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Modified Power Factor Correction (PFC) Control and Printed Circuit Board (PCB) Design for High-Efficiency and High-Power Density On-Board Charger

Author

Listed:
  • Jaeil Baek

    (Department of Electrical Engineering, Princeton University, Princeton, NJ 08540, USA)

  • Moo-Hyun Park

    (School of Electrical Engineering, KAIST, Daejeon 34141, Korea)

  • Taewoo Kim

    (School of Electrical Engineering, KAIST, Daejeon 34141, Korea)

  • Han-Shin Youn

    (Department of Electrical Engineering, Incheon National University, 119, Academy-ro, Yeonsu-gu, Incheon 406840, Korea)

Abstract

This paper presents a modified power factor correction (PFC) ON/OFF control and three-dimensional (3D) printed circuit board (PCB) design for a high-efficiency and high-power density onboard charger (OBC). By alternately operating one of two boost modules of the PFC stage at a 50% or less load condition, the proposed PFC control can reduce the load-independent power loss of the PFC stage, such as core loss and capacitor charging loss of switches. It enables OBCs to have high efficiency across a wide output power range and better thermal performance. The 3D-PCB design decouples a trade-off relationship of the PCB trace design and heat spreader design, increasing the power density of OBCs. A 3.3 kW prototype composed of an interleaved totem-pole bridgeless boost PFC converter and full-bridge (FB) LLC converter has been built and tested to verify the proposed PFC control and 3D-PCB effectiveness design. The prototype has 95.7% full power efficiency (98.2% PFC stage efficiency) and 52 W/in 3 power density.

Suggested Citation

  • Jaeil Baek & Moo-Hyun Park & Taewoo Kim & Han-Shin Youn, 2021. "Modified Power Factor Correction (PFC) Control and Printed Circuit Board (PCB) Design for High-Efficiency and High-Power Density On-Board Charger," Energies, MDPI, vol. 14(3), pages 1-15, January.
    • Handle: RePEc:gam:jeners:v:14:y:2021:i:3:p:605-:d:486851
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    Citations

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    Cited by:

    1. Vitor Monteiro & Joao L. Afonso, 2022. "Power Electronics Technologies and Applicationsfor EV Battery Charging Systems," Energies, MDPI, vol. 15(3), pages 1-4, January.
    2. Josué Lara-Reyes & Mario Ponce-Silva & Leobardo Hernández-González & Susana E. DeLeón-Aldaco & Claudia Cortés-García & Jazmin Ramirez-Hernandez, 2022. "Series RLC Resonant Circuit Used as Frequency Multiplier," Energies, MDPI, vol. 15(24), pages 1-18, December.
    3. Michał Gwóźdź & Łukasz Ciepliński, 2021. "An Algorithm for Calculation and Extraction of the Grid Voltage Component," Energies, MDPI, vol. 14(16), pages 1-12, August.
    4. Liangliang Lu & Gaoshuai Shen & Haoran Xu & Qiaoling Tong & Run Min & Qiao Zhang & Jun Yuan & Ningyu Liu, 2022. "Triple-Mode Average Current Control with Valley Current Shaping for DCM/CRM/CCM Boost PFC Converter," Energies, MDPI, vol. 15(19), pages 1-23, October.

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