Design and Simulation for a Full Bridge LLC DC-DC Converter for EV Charging Application

The growing adoption of electric vehicles (EVs) necessitates the development of high-efficiency, high-power density EV charging system (EVCS). Among the various topologies available, Full Bridge LLC (FBLLC) DC-DC converter has emerged as one of the promising solutions. This paper presents a complete design methodology of an FBLLC DC-DC converter tailored for an EVCS application. The magnetic components design, essential for enabling Zero Voltage Switching (ZVS) operation in the FBLLC topology, involves a complex iterative process that must account for numerous design constraints and trade-offs. The comprehensive design methodology, considering factors that significantly influence the key performance metrics such as efficiency, power density, and electromagnetic compatibility (EMC) is presented. The proposed design is validated through MATLAB-based simulations, and the results are presented to demonstrate its effectiveness. Furthermore, simulation outcomes for the FBLLC converter operation in both constant current and constant voltage modes, as applicable to EV charging scenarios, have also been presented.