High Efficiency Topologies for Dual Voltage Inputs
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Growing concerns about climate change have led governments to update their policies to require better efficiency in appliance power supplies. Additionally, consumer demand and economic drives in the last few decades have reduced the power supply cost and size. Another emerging trend in recent years is creating a single power supply design that can operate at the full Universal Mains range. The main reasons for this trend are logistics and travel reasons. The above reasons drive the requisite for low-cost, small, high-performance, improved efficiency and broad input range power supplies. The main limitation of the existing solutions is poor device utilization and difficulties optimizing the design in Universal Mains (90 – 265 Vac). In this thesis, a novel new solution, named the “Dual Range” (or Dual Voltage), is introduced and explored. The solution suggested is mainly attractive for high-efficiency Universal Mains power supplies by providing a smaller dynamic operating range in Universal Mains. The result is a reduction of device stress, better design optimization and increased efficiency.
The Dual Range converter comprises reconfigurable primary power loops enabled by additional State switches. This combination allows the converter to run in parallel or series modes, optimizing the performance at the high line, 230 Vac, and low line, 115 Vac Mains and enhancing the performance over the 90 – 265 Vac Universal Mains. The parallel/series configuration provides device size and cost reduction, two optimized working points instead of one and better device utilization. This thesis examines the theoretical effectiveness of this configuration. Later, analysis and simulations were performed to evaluate the design of 75 W prototype Dual Range Flyback and Dual Range Forward converters switching at 100 kHz. Last, the thesis presents experimental results of efficiency, operation and limitation compared to the conventional solutions.