An Improved Battery Charger for Electric Vehicle with High Power Factor

The incorporation of active power factor correction (PFC) converter reshapes the line current proportional to the input voltage and reduces the line current harmonics to the recommended IEC 61000-3-2 power quality (PQ) standard for the electric vehicle (EV) battery charger. However, modern vehicle charger with incorporated PFC, incurs additional high conduction loss owing to the use of rectification diode at the input end of the charger. This study discusses a simplified bridgeless (BL) topology for EV battery charger, depending upon the buck-boost configuration, which reduces the conduction loss, considerably, due to reduced number of semiconductor components conducting over one switching cycle during charging operation. The proposed bridgeless converter precedes a flyback converter to manage the charging of 48V/100Ah battery throughout the constant current (CC)/ constant voltage (CV) profile as well as built-in PFC capability at the mains side is inherited. An 850W prototype is designed and developed to support the enhanced performance of the battery charger by reconstructing the line current waveform and significantly reducing the input harmonics distortion to the recommended IEC 61000-3-2 standard.