Hardware design of SiC MOSFET-based Phase Shifted Full Bridge DC-DC Converter for EV Charging Application

An EV charging system (EVCS) needs a high efficiency and high power density power converters. The Phase Shifted Full Bridge (PSFB) DC-DC converter topology is one of the preferred isolated topology used for High Voltage, High Frequency and High Power application. PSFB converter employs ZVS switching, leveraging the low reverse recovery time of the SiC MOSFET and hence enables high efficiency. Also High frequency operation reduces the size of magnetics and hence enhances the power density. However, a meticulous design of magnetics for a chosen SiC MOSFET is necessary to achieve the ZVS in the given operating range. This paper presents a design methodology for the selection of magnetics considering the real-time challenges of high frequency transformers. Also, the PCB design of the converter has been presented which is a critical part for the successful operation of any high frequency converter. The design has been validated by simulation for a $48 \mathrm{~V}, 600 \mathrm{~W}$ PSFB converter and is found to be an attractive solution for an EV Charging application.