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Designing a 30A, variable output AC->DC converter

Rick Mann
Intellectual 370 points

I'm developing an application that uses at 24 V (nominal), 120 Ah battery pack (made up of 8 LiFePO4 cells in series). I'd like to design a charger that can accept 120 V AC mains power. I have a handle on the necessary charge profile and balancing, but I need an AC->DC converter capable of delivering 30 A, with a real-time (albeit slow), MCU-controllable output voltage between about 20 and 30 V.

I don't know if there are off-the-shelf Buck ICs that can do this, and I'm not sure of the best way to get DC from AC (just straightforward rectification and filtering?). I imagine I have to use my own MCU with MOSFETs and inductors (shouldn't be too hard, because the load doesn't change very dynamically, so the feedback loop should be easy to stabilize), but perhaps there's an IC that can interface to an MCU to handle the regulation?

What advice can people offer, or what references can you point me to? I really appreciate the help. Thanks!