Multi-objective Design and Benchmark of Wide Voltage Range Phase-Shift Full Bridge DC/DC Converters for EV Charging Application

This article presents an analysis, multiobjective design, and benchmark of three modified 3 phase shift full-bridge (PSFB) converters that are well-suited for electric vehicle (EV) battery charging applications, covering both typical battery voltage classes (400 and 800 V). These three modified PSFB converters, denoted as the t-PSFB, r-PSFB, and i-PSFB converters, have the ability to reconfigure and provide better efficiency performance in the wide voltage range necessary for public EV battery charging applications. In this article, the characteristics and design considerations of these reconfigurable PSFB converters are discussed in detail. A multiobjective converter design process is proposed to optimize the average efficiency, normalized cost, and power density of the magnetic components and heat sinks. This design process employs the correlations between the cost and performance indexes of the key components derived based on open and accessible components' data to estimate the design objectives. In this way, the design process is not constrained by certain component choices, making it easier to identify the most advantageous design. A benchmark study is conducted among the reconfigurable PSFB topologies and the conventional PSFB circuit using the proposed multiobjective design process. To validate the analysis, a close-to-Pareto-front 11-kW, 45-kHz r-PSFB converter prototype with 640-840-V input voltage and 250-1000-V output voltage ranges is developed and tested.