Hybrid DC/DC Converter for Electric Vehicle (EV) On-Board Charger (OBC) Using Full-Bridge (FB) and Resonant Converter with Single Transformer -Department of Electrical Engineering Myongji University Seoul Korea

ABSTRACT In this document a highly efficient hybrid DC/DC converter is proposed. Its design procedure, analysis and experimental results are presented by testing of the implemented prototype and. whole document is arranged into six chapters. Electrical vehicle battery chargers background, power level, different charging methods and purpose of the document is presented in chapter 1. High power DC/DC converter topologies suggested recently, and its benefits and drawbacks are briefly discussed in chapter 2. Proposed converter diagram, operational analysis and comparison of proposed converter with other DC/DC converter topologies are presented in chapter 3. Chapter 4 is about design procedure. Based on the design procedure suggested in chapter 4, prototype design and simulation results are given in chapter 5 and experimental results are given in chapter 6. Most of the previously proposed hybrid converters have used two transformers for each converter in hybrid structure that makes the size of the converter bulky and there was also low utilization and the power distribution problem between two transformers of the hybrid converters. To solve this problem, a new high efficient hybrid DC/DC converters using single transformer, which has characteristics of Full-bridge and resonant convertor for EV OBC, is proposed in this thesis. By using single transformer the power distribution problem has been solved and transformer utilization has become high. In the proposed converter, magnetizing inductance has been used at the primary side of the transformer to obtain the soft switching such as zero voltage switching (ZVS). Leakage inductance of the transformer has been used as resonant inductor on the secondary side to avoid the use of separate inductor as resonant. The prototype of 6.6KW has been implemented to verify the feasibility of the proposed converter and maximum efficiency of 97.4 is achieved at 413 V.

This paper proposes a dc/dc converter for electric vehicle onboard chargers using a secondary resonant tank. To attain soft switching characteristics, such as zero voltage switching, magnetizing inductance has been used at the primary side of the transformer. The leakage inductance of the transformer is used as a resonant inductor on the secondary side to avoid the use of a separate inductor as resonance. The proposed converter is applicable for a wide load range. A 6.6KW prototype has been implemented for a wide range of load variations (250V, 330V, 360V, and 413V). A maximum efficiency of 97.4% is achieved at 413V.

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