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Design of a 5.6 kW EV low-voltage DC/DC converter based on full-bridge converter with input series output parallel structure

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Abstract

This paper presents a design methodology for electric vehicle low-voltage DC/DC converter circuits with high power capacities and high input voltages. The proposed circuit is based on full-bridge converter with the input series output parallel structure adopting a coupled inductor in the primary side to eliminate the output current deviation even with a large deviation between transformer leakage inductances. It allows the distributed design of magnetic components and rectifiers and provides a good advantage in terms of cost and size of current monitoring devices using cheap and low-rating current sensors despite high output currents. In addition, to improve the efficiencies at medium load ranges, a method to expand ZVS range is suggested through the analysis of ZVS condition. The feasibility is verified through a 5.6 kW prototype implemented with design equations derived from theoretical analysis.

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Acknowledgements

This work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korean government (MSIP) (No. 2019R1F1A1041270) and the Korea Agency for Infrastructure Technology Advancement (KAIA) grant funded by the Ministry of Land, Infrastructure and Transport (Grant 21HCLP-C162885-01)

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  1. Department of Electrical Engineering, Myong-Ji University, Yong In, Republic of Korea

    Dae-Young Hong, So-Jeong Kong & Jun-Young Lee

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  1. Dae-Young Hong
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  2. So-Jeong Kong
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Correspondence to Jun-Young Lee.

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Hong, DY., Kong, SJ. & Lee, JY. Design of a 5.6 kW EV low-voltage DC/DC converter based on full-bridge converter with input series output parallel structure. J. Power Electron. 22, 395–405 (2022). https://doi.org/10.1007/s43236-021-00364-z

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  • DOI: https://doi.org/10.1007/s43236-021-00364-z

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