Comparative CCM-DCM Design Evaluation of Power Inductors in Interleaved PFC Stage for Electric Vehicle Battery Chargers

This paper deals with the evaluation of a comparative design of power inductors in two legs interleaved boost Power Factor Corrector (PFC) converter applied as front-end in 3.3kW battery charger for electric vehicles. The boost inductors have been designed and compared in the PFC application in Continuous Current Mode (CCM) and Discontinuous Current Mode (DCM) operation. A procedure to design the inductors in its electrical and magnetic parts procedure based on MATLAB scripts is described. The interleaved boost inductor power losses are evaluated. The leg current switching behavior in an actual PFC converter with the inductors carried out from the design procedure is presented. Finally, the advantages and drawbacks of the inductor in CCM and DCM operating conditions are discussed.