11-kW High-Frequency High-Density Bidirectional OBC with PCB Winding Magnetic Design
Abstract
The trend of increasing power in on-board chargers (OBCs) is evident as demand of faster charging time from customers. This will lead to challenges for engineers to design the OBCs with high-performance, high-density, and cost competitiveness. In this paper, a SiC-based 11-kW two-stage bidirectional on-board charger system is introduced. With proposed motherboard-daughterboard concept, high frequency soft switching operation and PCB-based integrated magnetics, the proposed system architecture becomes more compact and more efficient compared to the state-of-art products on the market. The design consideration of the PCB-based magnetic components, including integrated coupled inductors and transformer, will be focused on this paper. The prototype of the 11-kW system is built which achieves up to 53 W/in3power density and above 98% efficiency of each stage over the wide range of the battery voltage.
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A topology for a two-stage OBC rated at 11 kW is proposed in [116] by Virginia Tech (CPES), with two stages functioning at an efficiency of ≥98%, yielding a peak efficiency of 96%.
“A topology for a two-stage OBC rated at 11 kW is proposed in [116] by Virginia Tech (CPES).To charge an 800 V battery, it gets supplied from a single-phase AC grid.The two stages consist of a four-channel 350 kHz interleaved totem pole PFC and a CLLC 500 kHz resonant three-phase converter.Windings and inductors have been integrated for decreasing the size, therefore the topology enhances the power”
From On-Board Chargers for Electric Vehicles: A Comprehensive Performance and Efficiency Review (2024) · cites this paper as [116]
Cites
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A new core loss model for rectangular AC voltages
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A High Efficiency High Density DC/DC Converter for Battery Charger Applications
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Self-citationImproved Balance Technique for Common-Mode Noise Suppression of PCB-Based PFC
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Self-citationSoft Start-up of Three Phase CLLC Converter Based on State Trajectory Control
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Water-cooled on-board charger with optimized cooling channel
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On-Board Chargers for Electric Vehicles: A Comprehensive Performance and Efficiency Review
Dar, A. R., Haque, A., Khan, M. A., Kurukuru, V. S. B., & Mehfuz, S. (2024) · Energies · doi:10.3390/en17184534 · Cited by 45 · see citing works
“A topology for a two-stage OBC rated at 11 kW is proposed in [116] by Virginia Tech (CPES).”
- Authors
- Pham, P. H., Nabih, A., Wang, S., & Li, Q.
- Affiliations
- Virginia Tech (US)
- Venue
- 2022 IEEE Applied Power Electronics Conference and Exposition (APEC)
- Publisher
- IEEE
- Published
- 2022-03-20
- Pages
- 1176-1181
- ISSN
- 1048-2334 (ISSN-L)
- OpenAlex
- W4280612190
- Cited by
- 24
- References
- 13
- Citations by year
- 2026: 4 · 2025: 5 · 2024: 9 · 2023: 5 · 2022: 1
- FWCI
- 8.09
- Type
- conference paper
- Language
- en
- Open access
- closed
- Locations
- Conference proceedings/Conference proceedings - IEEE Applied Power Electronics Conference and Exposition (publishedVersion)
- Topics
- Physical Sciences › Engineering › Electrical and Electronic Engineering › Advanced DC-DC Converters
- Physical Sciences › Engineering › Electrical and Electronic Engineering › Wireless Power Transfer Systems
- Physical Sciences › Engineering › Mechanical Engineering › Induction Heating and Inverter Technology
- Keywords
- on-board charger, bidirectional power flow, silicon carbide power devices, two-stage power converter, soft switching, power density, battery charging, high-frequency converters
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