A Two-Stage DC-DC Isolated Converter for Battery-Charging Applications

Abstract

This paper proposes and analyzes a two-stage dc-dc isolated converter for electric vehicle charging applications, where high efficiency over a wide range of battery voltages is required. The proposed conversion circuit comprises a first two-output isolation stage with CLLC resonant structure and a second two-input buck regulator. The transformer of the first stage is designed such that its two output voltages correspond, ideally, to the minimum and maximum expected voltage to be supplied to the battery. Then, the second stage combines the voltages provided by the previous isolation stage to regulate the output voltage of the whole converter. The first stage is always operated at resonance, with the only function of providing isolation and fixed conversion ratios with minimum losses, whereas the second stage allows output voltage regulation over a wide range of battery voltages. Overall, it is shown that the solution features high conversion efficiency over a wide range of output voltages. This paper comprehensively describes the solution, including modeling, analyses, design considerations for the main circuit components (e.g., magnetics, switches), and modulation choices. Experimental results are reported considering a converter module prototype rated 10kW, input voltage 800V, and output range 250V to 500V, employing silicon-carbide and gallium-nitride semiconductors.