical analysis and the effectiveness of the proposed architecture to operate with high power conversion efficiency and to regulate the DC output voltage without sensing it while the sinusoidal input current is perfectly in-phase with the grid voltage.