Analysis of AC/DC/DC Converter Modules for Direct Current Fast-Charging Applications

Abstract

The paper is a comprehensive laboratory comparison study of two galvanic isolated solution off-board battery chargers: (1) Si-based cost-effective case, and (2) SiC-bidirectional ready for vehicle to grid concept case. All circuits are modular, and in both cases the DC/DC converter can be replaced according to the end user requirements (the coupled transformer remains the same and is constructed based on 12xC100 cores to avoid additional choke). In the case of single active bridge, an active RCD snubber is proposed to protect against overvoltage above 1kV in the DC_2 circuit. The dual active bridge is equipped with soft-star modulation using a zero vector to reduce in-rush current in case of no-load operation, while the AC/DC grid connected converter remains bidirectional to assure the highest power quality at the point of common coupling. All tests were made with real second-used batteries, which improves environmental, economic and technical feasibility of such systems for prosumers. The total efficiency of both AC/DC/DC converters (>97% in SiC and >94% in Si versions) was investigated in the same laboratory conditions.