Development Of 220V/10A Rectifier Module

The purpose of this paper is to design a 220V/10A rectifier module which will meet the needs of competitive market. In the module, full-bridge phase shift zero-voltage and zero-current switching converter were applied to achieve high efficiency, inside CPU circuit was applied to intelligentize rectifier, and also passive power factor correction was applied to reduce harmonic currents.This paper presents the structure, the principle and the design of 220V/10A switching mode rectifier module. The module consists of the AC input stage, DC/DC converter, output low-pass filter, CPU control circuit and load current sharing circuit, etc. The full bridge phase shift strategy was applied in DC/DC converter. Zero-voltage switching could be realized in leading-leg range from 1/10 load to full load, zero-current switching could be realized in lagging-leg over all load condition. The design principle was analyzed and the circuit parameters were discussed in detail in this paper. Paralleled power switches were applied in DC/DC converter to satisfy low cost. The static behavior and transient behavior of paralleled power switches in high power rectifier is analyzed.In this paper, inside CPU was applied to give the output voltage and output current limited reference by digitally controllable potentiometer, realize remote control function—control the rectifier module on and off, measure the output voltage/current, which is displayed by seven segment LED. The rectifier module provides RS485 interface and communicate with main monitor in a master-slave mode.The rectifier module proposed in this paper has perfect protect function, such as over-voltage, over-load and over-temperature, etc. By using master-slave load current sharing technique, modules can be paralleled easily, thus capacity-expansion is very convenient. It has ever been distributed into market. Its weight and volume are better than Emerson's module. Its full load efficiency reached 94.5% under rated input condition; and the low cost made it more competitive.