600VAC-800VDC Rectifier Design

I need a robust three-phase rectifier that takes 600 VAC input and delivers 800 V DC at a continuous 200 A for an industrial-machinery environment. High efficiency is essential; every watt saved reduces heat and improves uptime on the factory floor.

Key technical expectations
• Electrical: 600 VAC (Δ or Y) → 800 V DC, 200 A continuous, low ripple, high PF.
• Efficiency: design choices, component selection, and magnetic sizing should target best-in-class figures for this power level. Show calculated and simulated numbers as well as derating strategy.
• Thermal: I’m open to either forced-air or liquid cooling. Please justify the chosen method with thermal modelling and include a practical heatsink or cold-plate outline.
• Protection & compliance: include soft-start, OVP, OCP, shoot-through prevention and bring the design in line with IEC/UL standards typical for heavy-industrial drives.
• Deliverables:
– Complete schematic (Altium, KiCad or similar)
– Magnetic core specs and winding details
– Rated BOM with manufacturer part numbers
– Efficiency and thermal simulation files (PSIM, LTspice, PLECS, etc.)
– Brief report summarising design decisions, test plan and expected performance

If you have prior experience with high-power SiC or IGBT bridges, snubber optimisation, and EMI mitigation, your insight will be invaluable. I will review milestones at schematic freeze, simulation pass, and final documentation hand-off.