An industrial design of 400 V – 48 V, 98.2% peak efficient charger using E‐mode GaN technology with wide operating ranges for xEV applications

Abstract

This paper offers a wide‐operating range electric vehicle charger design by employing an interleaved inductor–inductor–capacitor iL2C DC–DC converter. It uses two parallel L2C converters with 8‐GaN switches on the primary side and a shared rectifier circuit on the secondary side, which it also enhances the circulating current, conduction losses, and current sharing. For iL2C converter, a constant voltage charging mode of operation is designed, also it proposes a hybrid control scheme of variable frequency + phase shift modulation (VFPSM). The entire concept is designed, simulated, and validated with a rated input voltage and load voltage of three different load conditions with converter line and load regulations are analyzed. To evaluate controller and converter performance, the idea is proven experimentally for variable load condition of full load, half load, light load with a rated input and output voltage of 400 Vin–48 V0. In addition, line regulation is also performed and validated for wide input voltage application of 300 Vin–500 Vin with an output voltage of 48 V0 at full load and peak efficiency of 98.2% is determined. Further, to provide the system effectiveness converter efficiencies are presented at various load operations from 3.3 kW to 330 W.

Analysis of Scalable Resonant DC–DC Converter Using GaN Switches for xEV Charging Stations

“…Conduction between the resonant inductor Lr1 and the resonant capacitor Cr1 commences simultaneously with the secondary current of iNS1 charging the filter capacitor C0. Equation (5) represents the voltage VNS1 at this juncture, while Equation ( 6) depicts the state space equation [24][25][26]. Stage 1: All secondary-side diodes are deactivated prior to time zero, while switches S 2 and S 3 are in the active state.…”

“…The voltage of the magnetizing inductance L m1 is specified by Equation (2), and the current increases incrementally. Furthermore, the voltage across V NS1 from time t 1 to time t 2 is equivalent to the output voltage V 0 , as calculated in Equation (3), and subsequently, the voltage at the resonant tank is described in Equation (4) [24].…”

“…The critical parameters of the iL 2 C converter for every single component are mentioned in [21][22][23][24]; the nominal input voltage is 400 V, and the output voltage is 48 V at a power range of 3.3 kW and a filter capacitor value of 100 µF, respectively. The associated step-bystep engineering calculations then followed with the appropriate values.…”

“…where n is transformer turn ratio, V in_max and V in_min are maximum and minimum input voltages, V 0_max and V 0_min are maximum and minimum output voltages, followed by maximum and minimum voltage gain M max and M min [24].…”

PV-Assisted grid connected multi output electric vehicle charger with PV2V, G2V and PV2G functions

“…GaN technology and an interleaved iL2C DC-DC converter are used to create a high-efficiency electric vehicle charger with 98.2% efficiency over a wide input voltage range [ 39 , 40 ]. However, the system’s complexity, cost, scalability, and thermal management may affect deployment and reliability.…”