Design and Simulation of EV Charger for Wide Voltage Range Based on Phase Shift Full Bridge DC/DC Converter

The Electric Vehicle Charging System is one of the crucial subsystems that plays a major role in the implementation and success of the E-mobility system. The development of an on-board charger is one of the crucial tasks for an Original Equipment Manufacturer (OEM). For each new EV, it is required to design a new EV charger based on the battery capacity and voltage, going through an entire new product development cycle of the charging system. It would be desirable to have a single hardware and firmware configurable charging system based on the different EV battery voltages, which would greatly minimize the development effort in terms of time and cost. However, most of the resonant topologies, such as the LLC converter, which is one of the preferred topologies for an EV charger, cannot work for a wide range of voltages without compromising on the other performance indices, such as efficiency and electromagnetic compatibility. The present work proposes an EV charger based on Phase Shift Full Bridge Topology for the isolated DC/DC converter stage preceded by a classic PFC boost rectifier stage. The design and simulation of both the power stages have been presented. The proposed EV charging system has been validated by simulation for a wide battery voltage range, and it is expected to be an attractive solution for EV chargers.