Phase-Shift Full-Bridge (PSFB) Converter Integrated Double-Inductor Rectifier With Separated Resonant Circuits (SRCs) for 800-V High-Power Electric Vehicles
Zhongchen Pei, Dongbo Guo, Tiancheng Cui, Chuang Liu, Dehao Kong, Di Zhu, Yu Jiang, Nan Chen
Abstract
The main battery voltage of electric vehicles (EVs) has been suggested to increase to an 800-V system, which improves driving distance and charging speed. However, the design of an 800-V dc/dc converter is challenging because of the high voltage and current stress of the switching devices. Therefore, this article proposes a novel double-inductor rectifier with separated resonant circuits (SRCs) based on a phase-shift full-bridge (PSFB) converter for 800-V on- board charger (OBC) applications, which overcomes the drawbacks of the frequency stress of the diodes in a single-series resonant circuit (SSRC). Moreover, the configuration of input-series–output-parallel (ISOP) improves the voltage safety margin, and the use of 650-V switching devices reduces the system cost. In addition, the SRC achieves more effective energy transfer, which greatly reduces the switching loss and the thermal effects of high-power transmission by achieving a wide range of zero-voltage switching (ZVS) in the leading-leg switches and zero-current switching (ZCS) in the lagging-leg switches. Finally, the effectiveness of the proposed converter is validated on a 760-V/20-kW experimental prototype with 98.3% maximum efficiency.