Phase-shift PWM-Controlled DC-DC converter with secondary-side current doubler rectifier for on-board charger application

A novel circuit topology for an on-board battery charger for plugged-in electric vehicles (PEVs) is presented in this paper. The proposed on-board battery charger is composed of three H-bridges on the primary side, a high-frequency transformer (HFT), and a current doubler circuit on the secondary side of the HFT. As part of an electric vehicle (EV) on-board charger, it is required to have a highly compact and efficient, lightweight, and isolated direct current (DC)-DC converter to enable battery charging through voltage/current regulation. In this work, performance characteristics of full-bridge phase-shift topology are analyzed and compared for EV charging applications. The current doubler with synchronous rectification topology is chosen due to its wider-range soft-switching availability over the full load range, and potential for a smaller and more compact size. The design employs a phase-shift full-bridge topology in the primary power stage. The current doubler with synchronous recitation is placed on the secondary. Over 92% of efficiency is achieved on the isolated charger. Design considerations for optimized zero-voltage transition are disused.