Design of Phase Shifted DC/DC Converter for Electric Vehicle Fast Chargers

Abstract

DC fast charging systems for electric vehicles (EVs) are rapidly growing trend. DC fast charger systems are two-stage in common. Each DC charging module consists of AC/DC stage followed by DC/DC stage. In this study, the design of DC/DC converter with wide voltage regulation range and high efficiency is targeted for use in EV fast charging applications. Commonly used DC/DC topologies in the market have been compared, and the phase-shifted full-bridge (PSFB) converter is selected. Therefore, two parallel PSFB construction is proposed due to advantages such as compatibility with parallel operation and modularity. Operation of PSFB converter is analyzed and design is carried out in line with the specified requirements. The proposed design is supported by techniques such as series/parallel reconfiguration and tap winding, which simplify implementation and enhance efficiency. Designed submodule and entire system were simulated, and accuracy of the design verified.