Design & Simulation for 2kW EV Charger Using

MATLAB SIMULINK

Ayuesh G D Manjunatha Babu P Rakesh P N

Dept. of Electrical & Electronics Dept. of Electrical & Electronics Dept. of Electrical & Electronics
Engineering. Engineering. Engineering.
2025 International Conference on Computing for Sustainability and Intelligent Future (COMP-SIF) | 979-8-3315-3853-8/25/$31.00 ©2025 IEEE | DOI: 10.1109/COMP-SIF65618.2025.10969861

BMS Institute of Technology & BMS Institute of Technology & BMS Institute of Technology &
Management Management Management
Bengaluru, India Bengaluru, India Bengaluru, India
[email protected] [email protected] [email protected]

Sneha Shetty Varun L B

Dept. of Electrical & Electronics Dept. of Electrical & Electronics
Engineering. Engineering.
BMS Institute of Technology & BMS Institute of Technology &
Management Management
Bengaluru, India Bengaluru, India
[email protected] [email protected]

Abstract— In this study, a 2kW electric vehicle (EV) infrastructure networks that included pipeline, refineries,
charger that incorporates a full-bridge (phase-shifted) fuel stations, and maintenance facilities, all of which centred
converter & an interleaved boost PF Correction circuit is around fossil fuel extraction and consumption were due to
designed and simulated. The suggested charger design will dominance of gasoline powered engines.
allow for changeable voltage and current outputs and may be
adapted to many kinds of electric vehicle batteries. The Even in the early years of the rise of IC Engine
charger's high efficiency, low ripple, and dependable dominance, there were clear signs that this mode of
performance are highlighted by the simulation findings, transportation came with significant drawbacks. IC engines
which also help to progress EV charging solutions that emit pollutants such as CO2, NO2, HC, etc., that contributed
provides steady power with little fluctuation, and is highly significantly to air pollution, global warming and eventually
reliable as a step towards reducing dependence on fossil fuels. all sorts of health issues. As the number of vehicles that
were powered through these fuels grew exponentially, these
Keywords—Interleaved Boost PFC, PSFB, DC-DC environmental consequences became increasingly apparent.
Converter, electric vehicles, sustainability
There is also this increasingly adverse effect of
I. INTRODUCTION extraction and consumption of oil due to emissions of
greenhouse gases. The transportation sector is one among
The dawn of the 20th century marked an era of
the largest contributors to global CO2 emissions, with road
unprecedented industrial growth and technological
vehicles alone responsible for approximately 24% of the
advancement. Among the most transformative innovations
entire world's CO2 output [1-5]. This reality has contributed
of this period was the internal combustion (IC) engine,
significantly to global climate change, leading to rising
which would soon become the backbone of the global
temperatures, extreme weather events, and the gradual
transportation system. IC engines, operating on the
destruction of ecosystems around the world.
principles of fuel combustion within a closed chamber, were
far more efficient than their predecessors—the steam As the global transportation system faced mounting
engines and early electric motors that, while innovative in challenges from resource depletion and environmental
their own right, lacked the power and range needed for degradation, electric vehicles occurred as a feasible and
widespread transportation applications. sustainable substitute to IC engine vehicles. The concept of
the electric vehicle is not new; in fact, some of the earliest
The rise of IC engines coincided with the rapid
automobiles were powered by electricity. However, due to
expansion of automobile manufacturing. When more
limitations in battery technology and the abundance of
companies started getting involved into development and
inexpensive fossil fuels, EVs were largely overshadowed by
mass production of IC Engine Vehicles, it democratized
gasoline-powered cars for much of the 20th century.
mobility. This also made personal transportation relatively
affordable for a lot of people. This brought changes to not II. LITERATURE SURVEY
only the way that people chose to move but also redefined
the society through redefined urban planning, commerce, The demand for electric vehicles has been rising at an
and society at large. accelerated pace. According to a report by ISEA [13], It is
anticipated that the EV market would expand at a
Another factor that contributed to success of IC Engines compounded annual growth rate of 44% between 2020 and
was the abundance and energy density of fossil fuels (such 2027, with projected sales reaching 6.34 million by 2027.
as gasoline & diesel). Fossil Fuels, which are derived from With a wide range of benefits and the continuous
the remains of ancient organic matter, have been the world's advancement of the EV ecosystem, more individuals are
primary energy source for a long period are now a relatively
turning to electric vehicles. While EV users still encounter
cheap & reliable energy solution. Creation of vast

XXX-X-XXXX-XXXX-X/XX/$XX.00 ©20XX IEEE

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many significant challenges, developments in charging A. AC-DC Converter:
infrastructure and technology have reduced charging times. This converter connects battery pack to grid, and the
performance of converter will directly affect the charging
Such rapid growth impacts more than just EV sales. Most time, quality, and harmonic distortion at the input. [15]. The
notably, it will necessitate a significant expansion in the efficiency, reliability, power density, cost, weight, and
volume of these converters are crucial parameters for
availability of both public and private chargers. For
electric vehicle (EV) applications. Single-stage converters
instance, the United States had around 2.6 million charging that are lighter and more cost-effective, are commonly used
ports in 2022, but with the number of EVs increasing for on board charging.
annually, the country will need approximately 9.5 million
ports by 2025 and 28 million by 2030 [6]. If the Two half-bridge circuits are part of the converter
development of charging infrastructure does not keep pace architecture, the output is sink voltage spikes, and LC filters
with demand, potential EV buyers may hesitate to transition on both sides decrease ripples.
from internal made up of two switches, and the input port
half bridge is made up of four MOSFETs. Inductors restrict Zero Voltage Switching (ZVS), which results in increased
abrupt current fluctuations, capacitors combustion engine efficiency and decreased Total Harmonic Distortion (THD),
(ICE) vehicles. Additional challenges, such as concerns is made possible by a Dual Active Bridge (DAB) single-
over convenient charging compared to traditional fuelling, stage converter that incorporates a Power Factor Correction
could further hinder widespread EV adoption. (PFC) scheme [7]. Isolated converters, such as DAB, or
resonant converters (full-bridge converters) are
Mousavi and Flynn (2016) analysed energy losses in EVs recommended for high-power applications. Benefits of
during charging under various scenarios. Apostolaki- series resonant converter includes ZVS & zero current
Iosifidou et al. (2017) studied power losses in a Vehicle-to- switching (ZCS), which reduce switching losses, as well as
Grid (V2G) system focus, including the role of EV Supply galvanic isolation. Fast charging is accomplished with
Equipment (EVSE) and electrical infrastructure matrix-based isolated single-phase & non-isolated 3-phase
components, with energy losses measured from the grid to AC-DC converters, with the latter being more beneficial.
the EV battery. Spyropoulos et al. (2016) [11-12]
B. Rectification and PFC:
conducted real-world experiments on the same commercial
EV model under varying charging speeds, loads, and Because of its great efficiency, interleaved boost converters
climatic conditions, assessing energy consumption and are frequently used in standalone AC-DC converters for EV
charging. Several modules share the load current across
charging efficiency. However, their study did not consider these converters, which lessens the strain on any one module
how specific State of Charge (SoC) levels influence energy and increases overall efficiency. [15-18]. EV chargers must
losses and total consumption comply with strict power quality standards, and the
inclusion of PFC in interleaved boost converters helps
III. METHODOLOGY reduce harmonic distortion and maintain a high power
Our approach incorporates detailed models of power factor, ensuring grid compatibility.
electronics, control systems, and various charging
standards. The integration of power electronics requires The interleaved design in our case contributes to size and
weight reduction, as smaller components can be used due to
careful simulation and adjustments to enhance energy
the distribution of current across multiple modules. This
transfer efficiency. Control algorithms are developed and feature is particularly beneficial for portable and compact
tested in MATLAB Simulink, managing the charging EV charger designs. Interleaved boost converters in EV
process by considering factors like battery charge level, charging applications maximize power utilization, enhance
voltage regulation, and thermal management. Compatibility efficiency, meet power quality requirements, and enable
with different EV models is ensured through the simulation compact designs. Their ability to share load currents, reduce
of multiple charging protocols. Additionally, the user component stress, and improve efficiency makes them ideal
interface is designed to feature wireless connectivity and for EV chargers.
intuitive controls. Optimization techniques are applied to
refine charging parameters for maximum efficiency, while In order for an interleaved boost converter to function,
sensitivity analyses evaluate the system's reliability. A energy is first stored in the inductors during on-time and
then released through switches during off-time. This process
crucial part of the methodology is simulating the portable produces a stable, low- ripple output voltage that enables
charger’s life cycle in MATLAB SIMULINK to assess its efficient high-frequency operation. The control circuit
environmental footprint and explore options for improving regulates the duty cycle of the switching circuit to produce
sustainability. a steady output voltage. This allows EV chargers to
maintain high efficiency while giving electric vehicles a
consistent charging voltage.

C. DC-DC Converter:
Driving DC loads is a frequent use for these converters.
Additionally, they operate traction motors in traditional
battery-powered vehicles (BPVs) during the 2nd stage of
AC-DC power conversion. Bidirectional DC-DC converters
have been used for regenerative braking in order to replenish
Fig. 1. Equivalent model without PFC battery power over time. Because of their benefits, isolated

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DC-DC converters are utilised extensively in addition to frequencies. To address electromagnetic interference
their traditional non-isolated counterparts. The output (EMI), it is vital to incorporate LC filters at both the input
current injection capacity increases with increase in levels and output stages, along with a well-considered PCB layout
because more legs contribute to the overall current. A to minimize parasitic inductances and capacitances.
smaller ripple reject filter is needed in an integrated system
since a multilayer converter with phase shifts in the The following formula is used to determine the maximum
individual responses helps minimise output ripple and line current.
improves ripple rejection at a lower operating frequency ( ) = (2)
min ( )
system.

IV. IMPLEMENTATION The current going through each of the boost converter's two
inductor branches is the average input current of an
The design of the Charger for Electric Vehicles (EVs) interleaved boost converter. The high-frequency ripple
relies on the integration of key power electronics current from peak to peak, typically between 20-40% of I
components [8-10], such as converters and inverters, which
are simulated and optimized within the MATLAB peak(L), is found by calculating △IL. Thus, the ripple
SIMULINK environment. These components are crucial for current passing through the inductor from peak to peak is
the efficient and seamless transfer of energy from the ∆ = 0.2 × ( ) (3)
charger to the battery. The use of a comprehensive
simulation environment allows for in-depth analysis of each The Vout of the boost PFC, Vin min, and Vo are used to
component's performance and its interaction within the determine the minimum duty factor, or Dmin.
overall system, ensuring the charger’s robustness, min ( )
reliability, and effectiveness. = (4)
Minimum duty factor, switching frequency, and minimum
input supply voltage should all be taken into account when
calculating the inductor value.
× min ( )
L= (5)
( ) × (∆ )
The chosen capacitors are for the output ripple voltage
Fig. 2. Simulation model of EV Charger values, which decay to a voltage at a hold-up duration of
16.6 ms.
TABLE I (2 × × ℎ !)
DESIGN PARMETERS "= ( 2 − 2 (6)
min ( )
Parameter Value
B. Design of PSFB Converter
AC supply voltage 230V RMS It is required that we carefully consider the turns ratio
which is the key to balancing current and voltage switching
Maximum input current (AC) 7A capabilities while designing the converter for this purpose.
While increasing the turns ratio decreases the current, we
Input frequency 50Hz can observe higher current when the turns ratio is decreased.
The performance can be optimized by fine tuning the turns
ratio, further enabling Zero Voltage Switching and resulting
Switching frequency 100kHz in broadened voltage range. This adjustment is essential and
plays a significant role in improving efficiency of the
Output power 2000W converter.
It is also crucial that we recognize the drawbacks
associated with such an adjustment. Lowering the turns ratio
A. Design of Boost PFC will lead to increased losses in both magnetic components
and semiconductors due to high conducting current.
The design must support a broad input voltage range to Therefore, we attain optimal converter efficiency, by
reliably accommodate fluctuations in AC supply from the choosing the appropriate turns ratio that necessitates
grid [14]. The choice of components is crucial for carefully weighing the balance between current levels and
optimizing performance; for instance, utilizing MOSFETs losses. It is necessary that enough energy is stored in the
or IGBTs helps reduce conduction losses, while coupled primary circuit during the commutation phase to enable
inductors improve efficiency and minimize size. Zero voltage switching (ZVS) on the primary side.
( ) Transformer turns are provided by,
( ) = (1)
2

Additionally, effective thermal management is essential, &

a= = (7)
employing heatsinks and thermal pads to dissipate heat and & (
ensure operational stability, particularly at high switching

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The parasitic capacitance of the MOSFET must be
discharged, in order to enable efficient ZVS functioning,
which requires the stored energy. Increased overall
efficiency and maximum performance can be obtained in
the PSFB converter, by carefully controlling the energy
storage and discharge process.

While designing a converter, we must decide between two

possibilities that includes selecting the proper magnetizing
inductance: a lower range (100 µH to 300 µH) or a greater
range (about 1 mH). This decision is mostly based on the
application's particular needs [19–23]. A lower inductance
value will lead to an increased serial voltage switching
range, which is especially advantageous under light load Fig. 3. Vin to Interleaved boost PFC
circumstances.
( 1 − D)
= 1 ( (8)
∆ × 05
&
&
The proper Series Inductance must be determined, in order
to provide enough energy storage to eliminate capacitive
energy during switch transitions. This will be a crucial
component, to successfully accomplish Zero Voltage
Switching (ZVS) function.
2
≥ (2 × " (9)
. − /0 ) 2
2 ∆ !
( − )
2 2×
Fig. 4. Output of Boost PFC
TABLE II
DESIGN PARMETERS FOR PFSB CONVERTER

Parameter Description Value

a Turns ratio 5.714

L Series Inductance 150µH

Count Output Capacitance 600µF

V. RESULTS
Fig. 5. Battery Voltage Levels
The Simulation Results highlights the suggested 2kW EV
charger's great performance and dependable functioning.
By lowering Harmonic Distortion and enhancing power
factor correction, the charger can reach excellent
efficiency. We can ensure steady output voltage and current
waveforms seen in Fig.3, which exhibit minimum
distortion. The charger shows great load control because it
keeps a steady output even when the load changes. It also
reacts quickly to changes in input voltage and load. In Fig.
4, we observe that the output voltage of the interleaved
boost converter (IBC), which matches the waveforms of the
input voltage and current. The charger has strong protective
features, making it safe and reliable to use. When compared
to industry standards, it performs well in areas like
Fig. 6. Li-ion based Battery Voltage
efficiency and power factor. While these results show the
charger’s potential, there's always room for improvement
and future research.

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