A Very High-Frequency High-Density WBG-Based 6.6kW Bidirectional On-Board Charger for Electrical Vehicles
Jun 30, 2016
A wide-band-gap (WBG) devices based 6.6kW bidirectional on-board charger (OBC) system has recently been developed for plug-in electrical vehicles (PEVs). With proposed novel variable DC-link voltage system architecture, high frequency soft switching operation, and PCB winding-based integrated magnetics, the OBC system achieves over 96% high efficiency in the entire battery charging profile while the state-of-the-art product can only achieve 94% peak efficiency in a narrow loading range. At the same time, its power density is 37W/in3 which is 3~5 times compared to the best industrial practice. Furthermore, the inductors and transformers are integrated with PCB winding which simplify the labor-intensive manufacturing process significantly, and make the whole system ready for manufacturing automation.