Design of On-Board Battery Charger using Interleaved Bridgeless Type PFC and Phase Shifted Full Bridge Converter

With increase of DC micro grids and electrical vehicles (EV), battery charging application has gained a lot of prominence. Many of these systems are fed by utility. The AC/DC conversion is done by classical diode bridge rectification which causes low input power factor and adversely affects the utility supply. Thus input power factor correction is one of the major concerns. Also, switched mode power converter incurs high switching losses at high frequencies of operation. Reduction of switching frequency is not a solution to reduce the losses as higher frequencies yield in many advantages such as reduction in converter size. This paper describes systematic design of 1.5 kW high power factor bridgeless interleaved boost converter fed on-board battery charger for EVs. Phase shifted full bridge converter having zero voltage switching (ZVS) up to 50% of the rated load is integrated with the high power factor AC/DC stage. The detailed design methodology of PFC controller, and phase shifted full bridgeless converter for EV is given in this paper. To validate the design of power stage and controller, PSIM simulation has been carried out and results are provided. Results show that power factor is greater than 0.99 and THD is less than 2 % at full load which is under the IEC standard.