Journal
IEEE JOURNAL OF EMERGING AND SELECTED TOPICS IN POWER ELECTRONICS
Volume 6, Issue 3, Pages 1627-1636Publisher
IEEE-INST ELECTRICAL ELECTRONICS ENGINEERS INC
DOI: 10.1109/JESTPE.2018.2845846
Keywords
Bidirectional on-board charger; high efficiency; high frequency; PCB winding magnetics; wide voltage range; wide-bandgap (WBG) devices
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Funding
- U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy [DE-EE0006834]
- Power Management Consortium
- Center for Power Electronics Systems, Virginia Polytechnic Institute and State University
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This paper proposes a novel two-stage topology for a 6.6-kW on-board charger. The first stage, employing an interleaved bridgeless totem-pole ac/dc in critical conduction mode to realize zero-voltage switching, is operated at over 300 kHz. A bidirectional CLLC resonant converter operating at 500 kHz is chosen for the second stage. A variable dc-link voltage is adopted to track the wide battery voltage range, so that the CLLC resonant converter can always operate at its most efficient point. The 1.2-kV SiC devices are adopted for the ac/dc stage and the primary side of dc/dc stage, while 650-V GaN devices are used for the secondary side of dc/dc stage. In addition, PCB winding coupled inductors and integrated transformer are implemented in ac/dc stage and dc/dc stage, respectively, for the purpose of high density and manufacture automation. The proposed structure is demonstrated to have 37-W/in(3) power density and above 96% efficiency over the entire battery voltage range, which far exceeds the current practice.
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