A Five-Level Switch Clamped On-Board EV Charger With Wide Input Voltage Range

• Published in: 2022 IEEE 2nd International Conference on Sustainable Energy and Future Electric Transportation (SeFeT) pp. 1 - 6
• Main Authors: Kumar, G k Naveen, Chaurasiya, Amar Nath, Verma, Arun Kumar, Sandeep, N
• Format: Conference Proceeding
• Language: English
• Published: IEEE 04.08.2022
• Subjects: Bridge circuits; Capacitors; Electric vehicle (EV); On-Board Charger (OBC); Phase-shifted full bridge (PSFB); Power Factor Correction (PFC); Prototypes; Pulse Width Modulation (PWM); Reactive power; Switches; Switching frequency; Zero voltage switching
• DOI: 10.1109/SeFeT55524.2022.9908911

This paper introduces a new multilevel dual boost power factor correction (PFC) based on-board charger (OBC). In this OBC, the front-end PFC stage employs a bidirectional switch submerged at the midpoint between the dual capacitors and the arm of the bridge-less PFC to generate five levels in each half of the AC cycle. The double carrier level shifted PWM method is utilized at a reduced switching frequency compared to conventional ones, reducing the amount of overall switching losses. Moreover, the front stage is robust to high frequency (HF) noise with reduced input current total harmonic distortion (THD). In the second stage, a phase-shifted full-bridge (PSFB) converter is employed to provide galvanic isolation and charge the battery. The PSFB achieves ZVS turn-on on primary side MOSFETs without any resonant elements leading to higher efficiencies. Presented AC-DC charger having a wide range of input voltage from 90V-270VAC. To assess the viability of the proposed scheme, a 1. 5kW OBC is built in MATLAB R2021b software and further verified experimentally from the built prototype. The PFC stage has a power factor of 0.9998, and an input current complies with the stringent THD limit of below 5%.