Inductor Design Method of DCM Interleaved PFC Circuit for 6.6-kW On-board Charger

유봉기,이병국,김동희 대한전기학회 2017 Journal of Electrical Engineering & Technology Vol.12 No.6

Because the on-board charger (OBC) is installed in electric vehicles (EVs), high power density is regarded as a key technology. Among components of the OBC, inductors occupy more than 30% of the total volume. Thus, it is important to reduce the volume and the weight of inductors while maintaining thermal stability. Discontinuous conduction mode (DCM) can satisfy these requirements; however, only a few studies have adopted the DCM operation for OBCs because of the large inductor current ripple. In this paper, a design process is proposed for application of the DCM operation to OBCs. In order to analyze the inductor losses accurately, a numerical formula for the inductor current ripple is deduced based on a detailed analysis. Two inductors are fabricated using several ferrite cores and powder cores taking into consideration the inductor size, inductor losses, and temperature rise. In order to verify the analysis and design process, experimental results are presented that show that the designed inductors satisfy the requirements of the OBCs.

Inductor Design Method of DCM Interleaved PFC Circuit for 6.6-kW On-board Charger

Bong-Gi You,Byoung-Kuk Lee,Dong-Hee Kim 대한전기학회 2017 Journal of Electrical Engineering & Technology Vol.12 No.6

Because the on-board charger (OBC) is installed in electric vehicles (EVs), high power density is regarded as a key technology. Among components of the OBC, inductors occupy more than 30% of the total volume. Thus, it is important to reduce the volume and the weight of inductors while maintaining thermal stability. Discontinuous conduction mode (DCM) can satisfy these requirements; however, only a few studies have adopted the DCM operation for OBCs because of the large inductor current ripple. In this paper, a design process is proposed for application of the DCM operation to OBCs. In order to analyze the inductor losses accurately, a numerical formula for the inductor current ripple is deduced based on a detailed analysis. Two inductors are fabricated using several ferrite cores and powder cores taking into consideration the inductor size, inductor losses, and temperature rise. In order to verify the analysis and design process, experimental results are presented that show that the designed inductors satisfy the requirements of the OBCs.

Inductor Design Method of DCM Interleaved PFC Circuit for 6.6-kW On-board Charger

You, Bong-Gi,Lee, Byoung-Kuk,Kim, Dong-Hee The Korean Institute of Electrical Engineers 2017 Journal of Electrical Engineering & Technology Vol.12 No.6

Because the on-board charger (OBC) is installed in electric vehicles (EVs), high power density is regarded as a key technology. Among components of the OBC, inductors occupy more than 30% of the total volume. Thus, it is important to reduce the volume and the weight of inductors while maintaining thermal stability. Discontinuous conduction mode (DCM) can satisfy these requirements; however, only a few studies have adopted the DCM operation for OBCs because of the large inductor current ripple. In this paper, a design process is proposed for application of the DCM operation to OBCs. In order to analyze the inductor losses accurately, a numerical formula for the inductor current ripple is deduced based on a detailed analysis. Two inductors are fabricated using several ferrite cores and powder cores taking into consideration the inductor size, inductor losses, and temperature rise. In order to verify the analysis and design process, experimental results are presented that show that the designed inductors satisfy the requirements of the OBCs.

High‑efficiency 11 kW bi‑directional on‑board charger for Evs

Sang-Youn Lee,Woo-Seok Lee,Jun-Young Lee,Il-Oun Lee 전력전자학회 2022 JOURNAL OF POWER ELECTRONICS Vol.22 No.2

This paper presents an 11 kW bi-directional on-board charger (OBC) for electric vehicles with 96% efficiency. The OBC consists of a three-phase two-level AC/DC converter and a CLLLC resonant DC/DC converter with bi-directional powertransfer. In order to achieve high efficiency, all the devices in the OBC are implemented using SiC-MOSFETs while the DC-link voltage is designed to track the battery voltage level in both the forward and reverse power modes. The AC/DC converter adopts a DC-link voltage controller that can adapt its control gain according to the status of the DC-link voltage. By adjusting the DC-link voltage level according to the battery voltage, the CLLLC resonant converter always runs at a switching frequency near its resonant frequency. This ensures high-efficiency operation in both the forward and reverse power modes while achieving a full voltage gain. The feasibility of the proposed 11 kW OBC is demonstrated experimentally by constructing a prototype converter with a 3-phase 60 Hz 380 VAC input, an 11 kW capacity, and a battery voltage range of 214–413 VDC. The prototype OBC achieves a conversion efficiency of over 96% in both the forward and reverse power modes resulting in a power density of over 1.0 kW/liter.

LLC 공진형 컨버터를 적용한 전기자동차 고압배터리 충전기 개발

김경만(Gyoung-Man Kim),유종욱(Jong-Uk Yoo),김태권(Tae-Kwon Kim),강찬호(Chan-Ho Kang),전태원(Tae-won Chun) 전력전자학회 2013 전력전자학회 논문지 Vol.18 No.5

This paper deals with LLC resonant converter of on-board charger for electric vehicle charging. Generally, the on-board charger must have a very widely charging voltage, higher efficiency, higher power factor, lower volume and lower weight. For reducing the switching losses, voltage and current stress of the device, the on-board charger is apply the half-bridge LLC resonant converter topology. To have a wide voltage range, it is design the hardware parameters and determine the switching frequency range of the LLC resonant converter. The experimental results show a wide charge voltage.

Double-Voltage Charger for On-Board Charger With 800 V Battery

Ji-Yeon Kim,Yeon-Ho Jeong,Jae-Kuk Kim 한국차세대컴퓨팅학회 2022 한국차세대컴퓨팅학회 학술대회 Vol.2022 No.10

It has been suggested that the main battery voltage of electric vehicles (EVs) is increased from 400 to 800 V to improve the charging speed and driving distance. However, the secondary components in the dc/dc converter of the on-board charger (OBC) have high voltage stresses due to the increased battery voltage. Therefore, this paper proposes a double-voltage charging technique. The previously designed and optimized dc/dc converter for 400 V battery is used to charge 800 V battery. The battery stack is divided into two modules. Dc/dc converter charges one of two modules alternatively using the battery selection circuit (BSC). Since the BSC has low voltage stresses, the proposed converter can have low voltage stresses on all the dc/dc and BSC parts. Moreover, the dc/dc converter and BSC can be decoupled by turning off the dc/dc converter while changing the charged battery. Therefore, the loss of BSC can be minimized by operating it with low frequency because the switching frequency of BSC can be independent of that of the dc/dc converter. The design process can also be simpler owing to decoupling operation. The LLC converter was adopted for dc/dc converter with 3.3 kW output to verify the proposed technique.

친환경 자동차용 통합형 전력변환장치의 개발 및 배터리 HILS를 이용한 LDC 검증에 관한 연구

김태훈(Tae-Hoon Kim),송현식(Hyun-Sik Song),이백행(Baek-Haeng Lee),이찬송(Chan-Song Lee),권철순(Cheol-Soon Kwon),정도양(Do-Yang Jung) 대한전기학회 2014 전기학회논문지 Vol.63 No.9

For OBC (On-Board Charger) and LDC (Low DC-DC Converter) used as essential power conversion systems of PHEV (Plug-in Hybrid Electric Vehicle), system performance is required as well as reliability, which is need to protect the vehicle and driver from various faults. While current development processor is sufficient for embodying functions and verifying performance in normal state during development of prototypes for OBC and LDC, there is no clear method of verification for various fault situations that occur in abnormal state and for securing stability of vehicle base, unless verification is performed by mounting on an actual vehicle. In this paper, a CCM (Charger Converter Module) was developed as an integrated structure of OBC and LDC. In addition, diverse fault situations that can occur in vehicles are simulated by a simulator to artificially inject into power conversion system and to test whether it operates properly. Also, HILS (Hardware-in-the-Loop Simulation) is carried out to verify whether LDC is operated properly under power environment of an actual vehicle.

Hybrid PWM-Resonant Converter for Electric Vehicle On-Board Battery Chargers

IEEE 2016 IEEE transactions on power electronics Vol.31 No.5

<P>A novel hybrid pulse-width-modulation resonant converter is presented in this paper for electric vehicle (EV) 3.3-kW on-board battery chargers (OBCs). While the proposed converter has all the benefits of the earlier developed hybrid converters for OBCs, the proposed converter has fewer components and achieves much lower voltage stress in the rectifying diodes compared to the earlier hybrid converters. As a result, it is possible to employ superior diodes such as Schottky barrier diodes below 300 V featuring low forward-voltage drop and better reverse-recovery for EV 3.3-kW OBC applications. In addition, the proposed converter achieves much better transformer utilization compared to the earlier hybrid converters. Due to this, the proposed converter can achieve more optimal efficiency over the overall battery charging profile. The effectiveness of the proposed converter has been verified with the experimental results under an output voltage range of 250-420-V dc at 3.3 kW.</P>

차량 탑재형 배터리 충전기의 인터리브드 부스트 PFC 컨버터 제어시스템 설계 및 구현

이준혁(Jun Hyok Lee),정광순(Kwang-Soon Jung),이경중(Kyung-Jung Lee),정재엽(Jae Yeop Jung),김호경(Ho Kyung Kim),홍성수(Sung-Soo Hong),안현식(Hyun-Sik Ahn) 대한전기학회 2016 전기학회논문지 Vol.65 No.5

In this paper, we propose a digital controller design process for the interleaved type of a boost PFC (Power Factor Correction) converter which can disperse the heat of the switching devices due to the interleaved topology. We establish a mathematical model of a boost PFC converter and propose a controller design method based on the root locus. The performance of the designed controller is verified by simulations. The measurement of the input voltage, inductor currents, and the converter output link voltage are needed for the control of the converter system which consists of a power unit and a control unit where a high-performance 32-bit microcontroller is used. The adjustment of A/D conversion timing is also needed to avoid high frequency noise generated when the switches on/off. It is illustrated by the real experiments that the designed control system with the properly adjusted ADC timing satisfies the given performance specifications of the interleaved boost PFC converter in the on-board slow battery charger.

전기자동차 충전시스템 효율 향상에 관한 연구

이상규(Sangkyu Lee),한대웅(Daewoong Han),강구배(Gubae Kang),임성엽(Seongyeop Lim) 한국자동차공학회 2013 한국자동차공학회 부문종합 학술대회 Vol.2013 No.5

A charging efficiency of Plug-in Electric Vehicles (PEVs) is related to on-board charger(OBC) efficiency, Low voltage DC-DC converter(LDC) efficiency, amount of vehicle 12V electric component load and AC input voltage. This paper suggests a optimal charging strategy of PEVs by analyzing the quantitative impact of OBC / LDC / Electric component load / AC input power.