An automotive on-board 3.3 kW battery charger for PHEV application

Abstract

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

Behavioral Characterization of Electric Vehicle Charging Loads in a Distribution Power Grid Through Modeling of Battery Chargers

“…However, the potential applications of a single phase twoswitch buck type AC-DC Converter topology with inductor voltage control appears to be a good candidate for high current battery charging applications, when used as a PFC converter due to the fact that the CC and CV type battery charging characteristics can be easily implemented [18]. A variety of circuit topologies, and control methods have been developed for PEV battery chargers [15,[19][20][21][22][23][24][25]. Single-stage AC-DC power conversion where the low frequency ripple is large in the output current is only suitable for lead acid batteries.…”

“…Therefore, this topology is good for power range below 1 kW [15,23]. Significant study outcomes related to single phase charger models are given in [15][16][17][18][19][20][21][22][23][24][25]. Based on a wide ranging study of literature it has been found that flyback converter operating in discontinuous current mode is the preferred topology [22].…”

A Novel PCCM Voltage-Fed Single-Stage Power Factor Correction Full-Bridge Battery Charger

“…Mode 4(t 3 <t<t 4 ): This mode begins when Q f is switched on. The primary current freewheels through Q 1 and Q 3 . The transformer primary current during this mode is given by:…”

Hybrid ZVS Converter with a Wide ZVS Range and a Low Circulating Current

“…Full-bridge converters with a high power density and high efficiency have been proposed and used in many industry products such as server power units [1], telecommunication power units [2], and electric vehicle (EV) and plug-in hybrid electric vehicle (PHEV) battery chargers [3], [4]. Single-phase power factor correction (PFC) is normally adopted in the front stage to eliminate the current harmonics, increase the input power factor and keep the dc bus voltage at a constant voltage against line voltage and load current variations.…”