A Novel Single‐Stage LLC Converter for High‐Power and Cost‐Effective EV On‐Board Charger

ABSTRACT In this paper, we propose a novel single‐stage LLC converter with power factor correction (PFC) for efficient and cost‐effective on‐board charging (OBC) for electric vehicles (EVs). This OBC circuit retains the advantages of zero‐voltage switching (ZVS) and zero‐current switching (ZCS) of LLC resonant converters while realizing high power factor performance. Detailed mathematical derivations and circuit design are presented, followed by experimental verification with a 200 W prototype circuit showing its efficacy. Furthermore, a comparison between the commercially available two‐stage OBC converter and the proposed single‐stage LLC converter is conducted. While the performance of these two converters is similar, the new single‐stage LLC resonant converter shows significant advantages with 24.97% reduction in size and 15.92% in bill‐of‐materials cost. This solution creates a compact and cost‐effective alternative for EV‐OBC.