Optimal Design Strategy and Electro-Thermal Modelling of a High-Power Off-Board Charger for Electric Vehicle Applications

This paper proposes an optimal design procedure of high-power off-board charger (Off-BC) systems for electric vehicle EV applications. The main purpose is to design a high-power DC charging system with low current ripples for achieving maximum efficiency. This paper presents linear and non-linear modelling of a 175kW three-phase AC/DC converter for EV applications. This paper also presents manufacturer’s datasheet driven accurate electro-thermal modelling. The design methodology is categorized into analytical modelling of three-phase active rectifier, optimal design strategy of passive filters, and control design of DC bus voltage. Finally, closed-loop dynamic electro-thermal behavior of Off-BC is simulated using MATLAB Simulink®. The proposed Off-BC operates with a current Total Harmonic Distortion (THD) below 3% and Power Factor (PF) above 99%, while the highest efficiency achieved is approximately 99% at rated power condition.

ISBN:978-1-7281-5642-2

Keywords:Power Electronic Converter, AC/DC converter, wide bandgap, passive filter, electric vehicle.

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