Design of a 2.5-kW 400/12-V High-Efficiency DC/DC Converter Using a Novel Synchronous Rectification Control for Electric Vehicles

This paper proposes the design of a 2.5-kW 400/12 V high-efficiency isolated dc/dc converter for electric vehicles. The designed system accommodates the wide-range input voltage (450 V–220 VDC) and output voltage (16 V–6 VDC). An LLC half-bridge topology is adopted as the primary side of the dc/dc converter. For the secondary side, a novel synchronous rectification control (SRC) strategy is developed to switch metal oxide semiconductor field effect transistors (MOSFETs) through accurately tracking the target switching moments. Experimental results were carried out to charge the on-board 12-V battery and validate the proposed control algorithm. The maximum system efficiency is 93.2%. System power loss is also itemized.