High-efficiency single-stage on-board charger for electrical vehicles

This paper presents an isolated single-stage on-board electric vehicle charger without an intermediate DC-link. Based on an isolated current-source topology, the converter features soft-switching in semiconductors regardless of load variation for the full AC line voltage range. Moreover, it requires no external snubber or clamp circuits. The power factor correction and voltage regulation are provided by a relatively simple phase shift modulation, while the amount of circulating energy is kept at minimum. The charger is distinguished by its efficiency characteristic – the maximum is achieved in the constant power charging mode. The control method, component stresses, and design constraints of the topology are analyzed. The concept is verified using a 3 kW experimental SiC-based prototype, which reaches a peak efficiency of 96.4%. Moreover, the charger has demonstrated efficiencies above 95% with the THD of 4.1% when operating in constant power mode at the maximal power.