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25093 PWR8: Multilevel AC/DC Power Supply Design Review (August 2025)
In this expert-level class you will review the design of a 5.5kW AC/DC power supply using a 4-level Flying Capacitor Multi-Level (FCML) Totem-Pole-Bridgeless Power Factor Correction (PFC) stage and a 4-level LLC Resonant DC/DC Converter, comparing conventional and multilevel architectures, and exploring design aspects like node driver design, control signal distribution, and non-linear control system implementation.
Since the early 1990s, multilevel topologies have been creating great interest as they promise highest power density and efficiency. Over the years, new power semiconductor technologies have been introduced and established, which now allow the cost effective application of these fascinating architectures in mass products. In this expert-level class, we will review the design of a 5.5kW AC/DC power supply comprised of a 4-level Flying Capacitor Multi-Level (FCML) Totem-Pole-Bridgeless (TTP) Power Factor Correction (PFC) stage with hold-up boost stage and a isolated 4-level LLC Resonant DC/DC Converter. The design review starts with a direct comparison between a conventional TTP PFC + LLC architecture and its 4-Level counter part, highlighting the impact on component size and circuit reduction. Specific design aspects, such as switch the node driver design and control signal distribution will be discussed, before discussing the non-linear control system implementation in detail.
Prerequisites:
None