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A DC/DC converter plays a vital role in on-board electric vehicle (EV) charger. Among the many converter topologies, the phase-shifted full-bridge DC/DC converter (PSFBDC) is widely used. For improved efficiency, PSFBDC is embedded with passive auxiliary networks resulting in several unique configurations for achieving soft-switching in entire load range. The architecture of the chosen DC/DC converter configuration should comply with the society of automotive engineers (SAE) standards. Although, the conduction loss of the converter can be minimised by choosing a proper topology configuration and proper switching of the configuration, the selection of appropriate for PSFBDC plays an important role in enhancing the overall efficiency. An optimistic method for the selection of switch configuration satisfying the reduced power loss and cost-effective aspects is presented. For demonstrating the proposed method, a 1 kW 100 kHz system with commercially available switches IRFP460, IXFN64N60P, and IPP65R045C7 is chosen and the obtained results are presented.

The DC/DC converter stage has a significant role in the on-board electric vehicle (EV) battery charger. This study proposes a zero voltage switching (ZVS) full-bridge DC/DC converter (FBDC) for efficient power conversion with minimal power loss. The simplified auxiliary circuit-based FBDC consolidate the modified pulse width modulation (MPWM) gating technique for DC/DC conversion stage according to battery profile of the EV. The proposed MPWM can minimise the conduction and switching losses in comparison to the previously proposed converter configuration using conventional phase shift modulation (PSM) gating technique. The size of auxiliary inductance required is reduced with MPWM in comparison to conventional FBDC auxiliary inductance with PSM gating technique. Design and implementation of proposed ZVS FBDC with MPWM are discussed for a 500 W, 80 kHz laboratory prototype and experimental results are presented to validate the design and performance of the proposed converter.

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