New EV Battery Charger PFC Rectifier Front-End Allowing Full Power Delivery in 3-Phase and 1-Phase Operation

Abstract

A new universal front-end PFC rectifier topology of a battery charger for Electric Vehicles (EVs) is proposed, which allows fast charging at rated and/or full power level in case of 3-phase (Europe) as well as 1-phase (USA) mains supply. In this regard, a conventional 3-phase PFC rectifier would facilitate only one-third of the rated power in case of 1-phase operation. The new topology is based on a two-level six-switch (2LB6) 3-phase boost-type PFC rectifier, which is extended with a diode bridge-leg and additional windings of the Common-Mode (CM) chokes of the EMI filter. Besides this extension of the power circuit, the general design of the new converter is explained, and the generated Differential Mode (DM) and Common Mode (CM) EMI disturbances are investigated for 3-phase and 1-phase operation, resulting in guidelines for the EMI filter design. The EMI performance (CISPR 11 class-B QP) is experimentally verified for 1-phase and 3-phase operation at an output power of 4.5 kW, using a full-scale hardware prototype that implements the proposed extensions for a 2LB6 3-phase boost-type PFC rectifier and that is designed for output power levels of 22 kW and 19 kW in case of 3-phase and 1-phase operation, respectively. Compared to a conventional 2LB6 PFC rectifier, the volume of the extended system increases from 2.7 dm3 to 3.4 dm3, of which 0.5 dm3 is due to the additional dc-link capacitance for buffering the power pulsation with twice the mains frequency occurring for 1-phase operation.

High-Performance Control Simulation of PFC Converter for Electric Vehicle Charger

“…In the charger, due to the large power of the whole machine, especially under low voltage and high current, the loss that occurs on the rectifer bridge when the current is rectifed by the rectifer bridge cannot be ignored [10]. Terefore, the traditional bridge PFC topology structure due to the existence of the rectifer bridge, the efciency of the whole machine cannot be further improved [11]. In order to reduce losses and improve the efciency of the whole PFC circuit, more and more people have begun to pay attention to new topologies in recent years [12].…”

Single-Phase PFC Rectifier With Integrated Flying Capacitor Power Pulsation Buffer

“…Another interesting field of application for the ac-dcstage-integrated FC PPB concept is an EV OBC capable of charging the battery both from the single-phase and the three-phase AC grid [18,19] as highlighted in Fig. 8c.…”

Design and testing of a high-performance solar LED streetlight

“…When charging batteries using a constant AC power supply, staged charging is commonly employed [1]. This approach typically involves constant current and voltage charging [2].…”