Abstract
This paper presents an analysis, multi-objective design, and benchmark of three modified Phase-Shift Full-Bridge (PSFB) converters that are well-suited for Electric Vehicle (EV) battery charging applications, covering both typical battery voltage classes (400V and 800V). These three modified PSFB converters, denoted as the t-PSFB, r-PSFB, and i-PSFB converters, have the ability to reconfigure and provide better efficiency performance in the wide voltage range necessary for public EV battery charging applications. In this paper, the characteristics and design considerations of these reconfigurable PSFB converters are discussed in detail. A multi-objective converter design process is proposed to optimize the average efficiency, normalized cost, and power density of the magnetic components and heat sinks. This design process employs the correlations between the cost and performance indexes of the key components derived based on open and accessible components data to estimate the design objectives. In this way, the design process is not constrained by certain component choices, making it easier to identify the most advantageous design. A benchmark study is conducted among the re-configurable PSFB topologies and the conventional PSFB circuit using the proposed multi-objective design process. To validate the analysis, a close-to-Pareto-front 11kW, 45kHz r-PSFB converter prototype with 640-840V input voltage and 250-1000V output voltage ranges is developed and tested.
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