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

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/in3 power density.

Power Electronics Technologies and Applicationsfor EV Battery Charging Systems

“…A modified power factor correction with an on/off control and with a 3D printed circuit board design is proposed in [4], targeting the application of a high-efficiency, highpower density EV onboard charger. By considering the adopted strategy, the proposed PFC control can diminish the load-independent power loss.…”

PFC Single-Phase AC/DC Boost Converters: Bridge, Semi-Bridgeless, and Bridgeless Topologies

“…This converter is used in low voltage and power applications, and its efficiency is lower than the one of the totem-pole and GaN totem-pole (between 94% and 97%) topologies due to the additional components in the converter. In the same way, the GaN totem-pole can be modified by adding diodes D 1 and D 2 and inductors L 2 and L 3 according to Figure 16b [8,23,134]. Diodes and inductors comply with the same function as the converter in Figure 16a (reducing reverse recovery issues and contribute with ZCS); additionally, efficiency is also reduced requiring a robust control strategy and filtering to comply with THD i limits given by the normative.…”

DC Voltage Sensorless Predictive Control of a High-Efficiency PFC Single-Phase Rectifier Based on the Versatile Buck-Boost Converter

“…According to the literature studies, the primary breakdown of total losses in a power converter is the switching and conduction losses of the transistors and the inductor losses. Other kinds of power losses such as capacitance losses, gate drive losses, printed circuit board layout losses, EMI filter losses, and auxiliary power and controller energy consumption are negligible concerning those mentioned above [ 17 , 18 , 19 , 20 , 21 , 22 ].…”