11 kW Integrated On-Board Fast Charger Using Partial Power Conversion

This work deals with new integrated EV on-board fast charger with interleaved boost AC-DC converter at frontend followed by half-bridge partial power processing (PPP) converter at DC-DC stage. The main objective is to improve the converter power density and efficiency over the conventional integrated chargers with full power processing converter (FPP). The AC-DC stage is derived using inverter switches and the electric motor windings as part of interleaved boost rectifier at front-end. However, the DC-DC stage is based on half-bridge configuration with PPP. The concept of partial power conversion at DC-DC stage reduces the power processed by the converter. The proposed topology has a minimal number of components and ensures that most of the charging power is taken directly through the rectifier DC-link reducing the number of conversion stages in the charger. The PPC design further helps in achieving smaller rating devices in the converter due to differential voltage applied as per PPP concept. The design of the converter is discussed in detail and dynamic performance is verified using MATLAB/Simulink based assessment. For an 11 kW rating, the efficiency of the proposed charger is compared with the FPP DC-DC converter-based integrated chargers in literature.