With the fast development of information technology (IT) industry, the demand and market volume for off-line power supplies keep increasing, especially those for telecommunication, computer servers and data centers. As the capital expenditure was measured by the square footage occupied rather than power consumption, the development of high power density converter system is of greater interesting. The rising energy prices have resulted in the cost of power and cooling exceeding the purchase cost in less than two years. Therefore, highly efficient power conversion is required for the power converter system. Generally, the power supply unit (PSU) for power distribution system (PDS) in data center and telecom are the standard two-stage approach which normally consists of power factor correction (PFC) circuit and isolated DC-DC converter. The two-stage power conversion has demonstrated excellent performance and high reliability, since the design can be optimized for each stage. However, limitations to prevent the existing two-stage PSU to fulfill future requirements for the PDS in data center and telecom applications are revealed, and a very promising and fundamentally different approach with the single-stage isolated converter is proposed in this dissertation.
The development of single-stage converters with the option of placing the energy storage outside of the PSU creates new degrees of freedom regarding e.g. simplified rectifier racks in telecom and data center. This provides tangible benefits in the form of space saving, better airflow for power unit in rectifier racks and improved lifespan. The three-phase isolated buck matrix-type rectifier, capable of achieving high power density and high efficiency, is identified as an excellent candidate for the medium power level (5 kW~10 kW) single-stage power supply design. Nevertheless, the matrix-type rectifiers are known for their relatively complex modulation and commutation techniques, and lack of ride-through capability such as the stringent case of one phase loss operation.
This dissertation work provides comprehensive study on the commutation method and modulation scheme design for the isolated buck matrix-type rectifier. It aims to analyze the operation principle of the rectifier and propose viable modulation and commutation schemes for this rectifier under both three-phase and single-phase operation. The method is verified by the hardware experiments of the PSUs with high efficiency (> 98%) and high power density (> 70 W/in3 ) for 54 V and 380 VDC applications. The prototypes demonstrated in the experiments show the effectiveness of the proposed modulation and commutation schemes for industry.
High-availability single-stage Stirling coolers with high power density
