Design and Implementation of a Two-Stage Resonant Converter for Wide Output Range Operation

This article proposes and analyzes a two-stage isolated dc-dc converter for electric vehicle charging applications, where high efficiency over a wide range of battery voltages is required. It employs a first preregulation stage and a second half-bridge LLC stage, integrated with the first. The secon...

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Bibliographic Details
Published in:IEEE transactions on industry applications 2022-11, Vol.58 (6), p.7457-7468
Main Authors: Zanatta, Nicola, Caldognetto, Tommaso, Biadene, Davide, Spiazzi, Giorgio, Mattavelli, Paolo
Format: Article
Language:English
Subjects:
Battery charger
buck–boost
Conversion ratio
DCX
dc–dc converter
Efficiency
Electric potential
Electric vehicle charging
fast-charging
Frequency modulation
Modulation
preregulation
resonant <named-content xmlns:xlink="http://www.w3.org/1999/xlink" xmlns:ali="http://www.niso.org/schemas/ali/1.0/" xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance" content-type="math" xlink:type="simple"> <inline-formula> <tex-math notation="LaTeX"> LLC</tex-math> </inline-formula> </named-content>
soft-switching
Switches
Topology
Voltage
Voltage control
Zero voltage switching
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Summary:This article proposes and analyzes a two-stage isolated dc-dc converter for electric vehicle charging applications, where high efficiency over a wide range of battery voltages is required. It employs a first preregulation stage and a second half-bridge LLC stage, integrated with the first. The second stage is always operated at resonance, ensuring high efficiency. The first preregulation stage is responsible for the desired input-to-output voltage conversion ratio and the zero-voltage switching operation of all the switches. This allows low conversion losses even with voltages that may vary over a wide range. The article presents the conversion structure, the converter analysis, the design of the magnetic elements, and demonstrates the converter operation considering an experimental prototype interfacing a {750\text{-}} \mathrm{V} dc-link with an output bus with nominal voltage range {250} \mathrm{}-{500}\, \mathrm{V}. The implemented module is rated {5}\,\text{kW} and achieves a peak efficiency of \boldsymbol{98.0\%} at {3\text{-}} \text{kW} output power.
ISSN:0093-9994
1939-9367
DOI:10.1109/TIA.2022.3199195