A phase shifted full bridge converter design for electrical vehicle battery charge applications based on wide output voltage range

In this study, high efficiency design procedure of a phase shifted full bridge (PSFB) converter is presented for on-board electrical vehicle (EV) battery charger. Presented design methodology used lithium-ion battery cells because of their high voltage and current rates compared to a lead-acid battery cells. In this case, PSFB converter can be regulated wide range output voltage with while its soft switching operation is maintained. The basic operation principles of PSFB converter is defined and its soft switching operation requirements are given. To evaluate the performance of the converter over wide output voltage range, zero voltage switching (ZVS) operation of converter is discussed based on dead time requirement. To improve efficiency, the snubber inductance effects on soft switching over wide output voltage range are evaluated. Finally, operation of the PSFB converter is validated experimentally with a prototype which has 42-54 V/15 A output range at 200 kHz switching frequency.