Design and Implementation of a Dual-Stage Compact Converter for Auxiliary Power and Accessory Charging in Electric Two/Three Wheelers
摘要
The rapid electrification of two and three-wheelers demands compact and efficient power conversion systems capable of supplying regulated auxiliary rails and isolated accessory charging outputs. This paper presents the design, simulation, and hardware implementation of a dual-stage compact converter intended for on-board auxiliary power and user-level accessory charging. The first stage is a 2 kHz Discontinuous Conduction Mode (DCM) Boost Converter that steps up an 8-10 V input from a 12 V battery or isolated supply to a regulated 24 V, 60 W auxiliary rail. This stage is fully implemented in hardware and experimentally validated. Building on this, a second stage delivering an isolated 11 V, 60 W output is developed using a 200 kHz full-bridge inverter with series-series (SS) resonant compensation and a high-frequency transformer. The cascaded (stage 2) converter (resonant converter) is analysed and validated by performing simulations. The peak efficiency of the cascaded converter is 98.12%. The input to the cascaded converter is fed from the 24V of stage 1 and the combination forms a unified dual-output setup suited for compact EV platforms. The stable DCM operation with effective switching behaviour and reliable 24 V regulations are confirmed through experimental results, while the efficient operation of isolated power delivery of the second stage is verified through simulations. The results project the feasibility to a scalable and modular architecture.