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A Novel Hybrid Converter with Wide Range of Soft-Switching and No Circulating Current for On-Board Chargers of Electric Vehicles
Van-Long Tran*, Dai-Duong Tran*, Van-Tuan Doan*, Ki-Young Kim* and Woojin Choi
Abstract In this paper, a novel hybrid configuration combining a phase-shift full-bridge (PSFB) and a half-bridge resonant LLC converter is proposed for the On-Board Charger of Electric Vehicles (EVs). In the proposed converter, the PSFB converter shares the lagging-leg switches with half-bridge resonant converter to achieve the wide ZVS range for the switches and to improve the efficiency. The output voltage is modulated by the effective-duty-cycle of the PSFB converter. The proposed converter employs an active reset circuit composed of an active switch and a diode for the transformer which makes it possible to achieve zero circulating current and the soft switching characteristic of the primary switches and rectifier diodes regardless of the load, thereby making the converter highly efficient and eliminating the reverse recovery problem of the diodes. In addition an optimal power sharing strategy is proposed to meet the specification of the charger and to optimize the efficiency of the converter. The operation principle the proposed converter and design considerations for high efficiency are presented. A 6.6 kW prototype converter is fabricated and tested to evaluate its performance at different conditions. The peak efficiency achieved with the proposed converter is 97.7%.
Keyword Hybrid converter, Lithium battery, On-board charger (OBC), Zero current switching (ZCS), Zero voltage switching (ZVS)
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