Modified Full Bridge Dual Inductive Coupling Resonant Converter For Electric Vehicle Battery Charging Applications
Modified Full Bridge Dual Inductive Coupling Resonant Converter For Electric Vehicle Battery Charging Applications
Corresponding Author:
Kondreddy Sreekanth Reddy
Center for Research in Power Electronics, Presidency University
Rajankunte, Yelahanka, Bengaluru, Karnataka-560064, India
Email: [email protected]
1. INTRODUCTION
The demand for electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs) is ever
increasing due to an impending scarcity of fossil fuels is expected. and the zero emission of carbon dioxide
(CO2), noise reduction, smooth functioning, and high efficiency. The power electronic converters in EVs and
PHEVs play a significant role in interfacing the battery and grid to drive the traction motor which are
discussed in [1]–[5]. The design of reliable, compact and efficient power electronic converters is of great
interest and challenge for the researchers and engineers [6]–[8].
Presently, many topologies have been proposed in the literature for isolated battery charging using
inductors capacitor (LLC) resonant converters [9]–[22]. The topologies proposed in reference [9]–[17]
describes the operation of direct current/alternating current (DC/AC) and AC/DC converter for battery
charging with high frequency transformer to achieve isolation during charging. Hu et al. [9] a modified LLC
converter with two transformers in series is proposed for wide input voltage range. Based on the input
voltage, a scheme is developed to reduce the magnetizing current by modifying the magnetising inductance
adaptively while keeping high DC voltage gain. However, the topology needs two extra switches and four
diodes which eventually leads to conduction loss as well as control complexity in operating extra switches.
Dusmez and Khaligh [10], by incorporating the resonant inductor inside the transformer, the LLC resonant
converter's bulk is reduced, making it particularly appropriate for use as an integrated onboard charger for
electric vehicles. However, the report gives no indication of the imbalanced leakage inductance that is fairly
prevalent in centre tapped transformers with bifilar windings or the parameter changes that occur when a
resonant inductor is used. Wu et al. [11] proposes a unique secondary-side phase-shift-controlled LLC
resonant converter to decrease magnetising inductance circulating current. The topology is not designed for
high DC voltage gain, thus activities like constant voltage (CV) charge, constant current (CC) charge, zero-
voltage switching (ZVS), and zero-current switching (ZCS) are not reported. To eliminate low and high
frequency current ripple on the battery a new resonant tank for an LLC resonant DC-DC converter is
proposed in [12] considering only half bridge inverter which doesn’t guarantee high DC voltage gain.
Though, peak to peak low frequency voltage ripple of 0.14 V is achieved but the peak to peak low frequency
current ripple is limited to 0.537 A only. An LLC resonant DC–DC converter design procedure is presented
in reference [13] for an onboard lithium-ion battery charger of a PHEV. Based on fundamental harmonic
approximation (FHA) the worst-case circumstances for primary-side ZVS operation are identified
analytically and charging profile is implemented considering a constant maximum power (CMP). To ensure
soft-switching throughout the operation, worst-case operating point is used. To avoid the inaccuracy of FHA
approach below the resonance region, based on specific operation mode the design constraints are explained
briefly. In order to validate the designed equations only full bridge LLC resonant converter is considered
which doesn’t guarantee high DC voltage gain or high DC current gain. Deng et al. [14], a dual-bridge LLC
resonant converter for wide input voltage range is proposed and a fixed frequency pulse width modulation
(PWM) control scheme is employed. The magnetising inductor limits the voltage gain range regardless of the
quality factor. In addition to this, two extra switches in the topology increases the cost and control
complexities. An LLC resonant converter is proposed in reference [15] with considerable resonant inductance
in order to form an adjustable wide-range regulated voltage source. Soft switching is employed by properly
choosing the dead time and maximum switching frequency for power switches under inductive region
operating conditions. A frequency control strategy is used for the proposed topology to handle wide regulated
output voltages against wide input voltage or output load variations. A novel dual full-bridge LLC (FBLLC)
resonant converter for implementing CC and CV charges is proposed in reference [16]. The paper quickly
explains ZVS for all primary switches in CV charge and approximately ZCS for all primary switches in CC
charge. Both CC and CV charge consider fixed frequency resonant operation to limit circulating current. To
get high DC voltage gain, the article includes an extra diode bridge, and which results in greater conduction
losses. However, the proposed topology is claimed to be operated at fixed switching frequency for both CC
and CV operations, although clarity on how same switching frequency may be used for two different
resonant frequencies is lacking. This is significant because when the resonance frequency is lower than the
switching frequency, the active switches of the inverter suffer from excessive turn-off current, when it is
greater, and the main side of the transformer suffers from circulating current. To operate a lower resonant
converter in CC charge mode, turn off the switch connected in series with an extra capacitor, and turn on the
switch to lower the resonant frequency. This contradicts the paper's CC and CV charge operational point of
view. Moreover, while the switch is off, the circuit lacks a discharge pathway for the added capacitor,
resulting heating and a deficit of current restriction. Besides the aforesaid, the suggested topology's closed
loop control approach lacks clarity on selecting a common proportional-integral (PI) controller for both CV
and CC charges. The paper also fails to describe the resonant converter's output voltage dependence on the ac
grid input voltage.
In the present paper, a modified full bridge LCL resonant converter topology is proposed to address
the afore-mentioned issues. The proposed topology comprises of power factor correction (PFC) converter and
an isolated full bridge dual-inductive coupling converter (FBD-LCL) is briefly explained in the next section.
The organization of the paper is being as: in section 2, the description of the proposed topology is explained
along with various modes of operation. Section 3 discusses, the control techniques used for the proposed
topology. In section 4 design analysis are included. The simulation results are included in section 5 and the
conclusion are outlined in section 6.
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L1 D5 S1 S3 Tr1
D1 D6 D8 Lr1 Cr1
D3 D10 D12
ig Lm1
a
vg C1 C2 b
Sb Lr2 C3 Vb
Cr2
D4 S4 D 9 S2 D7 Lr3 Sr Lm2
D2
D13 D11
Tr2
1
𝑓𝑟𝑙 = (2)
2𝜋√(𝐿𝑟+𝐿𝑚 )𝐶𝑟
When the resonant converter operates at 𝑓𝑟𝑢 it behaves as a constant voltage source, the DC voltage gain is
obtained based on FHA analysis [6] is given by (3):
𝑓𝑥
𝐺𝑣 = (3)
2 2
𝑛√(𝑓𝑥2 (1+𝐿𝑖 )−𝐿𝑖 ) +𝑄2 (𝑓𝑥2 −1)
𝑉𝑜 𝑓𝑠
Where 𝐺𝑣 = DC voltage gain. Normalized frequency 𝑓𝑥 = , 𝑓𝑠 is switching frequency. Inductance ratio
𝑉𝑎𝑐 𝑓𝑟𝑢
𝐿𝑟 𝑍𝑜 𝐿𝑟
𝐿𝑖 = . Quality factor = , 𝑍𝑜 = √ characteristic impedance. 𝑅𝑎𝑐 = 0.81 ∙ 𝑛2 ∙ 𝑅𝑜 is the AC equivalent
𝐿𝑚 𝑅𝑎𝑐 𝐶𝑟
𝑉𝑜
resistance. 𝑅𝑜 = is the output DC resistance. 𝑛 is the transformer turns ratio. When the resonant converter
𝐼𝑜
operates at 𝑓𝑟𝑙 it behaves as a constant current source, the output current is obtained as in (4):
𝑉𝑎𝑐
|𝐼𝑜 (𝑤)| = 1+𝑅𝑎𝑐 (4)
𝑤∙𝑛[{𝐿𝑟 +𝑅𝑎𝑐 (𝐿𝑚+𝐿𝑟)}−{ }]
𝑤𝐶𝑟
𝑓𝑠
where = 2𝜋𝑓𝑥 , 𝑓𝑥 = .
𝑓𝑟𝑙
The graph between voltage gain (GV) versus normalized frequency (fx) with constant inductor ratio
(Li) of 5 and variable quality factor (Q) is shown in Figure 2. It is very clear from the graph that, as Q
increases GV decreases, at fxmin gain is highest at fxmax gain is lowest and at fx = fs gain is unity. The ZVS and
ZCS regions are also indicated in the graph. In Figure 3, Gain versus normalized frequency with constant
quality factor and current increases at fx = fs for increasing value of Q and decreases when fx<1 or fx>1.
Modified full bridge dual inductive coupling resonant converter for … (Kondreddy Sreekanth Reddy)
776 ISSN: 2088-8694
Figure 2. Graph between gain (GV) versus fx with Figure 3. Graph between gain (GV) versus fx with
constant Li =5 and variable Q constant Q=0.7 and variable Li
Figure 4. Graph between output current versus fx Figure 5. Graph between Q versus Gain (GV) with
with constant Li =2 and variable Q variable Li
1
𝑓𝑟𝑢1_𝐶𝐶𝑀 = (5)
2𝜋√𝐿𝑟1 𝐶𝑟1
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1
𝑓𝑟𝑙1_𝐶𝐶𝑀 = (6)
2𝜋√(𝐿𝑟1 +𝐿𝑚1 )𝐶𝑟1
In order to operate FBD-LCL1 converter as constant voltage source, it is operated at upper resonant
frequency 𝑓𝑟𝑢1_𝐶𝐶𝑀 . The lower resonant converter FBD-LCL2 resonate at two frequencies, upper resonant
frequency 𝑓𝑟𝑢2_𝐶𝐶𝑀 as in (7) and lower resonant frequency 𝑓𝑟𝑙2_𝐶𝐶𝑀 as in (8).
1
𝑓𝑟𝑢2_𝐶𝐶𝑀 = (7)
2𝜋√(𝐿𝑟2 ||𝐿𝑟3 )𝐶𝑟2
1
𝑓𝑟𝑙2_𝐶𝐶𝑀 = (8)
2𝜋√((𝐿𝑟2 ||𝐿𝑟3 )+𝐿𝑚2 )𝐶𝑟2
In order to operate FBD-LCL2 converter as constant current source, it is operated at lower resonant frequency
𝑓𝑟𝑙2_𝐶𝐶𝑀 .
Figure 6. Charge profile characteristics of EV battery during CC/CV charge mode: battery voltage, FBD-
LCL1 converter voltage, FBD-LCL2 converter voltage (left y-axis) and battery current (right y-axis) in left-
figure, battery power (left y-axis), and battery impedance (right y-axis) right-figure
Figure 7. Discharge profile characteristics of EV battery: battery voltage (left y-axis) and battery current
(right y-axis) in left-figure, battery power (left y-axis), and battery impedance (right y-axis) in right-figure
1
𝑓𝑟𝑢1_𝐶𝑉𝑀 = (9)
2𝜋√𝐿𝑟1 𝐶𝑟1
1
𝑓𝑟𝑙1_𝐶𝑉𝑀 = (10)
2𝜋√(𝐿𝑟1 +𝐿𝑚1 )𝐶𝑟1
Modified full bridge dual inductive coupling resonant converter for … (Kondreddy Sreekanth Reddy)
778 ISSN: 2088-8694
In order to operate FBD-LCL1 converter as constant voltage source, it is operated at upper resonant
frequency 𝑓𝑟𝑢1_𝐶𝑉𝑀 . The lower resonant converter FBD-LCL2 resonate at two frequencies, upper resonant
frequency 𝑓𝑟𝑢2_𝐶𝑉𝑀 as in (11) and lower resonant frequency 𝑓𝑟𝑙2_𝐶𝑉𝑀 as in (12).
1
𝑓𝑟𝑢2_𝐶𝑉𝑀 = (11)
2𝜋√𝐿𝑟2 𝐶𝑟2
1
𝑓𝑟𝑙2_𝐶𝑉𝑀 = (12)
2𝜋√(𝐿𝑟2 +𝐿𝑚2 )𝐶𝑟2
In order to operate FBD-LCL2 converter as constant voltage source, it is operated at upper resonant
frequency 𝑓𝑟𝑢2_𝐶𝑉𝑀 .
3. CONTROL TECHNIQUE
The control technique for the proposed topology to obtain DC link voltage and to charge battery are
shown in Figure 8 and Figure 9 respectively. The references [23]–[25] deliberates few governing control
techniques used in EV applications for power factor correction. The implementation of CC and CV charge
mode of operation needs closed loop control scheme. Hence, the external feedback signals from the DC link
voltage, battery voltage, battery current, PFC inductor current, and resonating inductor current are used to
choose the control method inputs for the proposed design. The PFC converter and FBD-LCL converter
control techniques are concisely presented in the following sections.
Vbref Control
+ Logic
Rectifier + S1 S2 Sr
Grid PID - -
S3 S4
Vb VCO Vbref
CV
Ir
ILr + Vb
Vb PID -
- Vb
+ Limiter PID +
- +
IL PID -
+
- Sb
Mode CC Ibref
Select
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consists of five MOSFET switches Sb, S1, S2, S3, and S4 with body diodes and the bridge rectifier circuit is
formed with nine additional diodes D1-D5, and D10-D13 are considered.
where 𝑉𝑑𝑐 is rated input voltage, 𝑉𝑜 is rated output voltage and 𝑉𝐷 is the forward voltage drop of rectifier
diode.
𝑉𝐷𝐶
𝐶2 = (15)
4𝑓𝑠 𝑅∆𝑉𝐷𝐶
𝑉𝑏
𝐶3 = (16)
4𝑓𝑠 𝑅𝑏 ∆𝑉𝑏
Modified full bridge dual inductive coupling resonant converter for … (Kondreddy Sreekanth Reddy)
780 ISSN: 2088-8694
Figure 10. Waveforms of (top)-grid voltage Figure 11. Waveforms of switching pulses, inverter
(blue) and grid current (red) with PF=0.99, ITHD voltage, capacitor voltage, current through inductors
= 0.99, (middle)-DC link voltage and (bottom)- Lr and Lm and current through rectifier diodes iD10
DC link current and iD12
Figure 12. Waveforms of switching pulse applied Figure 13. Waveforms of transformer primary
between gate and source of S1, drain to source voltage, primary current, secondary voltage, and
voltage of S1 and current through S1 switch indicating secondary current
ZVS turn-on and ZCS turn-off
Figure 14. Waveforms of voltage across and current through rectifier diode D10 indicating ZVS turn-on and
ZCS turn-of
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6. CONCLUSION
In this paper a modified full bridge dual LCL resonant converter fit for implementing both CC and
CV charge operation for charging the batteries is proposed. The PFC converter is also included in the
proposed topology for power factor correction. The implementation of two resonant converters to resonate at
lower and upper resonant frequencies, results in ZVS and ZCS of the converter switches in the CC charge
and CV charge operations. The ZVS turn-on and ZCS turn-off is also achieved during rectification operation
of the converter at the output. The higher resonant frequency is obtained by operating lower resonant
converter also in CV charge mode with the help of mode selector switch. The operation of ZVS and ZCS
ensure that the converter operates with no switching losses. This will improve the efficiency of the converter
over a wide range of output voltage and hence the suggested architecture catches instant applications in
battery charging systems of electric vehicles.
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BIOGRAPHIES OF AUTHORS
Int J Pow Elec & Dri Syst, Vol. 13, No. 2, June 2022: 773-782