A Cost Effective High Power Factor General Purpose Battery Charger for Electric Two-Wheelers and Three Wheelers

A cost effective, efficient, and compact battery charger (BC) with a general-purpose charging characteristic, is presented in this work for the electric two-wheelers (E2Ws) and three-wheelers (E3Ws) consumers. In the presented BC, a flyback AC-DC converter with a fully bridgeless structure and simple control/gate drive circuitry is employed to facilitate efficient and high-performance charging of E2Ws/E3Ws. Notably, the presented AC-DC converter utilizes the least component count compared to the existing bridgeless buck-boost synthesized AC-DC converters, providing an inexpensive charging solution to the E2W’s/E3W’s consumers. The discontinuous current mode (DCM) design and operation of the charger considerably reduce its magnetic components’ volume and lessens its control intricacy and associated implementation cost. Additionally, the fully bridgeless configuration at the fore-end eliminates the diode bridge rectifier’s conduction losses. It thus improves the charger’s overall efficiency, especially during low supply voltage conditions. Considering the universal supply voltage range ( $90~\rm V_{\mathrm{ RMS}}$ – 265 VRMS) and wide output voltage range (24 V – 72 V), the presented BC realizes a general-purpose charging solution for the E2W/E3W owners, who own different E2Ws/E3Ws with distinct battery pack specifications. Finally, the validation of the presented BC is accomplished under diverse operating states through simulation and hardware implementation, and the corresponding results are discussed in detail.