Bi-directional on-board charger architecture and control for achieving ultra-high efficiency with wide battery voltage range

Abstract

One challenge of on board charger application is bi-directional operation. Due to the absence of reverse recovery charge and small junction capacitance, it is much easier to do bidirectional operation using wide band gap devices. Another challenge is the very wide battery voltage range. It is very difficult to optimize converter over the whole battery voltage range and efficiency drops either the battery voltage is too high or too low. In this paper, a novel two stage structure is proposed utilizing both SiC and GaN devices. Bi-directional power flow as well as zero voltage switching is achieved with the proposed structure. In addition, a variable DC-link voltage operation is adopted to deal with the wide battery voltage range so that the CLLC resonant converter can always work at its optimized point. Design considerations of the two stage on-board charger are introduced, including system structure evaluation, resonant converter design and control strategy. A 6.6kW on board charger prototype with 500kHz (300kH for AC/DC stage) switching frequency is demonstrated with 43W/in3 power density and above 96% efficiency over the whole battery voltage range.