Simulation Model Development and Experimental Validation of A PFC Converter
Simulation Model Development and Experimental Validation of A PFC Converter
Corresponding Author:
António Pina Martins
Department of Electrical and Computer Engineering, Faculty of Engineering, University of Porto
Rua Dr. Roberto Frias, s/n, 4200-465, Porto, Portugal
Email: [email protected]
1. INTRODUCTION
Small electric power loads, i.e. less than 200 W, are connected to the public power grid through simple
diode bridges with a bulk capacitor at the output but they can cause various problems, initially raised in research
[1] and, more recently, in [2]. These problems implied the appearance of standards (IEC 61000-3-2 and IEEE
519) that establish different limits for certain characteristics, in particular with regard to current harmonics. On
the other hand, the emergence of new semiconductors turned possible to improve some parameters of these
interface converters. Thus, the widespread adoption of electronic switches based on silicon carbide (SiC) and/or
gallium nitride (GaN) semiconductors, allowed for new and better solutions [3], [4]. Increased performance
and reduced size are always important objectives in the design of a switched mode power supply, especially
with regard to energy savings, greater portability, and a smaller environmental footprint.
Compliance with the referred standards and specifications led to the development of interfaces based
on different topologies, e.g. semi-bridgeless or bridgeless referred, among others, in [5]–[7], and containing
active devices in order to be able to adequately control the input current and increase the efficiency, as analyzed
in [8] and [9]. The different topologies are distinguished by several parameters: the number of controlled
semiconductors they use, the size and type of passive components, i.e., inductors and capacitors [10]–[13], the
voltage gain. Some aspects of electromagnetic interference (EMI) are also different depending on the topology,
as reported in [8]. In the low power range, all solutions comply well with the standards and do not present
relevant issues regarding the currents (as they are small) that active and passive elements of the topology must
support. In this power range, and particularly for light emitting diode (LED) driving, the boost integrated fly
back rectifier with energy storage (BIFRED) topology with only one controlled MOSFET is a successful
topology [14].
To control these power factor correction (PFC) converters there are several control architectures, all
of them using the same structure: outer output voltage control loop; inner current control loop; synchronization
with the grid voltage. However, there are some additional control approaches that do not use any kind of
synchronization with the grid voltage, namely the discontinuous conduction mode and the one-cycle control
method [15]. Also, the versatile power balanced control is used in research [16] to directly obtain a voltage
gain lower than one without synchronization and using a buck-boost DC/DC converter while keeping a small
device count.
Several integrated circuits (ICs) have appeared on the market implementing, although in a different
way, the control requirements for this interface. Interfaces based on bridgeless topologies, require other control
methods, slightly different from those applied to diode bridge-based solutions [6], [8], [13], [17]. In the same
way, there are integrated circuits on the market dedicated to the control of some variants of the bridgeless
solution. In addition to these, the most modern solutions are based on dedicated microcontrollers such as those
from NXP, Infineon and STMicroelectronics.
An accurate simulation model of a control circuit as well as of the power circuit is a helpful tool
mainly when used in conjunction with the design guidelines provided by the integrated circuit (IC)
manufacturer for predicting the converter behavior in different steady-state and transient conditions. However,
simulation models of most control ICs are not freely available and turn difficult to obtain a prior knowledge
(based on simulation studies) related to the converter performance. The performance indicators considered
most relevant in this work are the alternating current (AC) distortion and the output voltage dynamics, [11];
they directly interfere in the quality of the AC interface [17], and in the requirements of the direct current (DC)
stage where they are connected to.
In this paper it is developed a simulation model based on one IC block diagram and the topology based
on diode bridge followed by a boost converter and controlled in the critical conduction mode (CRM). This
helps the designer and allows a faster development of the complete converter. The rest of the paper is organized
as: i) Section 2 discusses methods for converter design and modelling; ii) Section 3 explains how the simulation
model is developed and the parameters used for validation and testing; iii) Section 4 presents the most relevant
simulation results related to the issues analyzed in the work and demonstrates, with an experimental set-up
using the same parameters employed in simulation, the model accuracy and its performance. The section also
discusses available options and additional related features; and iv) Section 5 outlines the relevant conclusions
of the work.
Figure 1. Global power circuit and generic/simplified control approach of the diode bridge-based PFC
converter with CRM control method
Simulation model development and experimental validation of a PFC converter (António Pina Martins)
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𝑠 2 +𝜔𝑜
2
𝐺𝑁𝐹 (𝑠) = 2 2 (1)
𝑠 +2𝑠𝜔𝑜 /𝑄+𝜔𝑜
To take advantage of this filter, it is needed a high Q and a precisely adjusted filter. If these conditions
are not met, the filter's performance degrades rapidly. As the output voltage ripple is only approximated by the
second harmonic component, other harmonic components are processed by the voltage controller, and when
multiplied by the sinusoidal AC voltage, are transmitted to the current reference, increasing its distortion.
Moreover, in the event of rapid dynamic changes, the filter's temporal response is poor in relation to the
application.
Considering that the converter is operating at a frequency much higher than the grid frequency and
has no losses, it can be assumed that the instantaneous powers at the input and output of the converter are
almost equal, i.e. 𝑝𝑖 (𝑡) = 𝑝𝑜 (𝑡). This approximation makes it possible to identify the low-frequency (LF)
component of the ripple in the output voltage, which occurs at twice the grid frequency. In steady-state the
instantaneous power at the input stage is given by (2).
Where Vs and Is are the root-mean-square values of the input voltage and the input current, respectively, and w
is the grid angular frequency. The pulsating instantaneous power propagates to the output, and after some
simple manipulations, the low-frequency output voltage ripple is given by (3). Where Io is the actual DC load
current, C is the total output capacitance and w is the grid angular frequency.
𝐼𝑜
𝛥𝑣𝑜 (𝑡) ≅ − 𝑠𝑖𝑛( 2𝜔𝑡) (3)
2𝜔𝐶
The estimated voltage ripple is subtracted from the measured DC voltage thus allowing a larger
bandwidth in the voltage controller. However, the implementation of this compensation term requires three
conditions: a sine wave at twice the AC frequency, which is commonly implemented using a phase-locked loop
(PLL), the equivalent DC capacitor at the converter output and the load current. These are three important
conditions which are not simple to satisfy, and therefore, the use of this method is only justified in high
performance systems.
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where vs(t) is the instantaneous AC voltage, Vo is the DC output voltage, Ld is the inductance, Po is the output
power and 𝛥𝐼𝐿 is the current ripple in the same inductor.
In the CRM control method, it is obvious that 𝛥𝐼𝐿 is proportional to |vs(t)| and, for an estimate of the
switching frequency variation along the half-cycle, 𝛥𝐼𝐿 can be replaced by 𝛥𝐼𝐿 =K|vs(t)|. Additional
manipulations relating K with the output power allows to obtain as in (5).
It is observed in (5) that Fs varies also with the load power level, increasing with the reduction of the output
power. For reference, Table 1. gives the parameters used in the simulation analysis of the converter; they will
also be used in the experimental set-up. As an example, Figure 2(a) shows the evolution of Fs during a half-
cycle for two output power values: nominal power and light load (20% of Pn). This dependency of Fs with the
load level requires a strategy for maintaining this frequency within acceptable limits either for the switching
devices in terms of losses and for the generated EMI noise. For the specifications given in the Table 1,
Figure 2(b) shows the evolution of Fs (with nominal power) where the constant on time is nearly 20 s and a
large interval of switching frequencies is observed.
(a) (b)
Figure 2. Switching frequency variation during a half-cycle: (a) with nominal power (Pn) and light load
(Pn/5) and (b) with Pn using the MC33262 and the parameters in Table 1
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3. METHOD
For controlling the PFC converter, it was selected the MC33262, available from ON Semiconductor
manufacturer [31], and it has been developed a simulation model including the main control and protection
features of this IC. It is given in Figure 3 the simplified block diagram of the main control functions of the IC
using the blocks available in PSIM simulation software; the MOSFET current is measured by a shunt resistor
and the DC-bus voltage (VDC) by a resistive voltage divider.
The simulation of the PFC converter under CRM control is made for different operating conditions,
focusing on aspects related to the distortion of the current in the AC source at the zero crossings, the frequency
spectrum of the AC current, and the dynamic response of the output voltage. The main parameters for analysis
are the waveform of the AC current and the regulation of the DC voltage. For illustration purposes it was
modeled, simulated and built a PFC converter, where the passive components were sized according to the
guidelines in research [31], with the parameters given in Table 1.
Figure 3. Simplified control block diagram, based on the MC33262, modelled with PSIM software
(low-pass filter (LPF), time constant (T), zero current detector (zcd), transistor current (iT),
and hysteresis comparator (Hyst))
|𝑣𝑠 (𝑡)|
𝑡𝑜𝑓𝑓 = 𝑡𝑜𝑛 (7)
𝑉𝑜 −|𝑣𝑠 (𝑡)|
The expression for the resulting switching frequency variation is similar to (5), only including the converter
efficiency, . It is given by (8).
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current (Iac) is supposed to be also very small either during the complete cycle and in the zero crossings, in
light load the distortion is more visible. The effect is intensified by the EMI filter when its current is quite low
compared to the nominal one. In order to further analyze the zero crossing of the AC input current, Figure 6(a)
shows the relation between the zero-crossing detector signal (ZCD) of the inductor current (iac) and the
generated PWM signal in light load and Figure 6(b) in nominal load condition.
(a) (b)
Figure 4. AC voltage (Vac) and current (Iac): (a) at light load [scales: 30 V/div, 0.5 A/div] and
(b) at nominal load [scale: 1.75 A/div], [time: 2.5 ms/div]
(a) (b)
Figure 5. Zero crossing detail of the input voltage and current: (a) at light load [scales: 10 V/div,
0.125 A/div], and (b) at nominal load [scale: 1 A/div], [time: 500 s /div]
(a) (b)
Figure 6. Zero crossing detection signal (ZCD) and PWM signal: (a) at light load and
(b) at full load, [time: 50 s /div]
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It can be noticed the absence of PWM signals in the vicinity of the zero crossing of the AC voltage,
either at t=0.81 s and at t=0.91 s. As shown in Figure 6(a), it can also be verified the increased switching
frequency in the light load condition. The main consequence of the small distortion in the zero crossings is the
appearance of some LF spectrum components, shown in Figure 7(a) for the operation in light load; they don’t
appear in Figure 7(b) for nominal load. The resulting THD is 3.1% for light load and 2.2% for nominal load.
Other important feature of the PFC converter is the output voltage dynamics. Under steep load changes
it is expected some transient variation in the output voltage. The selected IC is designed for a relatively small
bandwidth without feedforward of the load current, but including an overvoltage protection comparator.
In Figure 8(a) is shown the converter behavior (output DC voltage (Vo) and AC input current (Iac))
when the load changes from light load (nearly 15 W) to nominal load (120 W) and in Figure 8(b) in the opposite
direction, where it can be seen the nonlinear behavior of the IC regarding the output overvoltage protection.
The implemented experimental prototype used the same parameters as those in the simulation model, given in
Table 1. The converter is controlled by the IC MC33262 from ON Semiconductor and, for better comparison
and discussion, the experimental results shown follow the same order as in the simulation section.
(a) (b)
Figure 7. Frequency spectrum of the AC input current: (a) at light load, and (b) at nominal load
(a) (b)
Figure 8. Output voltage dynamics: (a) load step change from 10% to 100% of the nominal power and
(b) from 100% to 10% of the nominal power [scales: 20 V/div, 2 A/div, time: 25 ms/div]
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and 5(b), respectively, obtained in simulation conditions. The oscillations visible in the light load operation
have higher magnitude that their simulated equivalents. The main reason for the small distortion in the zero
crossing is the absence of PWM pulses in this zone. Regarding this cause, a similar behavior is obtained either
in simulation environment and in the experimental prototype; Figures 11(a) and 11(b) (experimental) and
Figures 6(a) and 6(b) (simulation) show very close results.
(a) (b)
Figure 9. Steady-state AC voltage (Vac-brown) and current (Iac-blue): (a) at light load [scales: 30 V/div,
0.5 A/div] and (b) nominal load [scales: 2 A/div]
(a) (b)
Figure 10. Zero crossing of the input current: (a) at light load [voltage signal Vac - brown, scale: 10 V/div,
current signal Iac: blue, scale: 0.1 A/div] and (b) at nominal load [scale: 1 A/div]
(a) (b)
Figure 11. Zero crossing detection signal (ZCD-brown) and switching signal (PWM-blue):
(a) at light load and (b) nominal load, [voltage signal scale: 2 V/div, PWM signal scale: 5 V/div]
As referred in the simulation section, the main consequence of the zero-crossing distortion is a slightly
increase of the THD of the AC current compared to ideal conditions; Figures 12(a) and 12(b) show
experimental results for the frequency spectrum of the AC current under light load and nominal load conditions,
Simulation model development and experimental validation of a PFC converter (António Pina Martins)
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respectively. Their comparison with the simulation ones, as seen in Figures 7(a) and 7(b), is difficult to perform
due to the presence of a small distortion in the grid voltage, as referred above. However, the low-frequency
components are present in all results being more evident in the light load operation.
A broader perspective of the low-frequency distortion is given by the THD of the AC current in the
complete load range. This parameter, obtained from the experimental prototype is given in Table 2. In the full
output power range, the THD is maintained at very low levels, highlighting the fact that part of this distortion
is created by the AC input voltage, as referred before.
As above for the steady-state operation, this section presents results in the same sequence as those
discussed in the simulation section. For load changes from 15 W to 120 W and from 120 W to 15 W,
Figures 13(a) and 13(b) show the waveforms of the DC output voltage (Vo) and the AC input current (Iac).
These results can be compared with the ones in Figures 8(a) and 8(b), respectively, for the same conditions.
(a) (b)
Figure 12. Frequency spectrum of the AC input current: (a) at light load, Po=25 W and
(b) nominal load, Po=120 W
(a) (b)
Figure 13. Output voltage dynamics in load changing conditions: (a) step from 10% to 100% of the
nominal power and (b) step from 100% to 10%
A very similar behavior is noticed thus validating the developed simulation model operating in quite
different conditions. Another very important parameter of any converter is its energy efficiency. For the studied
converter, the data gathered, giving the evolution of the efficiency for the whole power range, is summarized
in Table 3. The efficiency is quite high in the complete range although it can be increased if the semiconductors
would be based on SiC technology as referred in the section 1.
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4.3. Discussion
The schematic diagram of the real IC is a complex one but it was possible to identify and model its
most important control and protection blocks and related features. When comparing the simulation and
experimental results it can be stated that the developed model performs very well in all conditions. Details that
occur in the simulation stage also appear in the prototype, i.e., the model correctly predicts the real
performance. A relevant one is the output voltage dynamics during load power steps, the other being the PWM
generation at the AC voltage zero crossings with frequency variation and pulse dropping.
The AC current distortion (measured by the THD) created by the zero crossing is maintained within
very low values in the whole load power range. However, it also depends on the AC voltage distortion in the
point of coupling, that is, the specific application environment. The output voltage dynamics could be better
but it should be noted that the converter is usually part of a larger system and the DC-bus voltage is further
conditioned by additional power electronics stages either low power DC/AC inverters or DC/DC converters.
5. CONCLUSION
This paper proposed and validated a simulation model for predicting the performance of a PFC
converter controlled in the critical conduction mode and using a commercial IC, representative of the large
offer in the market. The most relevant aspects, related to the zero-crossing distortion of the AC input current
and the output voltage dynamics were analyzed either with the developed simulation model and using an
experimental set-up. An almost perfect match between simulation and experimental results demonstrated the
model accuracy and its performance in predicting the converter behavior.
ACKNOWLEDGEMENT
The authors acknowledge the financial support of the Foundation for Science and Technology in the
framework of the Associated Laboratory-Advanced Production and Intelligent Systems (contract
LA/P/0112/2020), the R&D unit SYSTEC (contracts UIDB/00147/2020 and UIDP/00147/2020), both funded
by national funds through the FCT/MCTES.
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BIOGRAPHIES OF AUTHORS
Vítor A. Morais has received his M.Sc. and Ph.D. degrees, both in electrical
and computer engineering, from University of Porto, Faculty of Engineering, in 2015 and
2021, respectively. He has been with SYSTEC–Research Center for Systems and
Technologies from 2016 to 2021 as a research fellow in the fields of digital control, industrial
electronics, power electronics and solar photovoltaic energy. He is currently working as a
senior development engineer in Nomad Tech, in Matosinhos, Portugal, a joint-venture
company between Portuguese Railways and Nomad Digital. His research activities are in the
railway power systems and train power electronics, with focus on power management of
STATCOM units to improve the energy efficiency, auxiliary power converters, and train
traction control units. He can be contacted at email: [email protected].
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