On-Board Power Converter for Battery Charging Application of E-Mobility Vehicles

The topologies for high power supply modules are emerging and transforming in advent of dynamically changing applications, requirements, and continuous growth in the semiconductor device technology. This paper proposes a simple design procedure for single phase 7.2 kW on-board charger (OBC) for battery charging and other energy storage application. The three inductor interleaved totem pole topology is used in first stage to regulate input power at high power factor. The dual active bridge (DAB) topology is used in second stage for high power DC-DC conversion. The ultrawide gap Silicon Carbide (SiC) power mosfets are used in both the stages to increase power density, reduce losses, and increase overall system efficiency. The average current control algorithm is used for pulse width modulated (PWM) control of power switches separately for both the stages which can be easily implemented using digital microcontrollers. The magnetics design for inductor of totem pole PFC and high-frequency transformer in DAB is presented in detail. The power supply can be powered from single phase 100–230 VAC, 50 Hz. The DAB generates output of 7.2 kW at 150–200 V to charge an 30 kWh Li-Ion battery bank. The hardware design of the charger is presented. The simulation results of the charger are presented and compared with the analytical values.