ZVS Turn-on integrated Triangular Current Mode Three-phase PFC for EV On-board Chargers

An efficient, compact and lightweight three-phase AC-DC power factor correction (PFC) converter becomes a necessity for electric vehicles (EVs) On-board chargers (OBCs) in conventional grid-to-vehicle (G2V) and vehicle-to-grid (V2G) charging methods. The commercially available OBCs have very limited power density despite the moderate efficiency under specific power levels. In this paper, the integrated triangular current mode (iTCM) control is implemented to improve the power density (kW/L) and specific power (kW/kg) of the three-phase PFC converter stage while maintaining high efficiency. Zero voltage switching (ZVS) turn-on is realized in the iTCM control with a higher switching frequency to reduce the LCL filter size without sacrificing efficiency. By adding an LC branch between the bridge leg and mid-point of the DC link, the high-frequency and low-frequency currents are split to minimize the inductor loss and to derive a better inductor design. Analytical modeling and simulation in PLECS are conducted to verify the idea of iTCM. The capacitor-current feedback active damping method is implemented to prevent instability from the LC and LCL filters. The design of an 11kW three-phase AC-DC PFC converter, including the input LCL filter, achieves an efficiency of 98.81%, a power density of 12.46 kW/L and a specific power per weight of 1.87 kW/kg. The proposed three-phase iTCM control is benchmarked in a 3 kW SiC MOSFET-based AC-DC converter.