SUPERVISOR:
DATE: 12/12/2014
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ABSTRACT
This project aims to looks at ways to improve power factor of large companies with high
harmonics generation, as well as analyse them for technical and financial feasibility.
A brief explanation of the causes and effect of low PF have been presented. Moreover, of
description of different options, topologies and architectures were also reviewed and
compared to develop the optimum solution for power factor correction. This project aims to
develop a circuit with high power output for power factor correction using active PFC
solutions. This is due to its high power factor, smaller size and high efficiency. Among
varieties of control techniques identified, nonlinear control was chosen as the viable solutions
due to its simplicity and high performance.
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1 TABLE OF CONTENTS
1. SECTION 1: INTRODUCTION ................................................................................................... 5
1.1 Problem Statement ................................................................................................................ 5
1.2 Power Factor ......................................................................................................................... 5
1.2.1 Effects of Low Power Factor ........................................................................................ 6
1.2.2 Causes of Low Power Factor........................................................................................ 6
2 POWER FACTOR CORRECTION ........................................................................................... 7
2.1 Passive Technique ................................................................................................................. 7
2.2 Active PFC methods.............................................................................................................. 8
2.2.1 Single phase active power faction correction .............................................................. 9
2.2.2 Dc-Dc Converters ........................................................................................................ 11
2.2.3 Buck converters ........................................................................................................... 11
2.2.4 Boost converters PFC. ................................................................................................ 12
3 Boost Active power factor control techniques .......................................................................... 13
3.1 Continuous conduction mode ............................................................................................. 13
3.1.1 Hysteresis current control (HCC).............................................................................. 14
3.1.2 Average current mode control. .................................................................................. 14
3.1.3 Non carrier control ..................................................................................................... 15
4 CONCLUSION ........................................................................................................................... 16
5 REFERENCE .............................................................................................................................. 17
6 BIBLIOGRAPHY ....................................................................................................................... 18
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Table of Figures
Figure 1 Power factor angle and equation .............................................................................................. 5
Figure 2 Series parallel resonant filter .................................................................................................... 7
Figure 3 Block diagram of Active power factor correction .................................................................... 8
Figure 4 the basic Active power factor correction .................................................................................. 9
Figure 5 Two stage active PFC converter ............................................................................................. 10
Figure 6 Single stage PFC converter..................................................................................................... 10
Figure 7. Basic buck converter PFC ..................................................................................................... 12
Figure 8 Basic active boost PFC circuits .............................................................................................. 13
Figure 9 Average current mode control base on unity power factor rectifier ....................................... 14
Figure 10 Nonlinear carrier control base unity power factor rectifier .................................................. 15
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1. SECTION 1: INTRODUCTION
1.1 Problem Statement
The widespread usage of nonlinear loads are causing various undesirable effect in the
operation of power systems. Therefore, many government agencies around the world, driven
especially by western government are setting a performance regulatory standard for power
consumption to improve efficiency of the network. This constitutes a marked shift in the
direction compared to more traditional approaches for supplying high power loads and
stricter limit were applied to the level of harmonics that can be injected into the transmission
line. The implication is companies with large power electronics and computer usage are
coming under increasing pressure to reduce their harmonics injection into power system
network.
Thus, nonlinear loads with poor power factors are getting increasing attention, as they are
liable to generate harmonics which are responsible for degrading the power factor [1]
An ideal power factor can be said to be at unity, where the loads consume the same amount
of real power as the apparent power, which translate to a current waveform with a perfect
sine wave in phase with the A.C voltage of the grid. While some electrical load devices do
have unity power factor, most does not behave this way as they tends to draw a pure sine
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wave current out of phase with the voltage, or draws current in a non-sinusoidal waveform
thus creating a power factor less than 1 [2]
Limitation to the amount of load current that can be used, especially as each office is
usually provided with a fixed power rating. For instance in England, with a typical
medium size office load current rating of 10A and a power of 0.5, that means the
maximum current the house can use is 5A while the other half will be wasted as heat
in the premises wire.
Typically most offices with lots of electronics with switch mode power supply like
computers generate a low frequency harmonics (2nd -13th) capable of degrading PF, of
which if not suppressed can cause overvoltage, cables overheating, fire, mechanical
stress and protection failure. This can be expensive for the distribution companies and
are passed on to customers in the long run.
For utilities companies, low power factors means distribution grids and generators are
not fully realised to their potential.
Companies with a power factor below the limit set by the regulatory body, are
charged a penalty for every kilovolts/Amps used [3].
1. Displacement power factor: This happens when the current and the voltage is out of
phase, it is normally caused by linear loads such as induction motors which exhibit
lagging current. This problem can be minimised by the use of capacitors and
synchronous motors used to compensate for the reactive power.
2. Distortion power factor: This is the components linked with the presence of harmonic
current and voltages as a result of nonlinear loads like fluorescent, arc regulators and
computers with switch mode power supplies [4].
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2 POWER FACTOR CORRECTION
In order to minimise the effects above, particularly distortion, power factor correction system
are employed. There are two main forms of power factors correction (PFC) technique which
can be used on nonlinear loads;
Ideally it requires that the AC input voltage be set manually. These passive method like
others, rely on reactive element for PFC, as such they are only ideal for low power ( 100W)
where there is a constant voltage, at which they are relatively cheap and efficient [5].
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Using passive PFC, the power factor can be increased tremendously, however the main
drawback are:
Lower power factor: Passive PF performance are between the range of 0.70-0.75
[6], therefore it becomes arduous to achieve a PF close to 0.99, especially when used
to correct the excessive harmonics generated from switch mode power supply found
in computers and TVs
Size of filter: In view of the operating line AC supply frequency which is 50Hz,
couple with high current and voltage the size of the suitable inductor and capacitor
will be too bulky for the intended application.
Cost of filter components: Keeping in mind the performance and size concern, it
can be really expensive especially compared to the active power factor.
Inability to regulate voltage and a narrow input allowable input voltages
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Ability to regulate the output voltage over wide range of frequencies through the use
of feedback control network
Feedback detection of the source current for waveform control
Active wave shaping of the input current.
Filtering of the high frequency switching.
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2.2.1.1 Two stage active PFC approach
As shown in Figure 5, there are two independent power stages controlled by two separate
controller. The PFC stage can either be boost or buck converters, an isolated DC-DC
converter form the output stage, it is used to regulate the output voltage by the pulse width
modulation (PWM) controller acting as a feedback loop control to monitor the output voltage
thus adjusting the switching accordingly for regulation [8]. The resulting advantage of two
controllers, is fast response output voltage together with high PFC, this makes it suitable for
high power applications. These control however are more expensive than a single control, in
addition they are also more complex and the resulting drawback is an increment in size.
Figure 6 shows a single phase PFC converter with an output electrolytic capacitor used to
store the energy from the converter, to free the output from line ripple. However, the
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implication of single stage is that the bus VB is not a regulated constant voltage as a result of
controller busy regulating the output voltage thus resulting in a varying value of VB for
universal line input. The voltage range between the low and the high line can be so wide thus
causing undesirable effects and making it hard to optimise the DC-DC stage and at the same
increasing the size of the capacitor required to withstand the hold-up time.
The obvious advantages are the simplicity in power stage and control of the circuit in
addition to cheaper cost compare to two stage PFC converter. However, this project deals
with medium to high power and the price of the capacitor can get expensive high thus
pushing the overall price closer to two stage.
A detailed discussion of different topologies, architectures and options are beyond the scope
of these literature, but some of the most common approach are discuss here. The most
commonly used topology are the boost and buck converters, because of their less complex
control couple with their relative cheap and high power PFC characteristics. It is worth noting
active PFC cannot improve the efficiency of the system, therefore designing a high efficient
converters together with a low total harmonic distortion (THD) and high PFC, are the design
approach.
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Figure 7. Basic buck converter PFC
Buck converter PFC offers some advantages over boost converter of which the relevant ones
are:
Improved reliability and robustness as a result of lower voltage downstream. This also
mean the bus voltage can be optimise with the use of more efficient design using
lower voltage device with better specifications .
Improvement in efficiency, as buck has to work harder at the input with higher
voltage and low current and thus, less mechanical stress compare to boost converter.
Easy to control with more flexibility, this helps to achieve a THD and PF.
Disadvantage of using Buck converter PFC over boos converter also includes:
Higher percentage output voltage ripple compared to boost converters and required
voltage control with narrow bandwidth
Lower PF
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Figure 8 Basic active boost PFC circuits
Using boost converter for this project, the following advantage can be realised are:
The mode of control are typically influenced by the power stage which they control and the
power level of the rectifiers. At power above 1kW, the peak current and rms current of both
CrCM and DCM becomes too large for efficient use of semiconductors and magnetic devices.
As a result CCM is the only viable control technique for this project.
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3.1.1 Hysteresis current control (HCC)
This method is used to generate a switching signals from the comparison of the current error
within a fixed window called hysteresis band. The switch is turned ON whenever the inductor
current reaches the lower hysteresis limit. Conversely, the controlled switch is turned OFF
when the inductor current reaches the upper limit of the hysteresis. Though this method have
the advantage of simplicity in implementation, but the pulse width modulated frequency
varies within the hysteresis band which makes it difficult to achieve a constant output voltage
[12].
Figure 9 Average current mode control base on unity power factor rectifier
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3.1.3 Non carrier control
Figure 10 shows another control method called Non carrier control that can be operated in
CCM. Unlike average current mode control, it doesnt sensed the input voltage to generate a
reference input current, as this it is generated by an analytical calculations.
The works with the use of comparators comparing the input current to the output of carrier
signal, of which the resulting the signal is used to generate a gate drive for switching. This
method offers the advantage of simplicity, and sensor less control [14].
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4 CONCLUSION
From the literature survey, varieties of solutions have been presented in order to achieve the
optimum power factor correction design. Active boost PFC was identified as the most viable
solutions, as it is capable of achieving close to unity power factor with a very low total
harmonic distortion when design properly. The downsides is the increased complexity
particularly with the control technique due to CCM operation. However, novel solutions like
Non carrier controls are found to offer simplicity together with the advantage of a very low
THD and high power factor.
The research presented in this paper comprised of the review of basic standards to achieving
the optimum PFC therefore a much more efficient solutions need to be conducted to achieve
a close to unity power factor and a low THD in addition to high efficiency. An example is to
look into soft switching techniques which offers robustness and the lowest switching losses in
high power applications at the expense of increase complexity and cost. Therefore their
respective performance, cost and complexity need to be research to find the best solution.
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5 REFERENCE
[1] K. R. K. A. Z. N. Majid Pakdel, Three Topologies and a Control Strategy for Harmonic
Suppression in Single-Phase Systems Using a Shunt Active Power Filter, IEEE Trans,
p. 1, 2007.
[4] L. Cividinho, Power Factor, Harmonic Distortin; Causes, Effects and Considerations,
IEEE, vol. 21, pp. 506-507, August 1992.
[5] Nuvation, Power Supply Design Basics: Passive PFC Design, [Online]. Available:
http://www.nuvation.com/blog/electronic-design-services/power-supply-basics-passive-
power-factor-correction. [Accessed 1 12 2014].
[6] CUI, Power Factor andPower Factor Correction, CUI, OREGON, 06/2013.
[8] K. M. C. P. K. V V. Vijetha Inti, A New Topology for Power Factor Correction using
Resonant Converters, International Journal of Soft Computing and Engineering
(IJSCE), vol. 3, no. 4, pp. 120-121, April 2013.
[9] R. Mamano, New developments in high power factor circuit topologies, Conference
Rec. HPFC, pp. 64-73, 1996.
[10] B. Keoghv, Power Factor Correction Using the Buck technology-Efficiency benefits
and Practical Design Considerations, Power Supply Design Seminar, pp. 2-5,
2010,2011.
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[12] M. Milosevia, Hysteresis Control in Three Phase Voltage Source Inverter, pp. 1-2,
2012.
6 BIBLIOGRAPHY
[2] P. S. Y. C. L.H. Tey, Improvement of Power Qaulity Using Adaptive shunt Active
Filter, IEEE Trans. On Power Delivery, vol. 20, p. 2, April 2005.
[4] L. U. A. Suma Umesh, Active Power Factor Correction Technique for Single Phase Full
Bridge Rectifier, IEEE, pp. 130-132, February 2014.
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