Design and Fabrication of an Isolated Two-Stage AC–DC Power Supply with a 99.50% PF and ZVS for High-Power Density Industrial Applications

Abstract

Power quality in terms of power factor (PF), efficiency, and total harmonic distortions (THDs) is an important consideration in power supplies designed for 5G telecom servers. This paper presents a different magnetic parts design and manufacturing techniques of power supplies, design and selection criteria of switching elements as well as the optimal design of control loops based on small-signal stability modeling and an appropriate stability criterion. The designed telecom power supply consists of the power factor correction (PFC) stage to increase the input power factor and the isolated phase-shift pulse width modulation (PWM) zero-voltage switching (ZVS) DC–DC converter stage to regulate the supply voltage to the specified load value while maintaining a high conversion efficiency. A two-stage outdoor telecom power supply with a power rating of 2 kW was designed and fabricated on a printed circuit board (PCB). The distinct two-stage power components of the power supply were subjected to loss analysis. Furthermore, PSIM simulation and experiments were used to demonstrate the total harmonic distortions (THDs), voltage ripples, power efficiency, and PF performance of the supply current for the proposed power supply under various operating situations. This work produces an industrial high power density power supply with a high PF, low THD and high conversion efficiency which is suitable for telecom power server applications.