Abstract
A new universal front-end PFC rectifier topology of a battery charger for Electric Vehicles (EVs) is proposed, which allows fast charging at rated and/or full power level in case of 3-phase (Europe) as well as 1-phase (USA) mains supply. In this regard, a conventional 3-phase PFC rectifier would facilitate only one-third of the rated power in case of 1-phase operation. The new topology is based on a two-level six-switch (2LB6) 3-phase boost-type PFC rectifier, which is extended with a diode bridge-leg and additional windings of the Common-Mode (CM) chokes of the EMI filter. Besides this extension of the power circuit, the general design of the new converter is explained, and the generated Differential Mode (DM) and Common Mode (CM) EMI disturbances are investigated for 3-phase and 1-phase operation, resulting in guidelines for the EMI filter design. The EMI performance (CISPR 11 class-B QP) is experimentally verified for 1-phase and 3-phase operation at an output power of 4.5 kW, using a full-scale hardware prototype that implements the proposed extensions for a 2LB6 3-phase boost-type PFC rectifier and that is designed for output power levels of 22 kW and 19 kW in case of 3-phase and 1-phase operation, respectively. Compared to a conventional 2LB6 PFC rectifier, the volume of the extended system increases from 2.7 dm3 to 3.4 dm3, of which 0.5 dm3 is due to the additional dc-link capacitance for buffering the power pulsation with twice the mains frequency occurring for 1-phase operation.
Highlights
The internationally increasing sales figures of Electric Vehicles (EVs) results in a demand for universal front-end PFC rectifier topologies of EV chargers that facilitate full power operation in presence of 3-phase and 1-phase mains
It is expected that, up to a certain production volume, the total cost of the presented converter structure is lower than the total cost of two separate EV chargers
The EMI measurements are conducted with the ESPI Test Receiver [46] and ENV216 single-phase Line Impedance Stabilization Networks (LISN) [47], both manufactured by Rohde & Schwarz
Summary
The internationally increasing sales figures of Electric Vehicles (EVs) results in a demand for universal front-end PFC rectifier topologies of EV chargers that facilitate full power operation in presence of 3-phase and 1-phase mains. It is expected that, up to a certain production volume, the total cost of the presented converter structure is lower than the total cost of two separate EV chargers (in case of very high production volumes, a lower total cost may be achieved with separate EV chargers for 3-phase and 1-phase operation, as a separate realization facilitates the independent optimization with regard to the specific requirements)
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