Seamless Grid-Compliant EV Charging Using DAB with EPS Modulation for Adaptive Current Control and Power Factor Correction

Maintaining optimal power factor correction (PFC) across diverse charging scenarios is critical for ensuring the efficiency and grid compatibility of electric vehicle (EV) charging systems. This study introduces a three-phase EV charger designed to deliver consistent PFC performance under varying load conditions. The architecture incorporates an active frontend (AFE) rectifier for PFC, coupled with a dual active bridge (DAB) converter for DC-DC power conversion. The AFE stage, governed by pulse-width modulation (PWM), achieves near-unity power factor while suppressing harmonic distortion. For dynamic current regulation, the DAB converter employs Extended Phase Shift (EPS) modulation, optimizing power flow control, enhancing soft-switching capabilities, and boosting system efficiency. Operating in constant current (CC) mode, the charger supports power levels from 2.5 kW to 7.2 kW, with adjustable charging currents between 40 A and 64 A. MATLAB/Simulink simulations confirm the system's robustness, showcasing superior PFC, minimized switching losses, and reliable performance across multiple current profiles.