Design and Optimal Control of a Two-Stage Efficient and High PF AC-DC Converter for High-Power Density Industrial Applications

power quality is an essential consideration in design of the power supply in high power industrial applications. Thus, this paper covers the design of the different magnetic components, switching element selection considerations, and the voltage current controllers optimal design on the basis of small-signal stability modeling and an adequate stability criterion to enhance the high-power factor (PF), high efficiency and lower current distortions. The proposed converter contains two stages, the power factor correction (PFC) stage and the isolated phase-shift PWM zero-voltage switching (ZVS) DC-DC converter stage. The proposed two-stage converter's total harmonic distortions (THDs), voltage and current ripples, conversion efficiency, and PF performance are investigated using PSIM simulations under various operating conditions. This study designs an industrial 2000 W, 54 V telecom AC-DC supply with a PF of more than 99%, a THD of about 5 %, and conversion efficiency of around 93% at full load.