An onboard charger is responsible for charging the battery pack in a plug-in hybrid electric vehicle (PHEV). In this paper, a 3.3-kW two-stage battery charger design is presented for a PHEV application. The objective of the design is to achieve high efficiency, which is critical to minimize the charger size, charging time, and the amount and cost of electricity drawn from the utility. The operation of the charger power converter configuration is provided in addition to a detailed design procedure. The mechanical packaging design and key experimental results are provided to verify the suitability of the proposed charger power architecture.
An on-board charger is responsible for charging the battery pack in a plug-in hybrid electric vehicle (PHEV). In this paper, a 3.3kW two stage battery charger design is presented for a PHEV application. The objective of the design is to achieve high efficiency, which is critical to minimize the charger size, charging time and the amount and cost of electricity drawn from the utility. The operation of the charger power converter configuration is provided in addition to a detailed design procedure. The mechanical packaging design and key experimental results are provided to verify the suitability of the proposed charger power architecture. I. INTRODUCTIONA plug-in hybrid electric vehicle (PHEV) is a hybrid vehicle with rechargeable batteries that can be restored to full charge by connecting the vehicle plug to an external electric power source. In recent years, PHEV motor drive and energy storage technology has developed at a rapid rate in response to expected market demand for PHEVs. Battery chargers are another key component required for the emergence and acceptance of PHEVs. For PHEV applications, the accepted approach involves using an on-board charger [1]. An onboard 3.3 kW charger can charge a depleted 16 kWh battery pack in PHEVs to 95% charge in about four hours from a 240 V supply. The most common charger power architecture includes an AC-DC converter with power factor correction (PFC) [2] followed by an isolated DC-DC converter. Selecting the optimal topology and evaluating power loss in power semiconductors are important steps in the design and development of these battery chargers [3]. In this paper a two stage battery charger is presented, including an AC-DC converter with an interleaved boost PFC followed by a PWM ZVS full-bridge DC-DC converter. The charging solution presented achieves a peak efficiency of 93.6%, while maintaining the ability to operate over a wide output voltage variation of 200V to 450V. The solution achieves a compact size of 5.46 L, 6.2 kg in weight and 273×200×100 mm in
In order to recover and fully charge batteries in Electric Vehicles, smart battery chargers should not only work under different loading conditions and output voltage regulations (close to zero to 1.5 times the nominal output voltage), but also provide a ripple-free charging current for battery packs and a noise-free environment for the Battery Management System (BMS). In this paper, an advanced LLC design procedure is investigated to provide advantageous extreme regulation and eliminate detrimental burst mode operation. A modified, special LLC tank driven by both Variable Frequency (VF) and Phase Shift (PS) proves to be a successful solution to achieve all the regulation requirements for battery charging (from recovery, bulk, equalization, to finish). The proposed solution can eliminate the negative impact of burst mode noises on the Battery Management System, provide a free-ripple charging current for batteries in different States of Charge, reduce the switching frequency variation, and facilitate the EMI filter and magnetic components designs procedure. In order to fully consider the characteristics of the full bridge LLC resonant converter, especially the output voltage regulation range and soft transitions of the MOSFETs in the Fixed Frequency Phase Shift mode, a new set of analytical equations is obtained for the LLC resonant converter with consideration of separated primary and secondary leakage inductances of the high frequency transformer. Based on the proposed strategy and analytical equations, multivariate statistical design methodology is employed to design and optimize a 120VDC, 3kW battery charger. The experimental results exhibit the excellent performance of the resulting converter, which has a peak efficiency of 96.5% with extreme regulation capability.Index Terms -Full bridge LLC resonant converter, hybrid modulation strategy, battery charger applications, recovering dead battery, wide output voltage regulation, full soft switching conditions. NOMENCLATURE CjDiode junction capacitance (F ).
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