A New Hybrid Modular Multilevel Rectifier as MVac–LVdc Active Front-End Converter for Fast Charging Stations and Data Centers

As the power demands from dc energy-storage and loads continue to grow in electric vehicle fast charging stations and data centers, the power delivery infrastructure faces challenges with the installation of bulky, heavy, and slow responsive line-frequency power transformer (LFT). These transformers are required to step-down the feeder voltage from medium-voltage (MV) ac grid-service to low-voltage (LV) ac, followed by LVac–LVdc rectifiers. This approach results in a large equipment footprint, heavy conductor copper usage, and lower efficiency. Consequently, there is increasing interest in exploring direct interface from MVac to LVdc without the need for LFT. This article proposed a new solution called MVac–LVdc hybrid modular multilevel rectifier (HMMR). The HMMR serves as a centralized step-down active front-end converter, enabling power delivery to LVdc with a reduced number of dc/dc back-end isolated converters. Compared to the modular multilevel converter (MMC) used as the MVac interface solution, the proposed HMMR could save the submodule number by 40%, reduce losses by 22%, and significantly reduce the footprint area by 37%, effectively increasing the power density and reducing the construction cost. Moreover, the proposed HMMR has the potential to operate in both unity and nonunity power factor modes, allowing it to provide the grid-support functionality. The performance of HMMR is evaluated and compared with full-bridge MMC in the case of 13.8 kV ac to 6 kV dc. The feasibility of the proposed converter is verified by the simulation results with the same specifications. Finally, a scale-down 1.4 kV HMMR prototype is developed to validate the effectiveness of the proposed converter.