Experimental Determination of the Transformer Equivalent Circuit Parameters in the Electric Vehicle Charger DC/DC Converter

Over the past decade, the production of electric vehicles and charging stations for them has grown at a significant rate. Thus, if in 2014 less than half a million electric vehicles were produced worldwide, then in 2023 this number exceeded forty million. This trend has not bypassed Russia either - over the past six months, the number of fast charging stations has grown by 142%. However, when traveling long distances in the central and eastern parts of our country, electric vehicle enthusiasts are still forced to carefully plan their route. One possible solution to this problem is the use of portable fast chargers that allow to connect directly to switchboards. The disadvantage of such chargers is their fairly large weight and dimensions. This article discusses the design and operating principle of portable fast chargers. The greatest attention is paid to the DC/DC converter as part of the charger power module. The pulse transformer has the largest mass in the DC/DC converter for fast chargers. The mass and dimensions of the pulse transformer in the prototype of the fast charger were determined experimentally. The parameters of its electric equivalent circuit (active resistance and inductance of the primary and secondary windings) were found. The computer model, assembled in the Matlab Simulink program, confirmed the reliability of the obtained results. Also, based on the obtained data, the current density of the transformer windings was calculated. The found values are the initial ones for designing a pulse transformer with improved mass and size indicators based on a multifunctional integrated electromagnetic component.