Proceedings of International Conference on xxxxxxxxxxxxxxxxxxxxxxxxx (XXXXXX2016) on XX & XX XXXXX2016, Organized by

International Organization of Scientific Research and Development (IOSRD), Chennai, India

DC-DC CONVERTER FOR ON BOARD BATTERY CHARGER

IN HYBRID VEHICLE
Athira C R1, Biya Sara Alex1, Indu V J1, Dr. D. Elangovan2
1,

2,

PG students, Dept. of Energy and Power Electronics ,VIT University, Vellore, crathira@gmail.com.
Associate Professor, Dept. Of. Energy and Power Electronics, VIT University, elangovan.devaraj@vit.ac.in.

Abstract
A hybrid electric vehicle is a unique proposal to the roads of our country which is eco friendly and fuel
conserving .Here the combustion engine is complimented by the battery which is charged using renewable
energy sources. The proposed paper provides an interleaved DC-DC boost converter, where MOSFET is used as
switching element. By implementing the interleaved concept the current rating of each MOSFET is reduced and
hence the cost .This topology has an output voltage which is 20 times as that of input voltage .This also
eliminates the front end AC-DC conversion stage which is present in conventional topologies .The input and
output voltages are 22V and 400V DC respectively .The output power is estimated to be 250W and switching
frequency is 100KHz.Due to this high switching frequency ,switching losses tends to reduce and hence this
approach is more efficient .The simulation of the proposed system is analyzed using PSIM software(version
9.1)
Keywords: Interleaving, Plug In Hybrid Electric Vehicle, Voltage fed DC-DC boost converter, Zero Voltage
Switching
I. Introduction
Plug in hybrid electric vehicles are the future of automobile industry which intends to achieve better fuel
economy and better performance. PHEV along with internal combustion engine and a rechargeable battery,
which can be charged to full capacity using external electric supply, is commonly used .Most of the chargers
have an AC-DC conversion stage for power factor correction and an isolated DC-DC conversion stage [2].An
onboard AC-DC charger with power factor correction is commonly used in PHEVs .A phase shifted semibridgeless boost pf corrected converter is used for these chargers[1].To reduce the size of passive
components ,high frequency switching is also used .It uses ZVS technology based on resonant characteristics
such as series-loaded resonant full-bridge dc-dc converter .But these are restricted to low and medium power
range applications[3].There are some integrated chargers which uses inverters and the electric motors which all
are the hardwares of the traction system[4].Multifunction bi-directional battery charger can be used , so that
vehicle to grid and grid to vehicle power transfer is possible[5].But for getting bi-directional power transfer,
battery charger is to be designed so as to handle reactive power capabilities like, reactive power consumption,
voltage regulation etc[6].Intelligent battery charger controller uses solar energy as extra energy source for
hybrid automobiles using electricity and gasoline where solar panel voltage is suitable for charging
battery[7].Embedded AC-DC charger with electric motor as filter can also be used[8].To reduce output current
ripple cascaded PWM boost rectifier and DC-DC converter is used[9].Most of the above mentioned topologies
deals with EMI and heat management problems. To overcome this AC-DC bridgeless interleaved topology can
be used as front end in PHEV battery chargers[10].
The recent developments in power electronics incorporated with renewable energy further marks a good
replacement for the conventional approaches. All the above mentioned topologies deals with front end stage ACDC conversion which increases the cost at input side and affects overall efficiency. In the proposed converter,
front end conversion stage is eliminated with the help of hybrid renewable energy sources which includes both
solar and fuel cell .Also input voltage is around 22V and hence our task can be accomplished by two solar
panels each having 12V rating .This reduces overall cost at the input side .Another major advantage regarding
the proposed one is the implementation of interleaved concept which enhances current sharing between two legs
of the converter. In real time implementation, power level of onboard battery chargers is high and it is around
3KW.So the single switch needs to handle high current which increases the current rating of the MOSFET which
in turn increases the cost of each switch. But through interleaving current handled by each MOSFET is reduced
and hence the cost.
ZVS based proposed onboard battery charger provides output voltage which is nearly 20 times as that of input
voltage which is accomplished using two isolation transformers with proper turns ratio. Also switching
frequency is about 100 KHz .This reduces magnetic core size of transformer thereby reducing leakage
inductance and switching losses. Zero Voltage Switching using dead time concept is also implemented in this

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Proceedings of International Conference on xxxxxxxxxxxxxxxxxxxxxxxxx (XXXXXX2016) on XX & XX XXXXX2016, Organized by

International Organization of Scientific Research and Development (IOSRD), Chennai, India

approach which will be explained in detail under steady state analysis. By soft switching, switching losses are
reduced and thus the efficiency is increased .In output side conventional diode rectifier is replaced by a voltage
doubler circuit which again reduces transformer turns ratio and hence its size. Also as renewable energy sources
are used to charge the battery , environmental pollution and unwanted emissions are reduced.
II. Circuit Topology
The proposed DC-DC boost converter circuit consists of 8 switches, 4 in one leg .Here power MOSFET is used
as switching element .Current sharing is implemented using interleaving concept .Two isolation transformers are
used with specified turns ratio. The output side has a voltage doubler circuit which doubles each of the
transformer secondary voltage and output is taken across R load.

Fig.1
III. Steady state Analysis
Steady state analysis of the voltage fed boost converter with voltage doubler is analyzed using four modes of
operation ie; conduction of switches S1 and S2 , charging and discharging of parasitic capacitances, body diode
conduction period , conduction of switches S3 and S4.In this the energy stored in leakage inductor is clamped
and recycled for the soft turnon of each of the power MOSFET.
3.1. Modes Of Operation
3.1.1. Mode 1
In this mode the switches S1 and S2 will be on and starts conduction while S3 and S4 are off. The current flows
from source and then through S1,leakage inductor, transformer primary and S2 , returns to source and delivers
power to the secondary. Here both s1 and s2 conducts from 0 to 173.

Fig.2
3.1.2. Mode 2
From 173 to 180 all the four switches are opened. This period is so called dead time and it is incorporated in
the above circuitry in order to achieve zero voltage switching.
When all the four switches are opened, there exists a tendency to develop an infinite voltage across the inductor
To avoid this, the leakage inductance current needs a path to circulate. This path is provided by the capacitors

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Proceedings of International Conference on xxxxxxxxxxxxxxxxxxxxxxxxx (XXXXXX2016) on XX & XX XXXXX2016, Organized by

International Organization of Scientific Research and Development (IOSRD), Chennai, India

connected across the MOSFETs. This current flows through two paths. One path is through C3, source, C4 and
returns. Other is through C2, source, C1 and then returns. Hence capacitors C3 and C4 which are already
charged to source voltage now gets discharged along with the inductor and C1 and C2 begins to charge to
source voltage. As C1 and C2 are charged to same voltages there will not be any further current flow through the
inductor and thus it is said to be in floating state.

Fig.3
3.1.3. Mode 3
Once the capacitor got completely discharged the magnetizing current due to further energy stored in inductor
flows through the body diode of MOSFETs S3 and S4, which are now turned on with zero voltage across it and
hence ZVS is obtained.

Fig.4
3.1.4. Mode 4
At 180 switches S3 and S4 are turned on with zero voltage across it. At this time current follows the path
source-S3-L1-S4 and back to source and power transfer to secondary is resumed. They will conduct till 353 and
the cycle repeats.

Fig.5

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Proceedings of International Conference on xxxxxxxxxxxxxxxxxxxxxxxxx (XXXXXX2016) on XX & XX XXXXX2016, Organized by

International Organization of Scientific Research and Development (IOSRD), Chennai, India

IV. SIMULATION RESULTS

Simulation parameters given. Its values ,simulation circuit and simulation control box are given below.

Simulation
Parameters
Duty ratio
Input Voltage
Output Current
Output Voltage
Power Output
Load Resistance
Transformer turns ratio
Operating frequency
C1,C2,C3,C4
C9,C10,C11,C12
C13

Values
0.48
22 V
0.62 A
400 V
250 W
640
1:5
100 KHz
0.4nF
2uF
10uF
Table.1

Fig.6
The various waveforms obtained after simulation is given below. Fig.7 shows input dc voltage provided and
fig.8 depicts the pulses provided to switches S1,S2,S3 and S4,respectively.The switch pulses for S1 is identical
to that of S2 and the one for S3 is same as that of S4. For an input voltage of 22V an output of 400V is obtained
with an output current of 0.627A.The output voltage and current waveforms are shown in fig.9.

Fig.7 DC input voltage

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Proceedings of International Conference on xxxxxxxxxxxxxxxxxxxxxxxxx (XXXXXX2016) on XX & XX XXXXX2016, Organized by

International Organization of Scientific Research and Development (IOSRD), Chennai, India

Fig.8 Gate pulses given to switches

Fig.9 Output voltage and output current

The primary and secondary voltages and currents of the transformer is shown in fig.10. It is observed that
transformer secondary voltage becomes 5 times as that of input voltage and output current gets reduced to 1/8 th
of the input current.

Fig.10 Transformer voltage and current of primary and secondary

Fig.11 shows the ZVS switching. From the waveform it is evident that the switching pulse is given at zero
voltage and Fig.12 gives the voltage and current waveforms of diode and capacitor.

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Proceedings of International Conference on xxxxxxxxxxxxxxxxxxxxxxxxx (XXXXXX2016) on XX & XX XXXXX2016, Organized by

International Organization of Scientific Research and Development (IOSRD), Chennai, India

V(2)-V(3)
20
15
10
5
0

I(MOS2)

20

0
-20

0.004755

0.00476

0.004765
T i me (s)

0.00477

0.004775

Fig.11 Waveform showing ZVS

Fig.12 Voltages across the capacitor and diode, also their respective currents.
V. Conclusion
By analyzing the circuit topology, simulated results and waveforms of voltage fed interleaved DC-DC boost
converter it can be concluded that , the proposed converter provides an output voltage of 400V dc when an input
of 24V dc is provided from a renewable source, with a switching frequency of 100KHz and power rating of
250W.Because of higher switching frequency transformer size is reduced .Here front end stage is eliminated and
interleaving is provided to implement current sharing. With the help of ZVS switching losses are reduced and
using isolation transformers and doubler circuit a higher voltage is obtained using lesser turns ratio .Thus the
battery charger for PHEVs with increased efficiency and compact size is designed.
References
[1] A Phase Shifted Semi-Bridgeless Boost Power Factor Corrected Converter for Plug in Hybrid Electric
Vehicle Battery Chargers.
[2] A Zero Voltage Switching Full-Bridge DC-DC Converter with Capacitive Output Filter for a Plug-in-Hybrid
Electric Vehicle Battery Charger.
[3] Design and Implementation of a High-Efficiency On-Board Battery Charger for Electric Vehicles with
Frequency Control Strategy.
[4] Integrated Chargers for EVs and PHEVs: Examples and New Solutions.
[5] Multi-Function Bi-directional Battery Charger for Plug-in Hybrid Electric Vehicle.
[6] Reactive Power Operation Analysis of a Single-Phase EV/PHEV Bidirectional Battery Charger
[7]Work in Progress - A Solar Powered Battery Charger for a Hybrid Electric Vehicle.
[8]An Integrated Fast Battery Charger for Electric Vehicle.
[9] Universal Input Battery Charger Circuit for PHEV Applications with Simplified Controller
[10]A High-Performance Single-Phase Bridgeless Interleaved PFC Converter for Plug-in Hybrid Electric
Vehicle Battery Chargers.

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