Coordinated Two-Stage Operation and Control for Minimizing Energy Storage Capacitors in Cascaded Boost-Buck PFC Converters

Cascaded boost-buck PFC (CBBPFC) converters offer a wide voltage conversion ratio and a near-unity power factor but require a large output electrolytic capacitor, leading to poor reliability and power density. In this paper, a coordinated two-stage operation and control strategy is proposed to significantly minimize the capacitor requirement without any other hardware changes. In a conventional CBBPFC converter, the boost and buck stages either operate independently nor complementally. In contrast, the proposed method operates the two stages in a concerted manner, so it is possible to use the dc-link capacitor with certain voltage fluctuation to buffer the power imbalance between the AC input and DC output. A new coordinated control strategy and a fluctuation-ratio based design consideration are developed to coordinate the operation of the two stages, further complement the system design. A 200W CBBPFC prototype based on the design concept exhibits a maximum reduction of the output capacitor by 83%, a peak efficiency of 95.8%, and a power factor of 0.99.