An 18-kW Wide-Output-Range Bidirectional DC Power Supply with 80V, 600A Using Totem-Pole Bridgeless PFC

This paper introduces an 18-kW wide-output-range bidirectional DC power supply with 80V, 600A using single-phase totem-pole bridgeless Power Factor Correction (PFC) circuit. The developed DC power supply is capable of 2.67 times output-current range (from 225A to 600A) at the rated power of 18 kW under AC 200V input. The DC power supply consists of three single-phase 6-kW AC-DC converters (AC-DC CONVs). And the AC-DC CONV is composed of three-stage converter, which includes single-phase Totem-Pole Bridgeless PFC (TP-BL PFC) circuit, the bidirectional LLC converter with fixed-frequency operation, and four-phase interleaved non-isolated bidirectional DC-DC converter. To achieve high efficiency, the single-phase TP-BL PFC circuit is adopted in three-phase input system. Isolated DC-DC converter is adopted to a bidirectional full-bridge LLC converter with fixed-frequency operation because the output voltage for the LLC converter is not needed to be regulated. In addition, minimizing a voltage rating of power devices for non-isolated bidirectional DC-DC converter can be used because the secondary bus-line voltage is kept stable. To confirm the feasibility of the developed DC power supply, a prototype is manufactured and tested. The measured overall efficiency at the rated power is around 91% at the rated current condition and over 93 % at the rated-voltage condition, respectively. In this paper, the results of the test equipment are shown, which is using the developed bidirectional DC power supply for realizing high energy saving in factories. This means that the low power losses of the developed bidirectional DC power supply can enhance environmental sustainability.