Inductor Design and ZVS Control for a GaN-Based High Efficiency CRM Totem-Pole PFC Converter

This paper details the inductor design and zero-voltage-switching (ZVS) control of a single-phase GaN-based critical-conduction-mode (CRM) totem-pole rectifier with power factor correction (PFC). A full-line-cycle ZVS strategy is derived, and an analytical converter model with ZVS margin is proposed. The boost inductor design is critical for the operation performance of the CRM totem-pole PFC. Based on analytical loss models, the inductor is designed and implemented using a toroidal powder core and litz wire to minimize converter loss and inductor size. Digital on-time control with real-time calculation and zero current detection (ZCD) is used to implement CRM. A 1.5 kW single-phase GaN-based CRM totem-pole PFC prototype is built and tested. With the on-time control, both the inductor current and the output voltage are well regulated. ZVS is realized for the whole line cycle, and the tested efficiency is 98.8% at full load.