A PFC Based Onboard Battery Charger using Isolated Full-Bridge DC-DC Converter for Electric Vehicle Application

A low voltage two-stage onboard battery charger of 1.5 kW rating for an electric vehicle application is presented in this paper. The first stage is the AC-DC conversion rectifier with a power factor correction circuit. The interleaving of the PFC boost converter helps in reducing the inductor size and output current ripple. The power factor is improved with reduced distortion in the input current waveform. The second stage is the battery charging circuit using isolated full-bridge DC-DC converter for a 48V/100Ah battery. The detailed design of the system and control method of both the converters are presented. The overall efficiency of the converter is found around 93% with improvement in input power quality. The simulation is carried out using MATLAB Simulink toolbox and the experiment results are also discussed.