Design and Analysis of a Full-Bridge LLC-Based PEV Charger Optimized for Wide Battery Voltage Range

In this paper, a two-stage onboard battery charger is analyzed for plug-in electric vehicles (PEVs). An interleaved boost topology is employed in the first stage for power factor correction (PFC) and to reduce total harmonic distortion (THD). In the second stage, a full-bridge LLC-based multiresonant converter is adopted for galvanic isolation and dc/dc conversion. Design considerations are discussed, focusing on reducing the charger volume and optimizing the conversion efficiency over the wide battery-pack voltage range. A detailed design procedure is provided for a 1-kW prototype, charging the battery with an output voltage range of 320-420 V from 110-V 60-Hz single-phase grid. Experimental results show that the first-stage PFC converter achieves THD of less than 4% and a power factor higher than 0.99, and the second-stage LLC converter operates with 95.4% peak efficiency and good overall efficiency over wide output voltage ranges.