Design Optimization of Single-Phase PFC Rectifier Using Pareto-Front Analysis and Including Electro-Thermal Modelling

The design of power converters that have both high efficiency and high power density performance while maintaining the lowest possible cost and highest possible reliability is a challenge for power electronics engineers. Therefore, optimization techniques are often used to obtain the optimal solution for a given set of specified objectives. As a result, engineers must devise the correct methodology to solve multi-variant problems arising from these fixed objectives. The aim of this paper is to investigate PFC rectifier performance as a function of design variables and temperature impact using a bi-objective optimization algorithm. A methodology based on a Pareto-Front analysis to find the optimal design variable is described and a design model including electro-thermal modeling and power loss calculations is presented. Subsequently, the optimization result of a single-phase boost PFC converter operating in continuous conduction mode (CCM) for input power levels of 3kW is analyzed, and then the methodology to evaluate cost and reliability variables for design optimization is presented. FEM simulations and experimental results are shown to demonstrate the effectiveness of the proposed models.