A Universal DC Fast Charging Front-End with Optimized Film Capacitor Design

This paper proposes a three-leg universal charging front-end capable of both single-phase (1ϕ) and three-phase (3ϕ) connectivity and operation depending on the deployment configuration. Hardware re-utilization of both active and passive components across 1ϕ and 3ϕ deployment modes results in a versatile, high power density charging unit. The paper discloses the design and volume/loss/cost optimization methodology for the unit’s dc link and buffering capacitors in film technology for a 800 V dc bus, 50 kW-3ϕ / 33 kW-1ϕ case study. Experimental operation is reported for a scaled-down 10 kW unit prototype.