Modified Power Factor Correction (PFC) Control and Printed Circuit Board (PCB) Design for High-Efficiency and High-Power Density On-Board Charger
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 condi...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-01-01
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| Series: | Energies |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1996-1073/14/3/605 |
| _version_ | 1797407446454501376 |
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| author | Jaeil Baek Moo-Hyun Park Taewoo Kim Han-Shin Youn |
| author_facet | Jaeil Baek Moo-Hyun Park Taewoo Kim Han-Shin Youn |
| author_sort | Jaeil Baek |
| collection | DOAJ |
| description | 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) <i>LLC</i> 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<sup>3</sup> power density. |
| first_indexed | 2024-03-09T03:41:37Z |
| format | Article |
| id | doaj.art-955e3b8260f548d4b8f16a941d605ece |
| institution | Directory Open Access Journal |
| issn | 1996-1073 |
| language | English |
| last_indexed | 2024-03-09T03:41:37Z |
| publishDate | 2021-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Energies |
| spelling | doaj.art-955e3b8260f548d4b8f16a941d605ece2023-12-03T14:39:48ZengMDPI AGEnergies1996-10732021-01-0114360510.3390/en14030605Modified Power Factor Correction (PFC) Control and Printed Circuit Board (PCB) Design for High-Efficiency and High-Power Density On-Board ChargerJaeil Baek0Moo-Hyun Park1Taewoo Kim2Han-Shin Youn3Department of Electrical Engineering, Princeton University, Princeton, NJ 08540, USASchool of Electrical Engineering, KAIST, Daejeon 34141, KoreaSchool of Electrical Engineering, KAIST, Daejeon 34141, KoreaDepartment of Electrical Engineering, Incheon National University, 119, Academy-ro, Yeonsu-gu, Incheon 406840, KoreaThis 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) <i>LLC</i> 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<sup>3</sup> power density.https://www.mdpi.com/1996-1073/14/3/605electrical vehicleinterleaved PFC converteronboard charger (OBC)totem-pole bridgeless boost converterwide power range |
| spellingShingle | Jaeil Baek Moo-Hyun Park Taewoo Kim Han-Shin Youn Modified Power Factor Correction (PFC) Control and Printed Circuit Board (PCB) Design for High-Efficiency and High-Power Density On-Board Charger Energies electrical vehicle interleaved PFC converter onboard charger (OBC) totem-pole bridgeless boost converter wide power range |
| title | Modified Power Factor Correction (PFC) Control and Printed Circuit Board (PCB) Design for High-Efficiency and High-Power Density On-Board Charger |
| title_full | Modified Power Factor Correction (PFC) Control and Printed Circuit Board (PCB) Design for High-Efficiency and High-Power Density On-Board Charger |
| title_fullStr | Modified Power Factor Correction (PFC) Control and Printed Circuit Board (PCB) Design for High-Efficiency and High-Power Density On-Board Charger |
| title_full_unstemmed | Modified Power Factor Correction (PFC) Control and Printed Circuit Board (PCB) Design for High-Efficiency and High-Power Density On-Board Charger |
| title_short | Modified Power Factor Correction (PFC) Control and Printed Circuit Board (PCB) Design for High-Efficiency and High-Power Density On-Board Charger |
| title_sort | modified power factor correction pfc control and printed circuit board pcb design for high efficiency and high power density on board charger |
| topic | electrical vehicle interleaved PFC converter onboard charger (OBC) totem-pole bridgeless boost converter wide power range |
| url | https://www.mdpi.com/1996-1073/14/3/605 |
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