Design and Analysis of a High-Efficiency Resonant Converter for EV Battery Charger

Abstract

The interest in electric vehicle (EVs) components such as battery, battery chargers, and battery management systems is increasing in parallel with the spread of electric vehicles. One of the most critical of these components is battery chargers. Battery chargers are equipped with DC-DC converters with high efficiency, low cost, and wide output voltage range. In order to provide reliable operation of the battery charger, it is of great importance that the DC-DC converters are operated with a robust and stable controller as well as designed optimally. In this paper, a design method for a CLLC resonant converter-based bidirectional dc-dc converter (BiDC) is presented for a battery charger. The resonant converter, whose design details are presented, suggests a resonant system to be used in battery chargers with fewer components than the CLLLC converter, and similar voltage gain characteristics for bidirectional power flow operations compared to the LLC converter. The design procedure highlights performing the soft switching operation and determining the resonant tank parameters. In addition, the forward mode and reverse mode gain equations required for the system to operate in the desired output voltage range have been presented. The design procedures have been validated with a CLLC BiDC model with ratings of 1 kW, 400 V input / 300-450 V output in the PSIM environment. The performance results reveal that the zero voltage switching (ZVS) has been performed for primary-side MOSFETs under a wide load range.