Journal of Power Electronics

The Korean Institute of Power Electronics (전력전자학회)
권호 표지
DOI QR코드

DOI QR Code

3.3 kW bidirectional charger design based on active-clamp flyback circuits

  • Received : 2022.09.20
  • Accepted : 2022.12.27
  • Published : 2023.03.20
⟨ Previous Next ⟩

Abstract

A 3.3 kW bidirectional charger using an active-clamp flyback circuit with a symmetrical structure is proposed in this paper. Unlike the currently used bidirectional resonant converter, the proposed charger has a simple structure. By adopting a symmetrical design for the proposed charger, it can achieve the same bidirectional gain and efficiency in forward and reverse operation. In addition, it has the advantage of being able to respond to a wide output voltage range through simple pulse-width modulation (PWM) control. Thus, it can be applied to multi-purpose charger designs for a variety of batteries. An elementary flyback converter has the disadvantage of having electrical stress of the switch. An active-clamp circuit is applied to solve this disadvantage and to implement zero-voltage switching (ZVS) on all of the switches. Thus, high efficiency can be achieved at a high frequency using four 1200 V class silicon-carbide field-effect transistors (SiC-FETs). The feasibility of the proposed charger was verified using a prototype converter with input and battery voltages of 400 and 100-450 V, respectively.

Keywords

Acknowledgement

This work was supported by the Korea Agency for Infrastructure Technology Advancement(KAIA) grant funded by the Ministry of Land, Infrastructure and Transport (Grant 21HCLP-C162885-01) and the Vehicle Industry Technology Development Program funded By the Ministry of Trade, Industry & Energy(Grant 20018958)

References

  1. Pillot, C.: Micro hybrid, HEV, P-HEV and EV market 2012-2025 impact on the battery business, in 2013 World Electric Vehicle Symposium and Exhibition (EVS27), 2013, pp. 1-6. https://doi.org/10.1109/EVS.2013.6914818.
  2. Wang, L., Qin, Z., Slangen, T., Bauer, P., van Wijk, T.: Grid impact of electric vehicle fast charging stations: trends, standards, issues and mitigation measures-an overview. IEEE Open J Power Electron 2, 56-74 (2021). https://doi.org/10.1109/OJPEL.2021.3054601
  3. Kwon, M., Jung, S., Choi, S.: A high efficiency bi-directional EV charger with seamless mode transfer for V2G and V2H application. IEEE Energy Convers Congr Expo (ECCE) 2015, 5394-5399 (2015). https://doi.org/10.1109/ECCE.2015.7310418
  4. Inamdar, S., Thosar, A., Mante, S.: Literature Review of 3.3kW On Board Charger Topologies, in 2019 3rd International conference on Electronics, Communication and Aerospace Technology (ICECA), 2019, pp. 276-281. https://doi.org/10.1109/ICECA.2019.8822063
  5. Wong, N., Kazerani, M.: A review of bidirectional on-board charger topologies for plugin vehicles, in 2012 25th IEEE Canadian Conference on Electrical and Computer Engineering (CCECE), 2012, pp. 1-6. https://doi.org/10.1109/CCECE.2012.6334957.
  6. Wang, X., et al.: A 25kW SiC Universal Power Converter Building Block for G2V, V2G, and V2L Applications, in 2018 IEEE International Power Electronics and Application Conference and Exposition (PEAC), 2018, pp. 1-6. https://doi.org/10.1109/PEAC.2018.8590435
  7. Sayed, H., Zurf, A., Zhang, J.: Design and experiments of a SiC power MOSFET bidirectional switching power pole, in 2016 IEEE 25th International Symposium on Industrial Electronics (ISIE), 2016, pp. 460-464. https://doi.org/10.1109/ISIE.2016.7744933.
  8. Lee, B., Kim, J., Kim, S., Lee, J.: A PWM SRT DC/DC converter for 6.6-kW EV onboard charger. IEEE Trans. Industr. Electron. 63(2), 894-902 (2016). https://doi.org/10.1109/TIE.2015.2480384
  9. Zou, S., Lu, J., Mallik, A., Khaligh, A.: 3.3kW CLLC converter with synchronous rectification for plug-in electric vehicles, in 2017 IEEE Industry Applications Society Annual Meeting, 2017, pp. 1-6. https://doi.org/10.1109/IAS.2017.8101708.
  10. Liu, G., Li, D., Zhang, J.Q., Hu, B., Jia, M.L.: Bidirectional CLLC resonant DC-DC converter with integrated magnetic for OBCM application. IEEE Int Conf Ind Technol (ICIT) 2015, 946-951 (2015). https://doi.org/10.1109/ICIT.2015.7125219
  11. Mun, S., Choi, S., Hong, D., Kong, S., Lee, J.: Three-phase 11 kW on-board charger with single-phase reverse function. J Power Electron 22(8), 1255-1264 (2022). https://doi.org/10.1007/s43236-022-00457-3
  12. Losee, P.A., et al.: SiC MOSFET design considerations for reliable high voltage operation, in 2017 IEEE International Reliability Physics Symposium (IRPS), 2017, pp. 2A-2.1-2A-2.8. https://doi.org/10.1109/IRPS.2017.7936254.
  13. Hua, C., Huang, C.: An active clamped two switch flyback Zeta converter with reduced switch voltage stress, in 2019 2nd International Conference on High Voltage Engineering and Power Systems (ICHVEPS), 2019, pp. 1-5. https://doi.org/10.1109/ICHVEPS47643.2019.9011046.
  14. Texas Instrument, Inductor and Flyback Transformer Design, https://www.ti.com/lit/ml/slup127/slup127.pdf.
  15. Texas Instrument, Power Transformer Design, https://www.ti.com/lit/ml/slup126/slup126.pdf.
  16. McLyman, Wm.T.: Transformer and Inductor Design Handbook, 2011, CRC Press.
  17. Bolte, S., Schafmeister, F., Bocker, J.: Bidirectional Resonant Converter with Integrated Magnetics for On-Board Chargers, in 2019 IEEE 28th International Symposium on Industrial Electronics (ISIE), 2019, pp. 770-774. https://doi.org/10.1109/ISIE.2019.8781295.