Balkan Journal of Electrical and Computer Engineering

2147-284X 2147-284X

Balkan Yayın

10.17694/bajece.1013720

Electrical Engineering

Elektrik Mühendisliği

Design and Analysis of a High-Efficiency Resonant Converter for EV Battery Charger

https://orcid.org/0000-0003-0784-7776

Erdoğan

Birand

Adana Alparslan Türkeş Bilim ve Teknoloji Üniversitesi

https://orcid.org/0000-0002-5227-2556

Tan

Adnan

Çukurova Üniversitesi

https://orcid.org/0000-0001-5847-5082

Savrun

Murat Mustafa

Adana Alparslan Türkeş Bilim ve Teknoloji Üniversitesi

https://orcid.org/0000-0001-6040-0362

Cuma

Mehmet Uğraş

Çukurova Üniversitesi

https://orcid.org/0000-0003-2938-8005

Tümay

Mehmet

Çukurova Üniversitesi

06 04 2023

11 2 198 206 10 23 2021 06 04 2023

2013

Balkan Journal of Electrical and Computer Engineering

The interest in electric vehicle (EVs) components such as battery, battery chargers, and battery management systems is increasing in parallel with the spread of electric vehicles. One of the most critical of these components is battery chargers. Battery chargers are equipped with DC-DC converters with high efficiency, low cost, and wide output voltage range. In order to provide reliable operation of the battery charger, it is of great importance that the DC-DC converters are operated with a robust and stable controller as well as designed optimally. In this paper, a design method for a CLLC resonant converter-based bidirectional dc-dc converter (BiDC) is presented for a battery charger. The resonant converter, whose design details are presented, suggests a resonant system to be used in battery chargers with fewer components than the CLLLC converter, and similar voltage gain characteristics for bidirectional power flow operations compared to the LLC converter. The design procedure highlights performing the soft switching operation and determining the resonant tank parameters. In addition, the forward mode and reverse mode gain equations required for the system to operate in the desired output voltage range have been presented. The design procedures have been validated with a CLLC BiDC model with ratings of 1 kW, 400 V input / 300-450 V output in the PSIM environment. The performance results reveal that the zero voltage switching (ZVS) has been performed for primary-side MOSFETs under a wide load range.

Battery Chargers CLLC Resonant Converter High Efficiency DC-DC Converter

[1] J. Chen, Y. Zhang and W. Su, "An anonymous authentication scheme for plug-in electric vehicles joining to charging/discharging station in vehicle-to-Grid (V2G) networks," in China Communications, vol. 12, no. 3, pp. 9-19, Mar. 2015, doi: 10.1109/CC.2015.7084359.

[2] S. Amamra and J. Marco, "Vehicle-to-Grid Aggregator to Support Power Grid and Reduce Electric Vehicle Charging Cost," in IEEE Access, vol. 7, pp. 178528-178538, 2019, doi: 10.1109/ACCESS.2019.2958664.

[3] M. A. Masrur et al., "Military-Based Vehicle-to-Grid and Vehicle-to-Vehicle Microgrid—System Architecture and Implementation," in IEEE Transactions on Transportation Electrification, vol. 4, no. 1, pp. 157-171, March 2018, doi: 10.1109/TTE.2017.2779268.

[4] B. Ray, "Bidirectional DC/DC power conversion using constant-frequency quasi-resonant topology," 1993 IEEE International Symposium on Circuits and Systems, 1993, pp. 2347-2350 vol.4, doi: 10.1109/ISCAS.1993.394234.

[5] D. Ha, N. Park, K. Lee, D. Lee and D. Hyun, "Interleaved Bidirectional DC-DC Converter for Automotive Electric Systems," 2008 IEEE Industry Applications Society Annual Meeting, 2008, pp. 1-5, doi: 10.1109/08IAS.2008.291.

[6] Hui Li, Fang Zheng Peng and J. S. Lawler, "A natural ZVS medium-power bidirectional DC-DC converter with minimum number of devices," in IEEE Transactions on Industry Applications, vol. 39, no. 2, pp. 525-535, March-April 2003, doi: 10.1109/TIA.2003.808965.

[7] Kwok-Wai Ma and Yim-Shu Lee, "An integrated flyback converter for DC uninterruptible power supply," in IEEE Transactions on Power Electronics, vol. 11, no. 2, pp. 318-327, March 1996, doi: 10.1109/63.486182.

[8] P. Das, B. Laan, S. A. Mousavi and G. Moschopoulos, "A Nonisolated Bidirectional ZVS-PWM Active Clamped DC–DC Converter," in IEEE Transactions on Power Electronics, vol. 24, no. 2, pp. 553-558, Feb. 2009, doi: 10.1109/TPEL.2008.2006897.

[9] Dehong Xu, Chuanhong Zhao and Haifeng Fan, "A PWM plus phase-shift control bidirectional DC-DC converter," in IEEE Transactions on Power Electronics, vol. 19, no. 3, pp. 666-675, May 2004, doi: 10.1109/TPEL.2004.826485.

[10] L. Zhu, "A Novel Soft-Commutating Isolated Boost Full-Bridge ZVS-PWM DC–DC Converter for Bidirectional High Power Applications," in IEEE Transactions on Power Electronics, vol. 21, no. 2, pp. 422-429, March 2006, doi: 10.1109/TPEL.2005.869730.

[11] E. Hiraki, K. Yamamoto, T. Tanaka and T. Mishima, "An Isolated Bidirectional DC-DC Soft Switching Converter for Super Capacitor Based Energy Storage Systems," 2007 IEEE Power Electronics Specialists Conference, 2007, pp. 390-395, doi: 10.1109/PESC.2007.4342018.

[12] G. Ma, W. Qu, G. Yu, Y. Liu, N. Liang and W. Li, "A Zero-Voltage-Switching Bidirectional DC–DC Converter With State Analysis and Soft-Switching-Oriented Design Consideration," in IEEE Transactions on Industrial Electronics, vol. 56, no. 6, pp. 2174-2184, June 2009, doi: 10.1109/TIE.2009.2017566.

[13] H. Xiao and S. Xie, "A ZVS Bidirectional DC–DC Converter With Phase-Shift Plus PWM Control Scheme," in IEEE Transactions on Power Electronics, vol. 23, no. 2, pp. 813-823, March 2008, doi: 10.1109/TPEL.2007.915188.

[14] L. Schuch, C. Rech, H. L. Hey, H. A. Grundlinggrundling, H. Pinheiro and J. R. Pinheiro, "Analysis and Design of a New High-Efficiency Bidirectional Integrated ZVT PWM Converter for DC-Bus and Battery-Bank Interface," in IEEE Transactions on Industry Applications, vol. 42, no. 5, pp. 1321-1332, Sept.-Oct. 2006, doi: 10.1109/TIA.2006.880847.

[15] F. Z. Peng, Hui Li, Gui-Jia Su and J. S. Lawler, "A new ZVS bidirectional DC-DC converter for fuel cell and battery application," in IEEE Transactions on Power Electronics, vol. 19, no. 1, pp. 54-65, Jan. 2004, doi: 10.1109/TPEL.2003.820550.

[16] S. Inoue and H. Akagi, "A Bidirectional DC–DC Converter for an Energy Storage System With Galvanic Isolation," in IEEE Transactions on Power Electronics, vol. 22, no. 6, pp. 2299-2306, Nov. 2007, doi: 10.1109/TPEL.2007.909248.

[17] Y. Liu, G. Du, X. Wang and Y. Lei, "Analysis and Design of High Efficiency Bidirectional GaN-Based CLLC Resonant Converter," in Energies, vol. 12, no. 20, pp. 3859-3871. Oct. 2019, doi:10.3390/en12203859

[18] Y. Wei, Q. Luo and A. Mantooth, "Comprehensive analysis and design of LLC resonant converter with magnetic control," in CPSS Transactions on Power Electronics and Applications, vol. 4, no. 4, pp. 265-275, Dec. 2019, doi: 10.24295/CPSSTPEA.2019.00025.

[19] R. Yu, G. K. Y. Ho, B. M. H. Pong, B. W. Ling and J. Lam, "Computer-Aided Design and Optimization of High-Efficiency LLC Series Resonant Converter," in IEEE Transactions on Power Electronics, vol. 27, no. 7, pp. 3243-3256, July 2012, doi: 10.1109/TPEL.2011.2179562.

[20] M. F. Menke, J. P. Duranti, L. Roggia, F. E. Bisogno, R. V. Tambara and Á. R. Seidel, "Analysis and Design of the LLC LED Driver Based on State-Space Representation Direct Time-Domain Solution," in IEEE Transactions on Power Electronics, vol. 35, no. 12, pp. 12686-12701, Dec. 2020, doi: 10.1109/TPEL.2020.2995942.

[21] I. Lee and G. Moon, "Analysis and Design of a Three-Level LLC Series Resonant Converter for High- and Wide-Input-Voltage Applications," in IEEE Transactions on Power Electronics, vol. 27, no. 6, pp. 2966-2979, June 2012, doi: 10.1109/TPEL.2011.2174381.

[22] J. Deng, S. Li, S. Hu, C. C. Mi and R. Ma, "Design Methodology of LLC Resonant Converters for Electric Vehicle Battery Chargers," in IEEE Transactions on Vehicular Technology, vol. 63, no. 4, pp. 1581-1592, May 2014, doi: 10.1109/TVT.2013.2287379.

[23] P. He and A. Khaligh, "Comprehensive Analyses and Comparison of 1 kW Isolated DC–DC Converters for Bidirectional EV Charging Systems," in IEEE Transactions on Transportation Electrification, vol. 3, no. 1, pp. 147-156, March 2017, doi: 10.1109/TTE.2016.2630927.

[24] J. Min and M. Ordonez, "Bidirectional Resonant CLLC Charger for Wide Battery Voltage Range: Asymmetric Parameters Methodology," in IEEE Transactions on Power Electronics, vol. 36, no. 6, pp. 6662-6673, June 2021, doi: 10.1109/TPEL.2020.3033982.

[25] J. Huang et al., "Robust Circuit Parameters Design for the CLLC-Type DC Transformer in the Hybrid AC–DC Microgrid," in IEEE Transactions on Industrial Electronics, vol. 66, no. 3, pp. 1906-1918, March 2019, doi: 10.1109/TIE.2018.2835373.

[26] P. He, A. Mallik, A. Sankar and A. Khaligh, "Design of a 1-MHz High-Efficiency High-Power-Density Bidirectional GaN-Based CLLC Converter for Electric Vehicles," in IEEE Transactions on Vehicular Technology, vol. 68, no. 1, pp. 213-223, Jan. 2019, doi: 10.1109/TVT.2018.2881276.

[27] W. Chen, P. Rong and Z. Lu, "Snubberless Bidirectional DC–DC Converter With New CLLC Resonant Tank Featuring Minimized Switching Loss," in IEEE Transactions on Industrial Electronics, vol. 57, no. 9, pp. 3075-3086, Sept. 2010, doi: 10.1109/TIE.2009.2037099.