High Frequency Closed-Loop H-Bridge Converter with CC-CV Mode for Electric Three-Wheelers Battery Charging Application

Owing to its simplicity and low cost, a transformer in step-down configuration and a rectifier operating at mains frequency has been the most popular method for charging lightweight electric three-wheelers (ETWs) and auto-rickshaws. Due to a lack of feedback or sensing, the conventional battery charger cannot control output voltage/current. This makes battery charging inconsistent & unreliable, which causes overcharging, overheating, waste of energy, and increased battery aging over time. This research presents the design and development of a battery charger based on a high-frequency full-bridge DC-DC converter. A modified digital closed-loop control system is used in the proposed charging system's lightweight size and light weight to independently regulate output voltage and current. This system can be used to charge ETW batteries effectively at preset voltage and current levels while automatically adhering to custom charging scheme based on battery type & SOC. Additionally, a hardware-prototype rated at 60V and 1.2kW is made for performance evaluation and result analysis. (Abstract)