Phase-shift Full-Bridge (PSFB) Converter Integrated Double-Inductor Rectifier with Separated Resonant Circuits (SRC) for 800V High-Power Electric Vehicles

The main battery voltage of electric vehicles (EVs) has been suggested to increase to an 800-V system, which improves driving distance and charging speed. However, the design of an 800 V DC/DC converter is challenging because of the high voltage and current stress of the switching devices. Therefore, this paper proposes a novel double-inductor rectifier with separated resonant circuits (SRC) based on a phase-shift full-bridge (PSFB) converter for 800 V on-board charger (OBC) applications, which overcomes the drawbacks of the frequency stress of the diodes in a single series resonant circuit (SSRC). Moreover, the configuration of input-series output-parallel (ISOP) improves the voltage safety margin, and the use of 650 V switching devices reduces the system cost. In addition, the SRC achieves more effective energy transfer, which greatly reduces the switching loss and the thermal effects of high-power transmission by achieving a wide range of zero-voltage switching (ZVS) in the leading-leg switches and zero-current switching (ZCS) in the lagging-leg switches. Finally, the effectiveness of the proposed converter is validated on a 760 V/20 kW experimental prototype with 98.3% maximum efficiency.