A Novel Topology and Design Methodology for Improved Power Quality of High-Power Charger

This article introduces a novel topology and design methodology of a high-power charger. The proposed topology integrates a modified 12-pulse Diode Bridge Rectifier (12pDBR) with an interleaved boost converter (IBC) to meet the charging requirements and power quality standards. This results in an efficient charger with a reduced number of components and magnetic ratings compared to its counterparts. The mathematical analysis that highlights the significance of triangular shaping of the output currents of a 12pDBR and its impact on the input current harmonics is presented. Furthermore, the role of overlap angle, which is a function of system inductances, in triangular wave shaping is emphasized. A systematic methodology for the coordinated design of 12pDBR and IBC is proposed. To verify the design, MATLAB/Simulink simulations are conducted, followed by experimental validation using a 1 kW prototype. The proposed topology attains a grid current Total Harmonic Distortion (%iTHD) of 4.9%, a power factor (PF) of 0.97 lag, and a charging current ripple of 2.75% at full load condition.