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Energy Efficiency in Plug-in Hybrid Electric Vehicle
Chargers: Evaluation and Comparison of Front End
AC-DC Topologies
1

Fariborz Musavi, Murray Edington
Department of Research, Engineering
Delta-Q Technologies Corp.
Burnaby, BC, Canada
fmusavi@delta-q.com, medington@delta-q.com
Abstract—As a key component of a plug-in hybrid electric
vehicle (PHEV) charger system, the front-end ac-dc converter
must achieve high efficiency and power density. This paper
presents a topology survey evaluating topologies for use in
front end ac-dc converters for PHEV battery chargers. The
topology survey is focused on several boost power factor
corrected converters, which offer high efficiency, high power
factor, high density and low cost. Experimental results are
presented and interpreted for five prototype converters,
converting universal ac input voltage to 400 V dc. The results
demonstrate that the phase shifted semi-bridgeless PFC boost
converter is ideally suited for automotive level I residential
charging applications in North America, where the typical
supply is limited to 120 V and 1.44 kVA. For automotive level
II residential charging applications in North America and
Europe the bridgeless interleaved PFC boost converter is an
ideal topology candidate for typical supplies of 120 V and 240
V, with power levels of 3.3 kW, 5 kW and 6.6 kW.

I.

INTRODUCTION

A plug-in hybrid electric vehicle (PHEV) is a hybrid
vehicle with a battery electric storage system that can be
recharged by connecting a plug to an external electric power
source. The vehicle charging ac inlet requires an on-board
ac-dc charger with power factor correction [1]. An on-board
3.4 kW charger can charge a depleted battery pack in PHEVs
to 95 % charge in about four hours from a 240 V supply [2].
A variety of power architectures, circuit topologies and
control methods have been developed for PHEV battery
chargers. However, due to large low frequency ripple in the
output current, the single-stage ac-dc power conversion
architecture is only suitable for lead acid batteries.
Conversely, two-stage ac-dc/dc-dc power conversion
provides inherent low frequency ripple rejection. Therefore,
the two-stage approach is preferred for PHEV battery
chargers, where the power rating is relatively high, and
lithium-ion batteries, requiring low voltage ripple, are used

This work has been sponsored and supported by Delta-Q Technologies
Corporation.

Wilson Eberle, 2 William G. Dunford

Department of Electrical and Computer Engineering
University of British Columbia | 1 Okanagan | 2 Vancouver
1
Kelowna, BC, Canada | 2 Vancouver, BC, Canada
1
wilson.eberle@ubc.ca | 2 wgd@ece.ubc.ca
as the main energy storage system [3]. A simplified block
diagram of a universal input two-stage battery charger used
for PHEVs is illustrated in Figure 1.

Figure 1. Simplified block diagram of a universal battery charger.

The ac/dc plus PFC stage rectifies the input ac voltage
and transfers it into a regulated intermediate dc link bus. At
the same time, power factor correction is achieved [4]. The
isolated dc-dc stage that follows then converts the dc bus
voltage to a regulated output dc voltage for charging
batteries. Boost circuit-based PFC topologies operated in
continuous conduction mode (CCM) and boundary
conduction mode (BCM) are surveyed in this paper,
targeting front end single-phase ac-dc power factor corrected
converters in PHEV battery chargers.
In the six sections that follow, five different boost based
PFC topologies are discussed and experimental results are
presented for each. The topologies in each section include:
II. Conventional Boost Converter, III. Interleaved Boost
Converter, IV. Phase Shifted Semi-Bridgeless Boost
Converter, V. Bridgeless Interleaved Boost Converter, and
VI. Bridgeless Interleaved Resonant Boost Converter. A
topology comparison is presented in section VII and the
conclusions are presented in section VIII.
II.

CONVENTIONAL BOOST CONVERTER

The conventional boost topology is the most popular
topology for PFC applications. It uses a dedicated diode
bridge to rectify the ac input voltage to dc, which is then
followed by the boost section, as shown in Figure 2.

This requires a design compromise between the core,
inductor size and inductance value. A lower inductance value
for a boost inductor increases the input current ripple and
consequently increases the input EMI filter size. It also
increases the output capacitor high frequency ripple, thereby
reducing the output capacitor lifetime. Therefore, it can be
concluded that a conventional boost converter is not the
preferred topology for PHEV battery charging applications.

Part # / Value

# of Devices

Regular Diode

25ETS08S

4

Fast Diode

IDB06S60C

1

MOSFET

IPB60R099CP
400 μH

1

98
97
96
95
Vin = 90 V

94

Vin = 120 V
Vin = 220 V

93

Vin = 240 V

1

Inductors

99

B. Performance Evaluation of the Conventional Boost
Converter
Figure 4 shows the efficiency of a conventional boost
converter at input voltages ranging from 90 V to 265 V. As it
can be noted from this graph, the efficiency drops
significantly at low input line as the power increases. To
solve this problem for power levels >1 kW, discrete

Vin = 265 V

92
91
500

Device

Figure 3. Input current, input voltage and output voltage of a conventional
boost converter at Vin = 240 V. Y-axis scales: Iin 10 A/div, Vin 100 V/div
and Vo 100 V/div.

2000

Components Used in Prototype Unit

Input Current
Iin

0

Conventional
PFC Boost
Converter

Topology

CONVENTIONAL BOOST CONVERTER PROTOTYPE
COMPONENTS

Output Voltage
Vo

1500

A. Experimental Results of Conventional Boost Converter
An experimental prototype was built to verify the
operation of the conventional boost PFC converter. The
components used to build the prototype are listed in Table I.
Figure 3 shows the input voltage, input current and PFC bus
voltage of the converter under the following test conditions:
Vin = 240 V, Iin = 7.5 A, Po = 1.7 kW, Vo = 400 V, fsw =
70 kHz.

Input Voltage
Vin

1000

In this topology, the output capacitor ripple current is
very high [5] and is the difference between diode current and
the dc output current. Furthermore, as the power level
increases, the diode bridge losses significantly degrade the
efficiency, so dealing with the heat dissipation in a limited
area becomes problematic. The inductor volume also
becomes a problematic design issue at high power. Another
challenge is the power rating limitation for current sense
resistors at high power. Due to these constraints, this
topology is good for the low to medium power range, up to
approximately 1 kW. For power levels >1 kW, typically,
designers parallel discrete semiconductors, or use expensive
MOSFET + SiC Diode semiconductor modules in order to
deliver greater output power. An example of a module
commonly used in industry is the APT50N60JCCU2 from
Microsemi Corporation.

Efficiency (%)

Figure 2. Conventional PFC boost converter.

TABLE I.

semiconductors are paralleled, or expensive modules are
used. This reduces the power loss in the MOSFETs, but at
low line, the input current increases and consequently the
input bridge losses increase. As a result, the inductor current
also increases.

Output Power (W)
Figure 4. Efficiency versus output power at different input voltages for a
conventional boost converter.

III.

INTERLEAVED BOOST CNVERTER

The interleaved boost converter, illustrated in Figure 5,
consists of two boost converters in parallel operating 180 °
out of phase [6-8]. The input current is the sum of the two
input inductor currents. Because the inductors’ ripple
currents are out of phase, they tend to cancel each other and
reduce the input ripple current caused by the boost switching
action. The interleaved boost converter has the advantage of
paralleled semiconductors. Furthermore, by switching 180 °
out of phase, it doubles the effective switching frequency and
introduces smaller input current ripple, so the input EMI
filter is relatively small [9-11]. With ripple cancellation at
the output, it also reduces stress on output capacitors.
However, similar to the boost, this topology has the heat
management problem for the input diode bridge rectifiers;
therefore, it is limited to power levels up to approximately
3.5 kW.

B. Performance Evaluation of the Interleaved Boost
Converter
Figure 7 shows the efficiency of an interleaved boost
converter at input voltages ranging from 90 V to 240 V. As it
can be noted from these graphs, the output power level has
increased. Hence, the efficiency profiles for each curve
resemble those from the conventional boost converter.
Despite the stated advantages of interleaving, the total power
losses are the same compared to a conventional boost
converter.

98
97

Efficiency (%)

96
95

Figure 5. Interleaved PFC boost converter.

94

TABLE II.

INTERLEAVED BOOST CONVERTER PROTOTYPE COMPONENTS

Interleaved PFC
Boost Converter

Topology

Components Used in Prototype Unit
Device

Part # / Value

# of Devices

Regular Diode

25ETS08S

4

Fast Diode

IDB06S60C

2

MOSFET

IPB60R099CP

2

Inductors

400 μH

Vin = 90 V

93

Vin = 120 V

92

Vin = 220 V
Vin = 240 V

91

3500

3000

Output Power (W)

2500

2000

1500

1000

500

90
0

A. Experimental Results of Interleaved Boost Converter
An experimental prototype was built to verify the
operation of the interleaved boost PFC converter. The
components used to build the prototype are listed in Table II.
Figure 6 shows the input voltage, input current and PFC bus
voltage of the converter under the following test conditions:
Vin = 240 V, Iin = 15 A, Po = 3.4 kW, Vo = 400 V, fsw = 70
kHz.

Figure 7. Efficiency versus output power at different input voltages for an
interleaved boost converter.

IV.

PHASE SHIFTED SEMI-BRIDGELESS BOOST
CONVERTER

2

Input Voltage
Vin

The bridgeless boost PFC topology avoids the need for
the rectifier input bridge yet maintains the classic boost
topology [12-19], as shown in Figure 8.

Output Voltage
Vo

Figure 8. Bridgeless PFC boost converter.

Input Current
Iin

Figure 6. Input current, input voltage and output voltage of an interleaved
boost converter at Vin = 240 V. Y-axis scales: Iin 10 A/div, Vin 100 V/div
and Vo 100 V/div.

It is an attractive solution for applications >1 kW, where
power density and efficiency are important. This converter
solves the problem of heat management in the input rectifier
diode bridge inherent to the conventional boost PFC, but it
introduces increased EMI [20, 21]. Another disadvantage of
this topology is the floating input line with respect to the
PFC ground, making it impossible to sense the input voltage
without a low frequency transformer or an optical coupler.
Also, in order to sense the input current, complex circuitry is
needed to sense the current in the MOSFET and diode paths
separately, since the current path does not share the same
ground during each half-line cycle [14, 22]. In order to
address these issues, a phase shifted semi-bridgeless boost
converter, shown in Figure 9 was introduced in [23].
However, this topology does not achieve high full load
efficiency since there is high power stress in the main
MOSFETs due to high intrinsic body diode losses.

B. Performance Evaluation of the Semi-bridgeless Boost
Converter
Figure 11 shows the efficiency of phase shifted semibridgeless boost converter at input voltages ranging from 90
V to 240 V. As it can be noted from this graph, the efficiency
is significantly improved at light load.
99

Efficiency (%)

98
97
96
95

Vin = 90 V
Vin = 120 V

93

Vin = 240 V

Vin = 220 V

TABLE III. COMPONENT USED IN THE SEMI-BRIDGELESS BOOST
CONVERTER PROTOTYPE

Phase Shifted
Semi-bridgeless
PFC Boost
Converter

Topology

Components Used in Prototype Unit
Device

Part # / Value

# of Devices

Regular Diode

25ETS08S

2

Fast Diode

IDB06S60C

2

MOSFET

IPB60R099CP

2

Inductors

400 μH

2

Input Voltage
Vin

Input Current
Iin
Figure 10. Input current, input voltage and output voltage of a phase shifted
semi-bridgeless boost converter at Vin = 240 V. Y-axis scales: Iin 10 A/div,
Vin 100 V/div and Vo 100 V/div.

3500

3000

2500

2000

1500

Output Power (W)
Figure 11. Efficiency versus output power at different input voltages for a
phase shifted semi-bridgeless boost converter.

These results show that the phase shifted semi-bridgeless
PFC boost converter is ideally suited for automotive level I
residential charging applications in North America where the
typical supply is limited to 120 V and 1.44 kVA. As an
example, for 120 V input voltage and 1700 W load the
efficiency is 95 %, which is the same efficiency achieved
with an interleaved boost converter operating with the same
conditions. But at lighter loads, the semi-bridgeless converter
achieves much higher efficiency. This is critical for
converters used in applications such as battery chargers. In
battery chargers, the converter is fully loaded for only one
third of the total charging time (i.e. during the bulk charging
stage). However, during the absorption and float stages,
which are two thirds of the total charging time, the charger is
only partially loaded, so light load efficiency is an important
consideration.
V.

Output Voltage
Vo

1000

A. Experimental Results of the Phase Shifted Semibridgeless Boost Converter
An experimental prototype was built to verify the
operation of the phase shifted semi-bridgeless boost PFC
converter. The components used to build the prototype are
listed in Table III. Figure 10 shows the input voltage, input
current and PFC bus voltage of the converter under the
following test conditions: Vin = 240 V, Iin = 15 A, Po = 3.4
kW, Vo = 400 V, fsw = 70 kHz.

500

92
0

Figure 9. Phase shifted semi-bridgeless PFC boost converter.

94

BRIDGELESS INTERLEAVED BOOST CONVERTER

The bridgeless interleaved topology, shown in Figure 12,
was proposed as a solution to operate at power levels at and
above 3.5 kW. In comparison to the interleaved boost PFC, it
introduces two MOSFETs and also replaces four slow diodes
with two fast diodes. The gating signals are 180 ° out of
phase, similar to the interleaved boost. A detailed converter
description and steady state operation analysis are given in
[24, 25]. This converter topology shows a high input power
factor, high efficiency over the entire load range and low
input current harmonics.
Since the proposed topology shows high input power
factor, high efficiency over the entire load range, and low
input current harmonics, it is a potential option for single
phase PFC in high power level II battery charging
applications.
Q3

Q4

Figure 12. Bridgeless interleaved PFC boost converter.

A. Experimental Results Bridgeless Interleaved Boost
Converter
An experimental prototype was built to verify the
operation of the bridgeless interleaved boost PFC converter.
The components used to build the prototype are listed in
Table IV. Figure 13 shows the input voltage, input current
and PFC bus voltage of the converter under the following
test conditions: Vin = 240 V, Iin = 15 A, Po = 3.4 kW, Vo =
400 V, fsw = 70 kHz.
TABLE IV. BRIDGELESS INTERLEAVED BOOST CONVERTER PROTOTYPE
COMPONENTS

Bridgeless
Interleaved
PFC
converter

Topology

Components Used in Prototype Unit
Device

Part # / Value

IDB06S60C
IPB60R099CP

4

Inductors

400 μH

4

97
96

Vin = 90 V
Vin = 120 V

95

Vin = 220 V
Vin = 240 V

94

4

MOSFET

98

# of Devices

Fast Diode

99

Input Voltage
Vin

Output Voltage
Vo

Input Current
Iin

Figure 14. Efficiency versus output power at different input voltages for a
bridgeless interleaved boost converter.

VI.

BRIDGELESS INTERLEAVED RESONANT BOOST
CONVERTER

The bridgeless interleaved resonant topology operating in
BCM was first introduced by Infineon Technologies [26] and
proposed for front end ac-dc stage of level II on-board
chargers. The topology is illustrated in Figure 15. Compared
to the bridgeless interleaved boost converter, it replaces the
four fast diodes with four slow diodes; however it requires
two high side drivers for MOSFETs – Q1 and Q2 as well as
two low side drivers for Q3 and Q4. The other drawbacks
with this topology include the need for at least two sets of
current sensors, two snubbers and a complex digital control
scheme.
D1

Figure 13. Input current, input voltage and output voltage of a bridgeless
interleaved boost converter at Vin = 240 V. Y-axis scales: Iin 10 A/div, Vin
100 V/div and Vo 100 V/div.

B. Performance Evaluation of the Bridgeless Interleaved
Boost Converter
Figure 14 shows the efficiency of the bridgeless
interleaved boost converter at input voltages ranging from 90
V to 240 V. In general, this converter achieves higher
efficiency than both the phase shifted semi-bridgeless
converter and interleaved boost at the same power levels. In
addition, due to the improved efficiency, greater output
power can be achieved for a given input current. For

Output Power (W)

4500

Q2

4000

Q1

3500

L4

L
O
A
D

3000

Co

2500

L2

2000

L3
Vin

example, at 240V input, the maximum output power
increases from 3.4kW for the phase shifted semi-bridgeless
converter up to 4.2kW for the bridgeless interleaved boost
converter. These results demonstrate that the bridgeless
interleaved boost converter is ideally suited for automotive
level II residential charging applications in North America
and Europe where the typical supply is limited to input
voltages of 120/240/250 V, and power levels up to
approximately 8kVA - depending on the input supply
breaker limitation.

1500

D4

1000

D3

500

D2

0

D1

Efficiency (%)

L1

D4
LB1

Q1

Q2

LB2

Vin

D2

D3

Co

Q3

Q4

Figure 15. Bridgeless interleaved resonant PFC boost converter.

L
O
A
D
# of Devices

Fast Diode

-

4

MOSFET

IPW60R045CP

4

Inductors

-

2

98

Efficiency (%)

97.5

97

96.5

Vin = 230 V

3500

3000

2500

2000

1500

1000

96

Output Power (W)
Figure 16. Efficiency versus output power at 230 V input voltages for a
bridgeless interleaved resonant boost converter by Infineon Technologies
AG [26].

VII. TOPOLOGY COMPARISON
Prototypes of the converter presented in sections II-V
were built to provide data for a qualitative and quantitative
performance comparison. Loss analysis modeling was also
performed to gain insight into the noted qualitative
advantages/disadvantages of each prototype in comparison to
the measured efficiency. Figure 17 shows the modeled loss
distribution within the semiconductors for these topologies at
Vin = 240 V, Po = 3400 W, Vo = 400 V and fsw = 70 kHz.
The regular diode losses consist of only conduction losses in
bridge rectifier diodes, i.e. reverse recovery losses were
neglected due to the low frequency mains input. Due to the
low reverse recovery characteristics of SiC, these diodes
were selected for the boost diodes. Therefore reverse
recovery losses were neglected for these diodes, so that only
conduction losses were considered. Switching loss,
conduction loss, gate charge loss and ½ CV2 loss are

48.7
35.7

48.7

39.6
7.8

0.0

0.0

7.8

16.6

19.1

0.0

0.0

10

8.3

20

8.3

12.9
12.7
12.9
11.3

27.6

27.6

30

Bridgeless Interleaved Boost

FETs

0

Devices / Total Losses

Total Losses

Part # / Value

Interleaved Boost
40

Intrinsic Body
Diodes

Bridgeless
Interleaved
Resonant
PFC
converter

Device

Phase Shifted Semi-Bridgeless Boost

50

Fast Diodes

Components Used in Prototype Unit

Topology

Conventional Boost

Regular
Diodes

TABLE V. BRIDGELESS INTERLEAVED RESONANT BOOST CONVERTER
PROTOTYPE COMPONENTS

60

Power Losses (W)

A. Experimental Results and Performance Evaluation of
Bridgeless Interleaved Resonant Boost Converter
The operation of this converter and efficiency was
reported in [26]. The components used for the prototype are
listed in Table V. Figure 16 shows the reported efficiency
(reproduced) of the converter under the following test
conditions: Vin = 230 V, Iin = 16 A, Po = 3.6 kW, Vo = 400
V. This converter achieves a peak efficiency of 97.9% at
2.7kW load, but the efficiency degrades rapidly beyond
2.7kW of output power, so based on the reported data, it is
not an ideal candidate for automotive level II charging.

Figure 17. Loss distribution in semiconductors at Vin = 240 V, Vo = 400 V,
Po = 3.4 kW and fsw = 70 kHz.

included in the MOSFET losses. The inductor losses were
neglected in the comparison.
The regular diodes in input bridge rectifiers have the
largest share of losses among the topologies with the input
bridge rectifier. The bridgeless topologies eliminate this
large loss component (~27.6 W). However, the tradeoff is
that the MOSFET losses are higher and the intrinsic body
diodes of MOSFETs conduct, producing new losses (~7.8
W). The fast diodes in the bridgeless interleaved PFC have
slightly lower power losses, since the boost diode average
current is lower in these topologies. Overall the MOSFETs
have increased current stress in the bridgeless topologies, but
the total semiconductor losses for the bridgeless interleaved
boost are 37% lower than the benchmark conventional boost
and 37% lower than the interleaved boost.
Since the bridge rectifier losses are so large, it was
expected that bridgeless interleaved boost converter would
have the lowest power losses among the topologies studied
in section II-V. Also, it was noted that the losses in the input
bridge rectifiers were 56% of total losses in the conventional
PFC converter and in the interleaved PFC converter.
Therefore eliminating the input bridges in PFC converters is
justified despite the fact that new losses are introduced.
Figure 18 illustrates the measured efficiency as a
function of output power for all five topologies studied under
the following operating conditions: fsw = 70 kHz, Vin = 240
V and Vo = 400 V. All semiconductor and magnetic devices
used in prototype units were the same. Limited information
was available for Infineon bridgeless interleaved resonant
converter. Notably it was measured at 230 V input voltage.
Table VI demonstrates an overall overview and
comparison of all candidate topologies discussed for the
front end ac-dc stage of a PHEV battery charger. The phase
shifted semi-bridgeless PFC converter was the topology of
choice for level I chargers and the bridgeless interleaved
PFC converter is an optimal topology for level II chargers.
99

REFERENCES
[1]

Efficiency (%)

98
97

[2]
Bridgeless Interleaved PFC Converter Vin = 240 V

96

[3]

Phase Shifted Semi-Bridgeless Converter Vin = 240 V
Interleaved PFC Converter Vin = 240 V

95

Infineon Bridgeless Resonant Converter Vin = 230 V
Conventional PFC Vin = 240 V

[4]
4500

Output Power (W)

4000

3500

3000

2500

2000

1500

1000

500

0

94

[5]

Figure 18. Efficiency versus output power for different PFC boost
converters.

[6]

Conventional
PFC boost
converter

Phase shifted
semibridgeless
PFC boost

Interleaved
PFC boost
converter

Bridgeless
interleaved
PFC boost
converter

Bridgeless
interleaved
resonant PFC
converter

TABLE VI. TOPOLOGY OVERVIEW/COMPARISON

< 1 kW

< 3.5 kW

< 3.5 kW

> 5 kW

> 5 kW

Poor

Fair

Fair

Best

Best

High

Medium

Low

Low

Low

High

Medium

Low

Low

Low

Large

Medium

Small

Small

Small

Driver

2 LS

2 LS

2 LS

2 LS

2LS+2HS

Efficiency

Poor

Best

Fair

Best

Fair

Cost

Low

Medium

Medium

High

[7]

Highest

Topology

Power
Rating
EMI /
Noise
Capacitor
Ripple
Input
Ripple
Magnetic
Size

[8]

[9]

[10]

[11]

[12]

[13]

VIII. CONCLUSIONS
A topology survey aimed at evaluating topologies for use
in front end ac-dc converters for PHEV battery chargers is
presented in this paper. The potential converter solutions
have been analyzed and their performance characteristics are
presented. Several prototype converter circuits were built to
verify the proof-of-concept. The results show that the phase
shifted semi bridgeless converter is ideally suited for
automotive level I residential charging applications in North
America where the typical supply is limited to 120 V and
1.44 kVA. For high power level II residential charging
applications, the bridgeless interleaved boost converter is an
ideal topology candidate in North America and Europe
where the typical supply is limited to input voltages of
120/240/250 V, and power levels up to 8kVA.

[14]
[15]
[16]

[17]

[18]

[19]

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Industrial Electronics, vol. 54, pp. 769 – 780, April 2007.
[20] T. Baur ; M. Reddig ; M. Schlenk, "Line-conducted EMI-behaviour
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[21] W. Frank ; M. Reddig ; M. Schlenk, "New control methods for
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[24] F. Musavi ; W. Eberle ; W.G. Dunford, "A High-Performance SinglePhase AC-DC Power Factor Corrected Boost Converter for plug in
Hybrid Electric Vehicle Battery Chargers," in IEEE Energy
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[25] F.Musavi ; W. Eberle ; W.G. Dunford, "Efficiency Evaluation of
Single-Phase Solutions for AC-DC PFC Boost Converters for Plugin-Hybrid Electric Vehicle Battery Chargers," in IEEE Vehicle Power
and Propulsion Conference Lille, France, 2010.
[26] "On Board Charging: Concept Consideration and Demonstrator
Hardware," in The World Electric Vehicle Symposium and
Exposition (EVS) Shenzhen, China: Infineon Technologies, 2010.

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Energy efficiency in plug in hybrid electric vehicle chargers - evaluation and comparison

  • 1. Energy Efficiency in Plug-in Hybrid Electric Vehicle Chargers: Evaluation and Comparison of Front End AC-DC Topologies 1 Fariborz Musavi, Murray Edington Department of Research, Engineering Delta-Q Technologies Corp. Burnaby, BC, Canada fmusavi@delta-q.com, medington@delta-q.com Abstract—As a key component of a plug-in hybrid electric vehicle (PHEV) charger system, the front-end ac-dc converter must achieve high efficiency and power density. This paper presents a topology survey evaluating topologies for use in front end ac-dc converters for PHEV battery chargers. The topology survey is focused on several boost power factor corrected converters, which offer high efficiency, high power factor, high density and low cost. Experimental results are presented and interpreted for five prototype converters, converting universal ac input voltage to 400 V dc. The results demonstrate that the phase shifted semi-bridgeless PFC boost converter is ideally suited for automotive level I residential charging applications in North America, where the typical supply is limited to 120 V and 1.44 kVA. For automotive level II residential charging applications in North America and Europe the bridgeless interleaved PFC boost converter is an ideal topology candidate for typical supplies of 120 V and 240 V, with power levels of 3.3 kW, 5 kW and 6.6 kW. I. INTRODUCTION A plug-in hybrid electric vehicle (PHEV) is a hybrid vehicle with a battery electric storage system that can be recharged by connecting a plug to an external electric power source. The vehicle charging ac inlet requires an on-board ac-dc charger with power factor correction [1]. An on-board 3.4 kW charger can charge a depleted battery pack in PHEVs to 95 % charge in about four hours from a 240 V supply [2]. A variety of power architectures, circuit topologies and control methods have been developed for PHEV battery chargers. However, due to large low frequency ripple in the output current, the single-stage ac-dc power conversion architecture is only suitable for lead acid batteries. Conversely, two-stage ac-dc/dc-dc power conversion provides inherent low frequency ripple rejection. Therefore, the two-stage approach is preferred for PHEV battery chargers, where the power rating is relatively high, and lithium-ion batteries, requiring low voltage ripple, are used This work has been sponsored and supported by Delta-Q Technologies Corporation. Wilson Eberle, 2 William G. Dunford Department of Electrical and Computer Engineering University of British Columbia | 1 Okanagan | 2 Vancouver 1 Kelowna, BC, Canada | 2 Vancouver, BC, Canada 1 wilson.eberle@ubc.ca | 2 wgd@ece.ubc.ca as the main energy storage system [3]. A simplified block diagram of a universal input two-stage battery charger used for PHEVs is illustrated in Figure 1. Figure 1. Simplified block diagram of a universal battery charger. The ac/dc plus PFC stage rectifies the input ac voltage and transfers it into a regulated intermediate dc link bus. At the same time, power factor correction is achieved [4]. The isolated dc-dc stage that follows then converts the dc bus voltage to a regulated output dc voltage for charging batteries. Boost circuit-based PFC topologies operated in continuous conduction mode (CCM) and boundary conduction mode (BCM) are surveyed in this paper, targeting front end single-phase ac-dc power factor corrected converters in PHEV battery chargers. In the six sections that follow, five different boost based PFC topologies are discussed and experimental results are presented for each. The topologies in each section include: II. Conventional Boost Converter, III. Interleaved Boost Converter, IV. Phase Shifted Semi-Bridgeless Boost Converter, V. Bridgeless Interleaved Boost Converter, and VI. Bridgeless Interleaved Resonant Boost Converter. A topology comparison is presented in section VII and the conclusions are presented in section VIII. II. CONVENTIONAL BOOST CONVERTER The conventional boost topology is the most popular topology for PFC applications. It uses a dedicated diode
  • 2. bridge to rectify the ac input voltage to dc, which is then followed by the boost section, as shown in Figure 2. This requires a design compromise between the core, inductor size and inductance value. A lower inductance value for a boost inductor increases the input current ripple and consequently increases the input EMI filter size. It also increases the output capacitor high frequency ripple, thereby reducing the output capacitor lifetime. Therefore, it can be concluded that a conventional boost converter is not the preferred topology for PHEV battery charging applications. Part # / Value # of Devices Regular Diode 25ETS08S 4 Fast Diode IDB06S60C 1 MOSFET IPB60R099CP 400 μH 1 98 97 96 95 Vin = 90 V 94 Vin = 120 V Vin = 220 V 93 Vin = 240 V 1 Inductors 99 B. Performance Evaluation of the Conventional Boost Converter Figure 4 shows the efficiency of a conventional boost converter at input voltages ranging from 90 V to 265 V. As it can be noted from this graph, the efficiency drops significantly at low input line as the power increases. To solve this problem for power levels >1 kW, discrete Vin = 265 V 92 91 500 Device Figure 3. Input current, input voltage and output voltage of a conventional boost converter at Vin = 240 V. Y-axis scales: Iin 10 A/div, Vin 100 V/div and Vo 100 V/div. 2000 Components Used in Prototype Unit Input Current Iin 0 Conventional PFC Boost Converter Topology CONVENTIONAL BOOST CONVERTER PROTOTYPE COMPONENTS Output Voltage Vo 1500 A. Experimental Results of Conventional Boost Converter An experimental prototype was built to verify the operation of the conventional boost PFC converter. The components used to build the prototype are listed in Table I. Figure 3 shows the input voltage, input current and PFC bus voltage of the converter under the following test conditions: Vin = 240 V, Iin = 7.5 A, Po = 1.7 kW, Vo = 400 V, fsw = 70 kHz. Input Voltage Vin 1000 In this topology, the output capacitor ripple current is very high [5] and is the difference between diode current and the dc output current. Furthermore, as the power level increases, the diode bridge losses significantly degrade the efficiency, so dealing with the heat dissipation in a limited area becomes problematic. The inductor volume also becomes a problematic design issue at high power. Another challenge is the power rating limitation for current sense resistors at high power. Due to these constraints, this topology is good for the low to medium power range, up to approximately 1 kW. For power levels >1 kW, typically, designers parallel discrete semiconductors, or use expensive MOSFET + SiC Diode semiconductor modules in order to deliver greater output power. An example of a module commonly used in industry is the APT50N60JCCU2 from Microsemi Corporation. Efficiency (%) Figure 2. Conventional PFC boost converter. TABLE I. semiconductors are paralleled, or expensive modules are used. This reduces the power loss in the MOSFETs, but at low line, the input current increases and consequently the input bridge losses increase. As a result, the inductor current also increases. Output Power (W) Figure 4. Efficiency versus output power at different input voltages for a conventional boost converter. III. INTERLEAVED BOOST CNVERTER The interleaved boost converter, illustrated in Figure 5, consists of two boost converters in parallel operating 180 ° out of phase [6-8]. The input current is the sum of the two input inductor currents. Because the inductors’ ripple currents are out of phase, they tend to cancel each other and reduce the input ripple current caused by the boost switching
  • 3. action. The interleaved boost converter has the advantage of paralleled semiconductors. Furthermore, by switching 180 ° out of phase, it doubles the effective switching frequency and introduces smaller input current ripple, so the input EMI filter is relatively small [9-11]. With ripple cancellation at the output, it also reduces stress on output capacitors. However, similar to the boost, this topology has the heat management problem for the input diode bridge rectifiers; therefore, it is limited to power levels up to approximately 3.5 kW. B. Performance Evaluation of the Interleaved Boost Converter Figure 7 shows the efficiency of an interleaved boost converter at input voltages ranging from 90 V to 240 V. As it can be noted from these graphs, the output power level has increased. Hence, the efficiency profiles for each curve resemble those from the conventional boost converter. Despite the stated advantages of interleaving, the total power losses are the same compared to a conventional boost converter. 98 97 Efficiency (%) 96 95 Figure 5. Interleaved PFC boost converter. 94 TABLE II. INTERLEAVED BOOST CONVERTER PROTOTYPE COMPONENTS Interleaved PFC Boost Converter Topology Components Used in Prototype Unit Device Part # / Value # of Devices Regular Diode 25ETS08S 4 Fast Diode IDB06S60C 2 MOSFET IPB60R099CP 2 Inductors 400 μH Vin = 90 V 93 Vin = 120 V 92 Vin = 220 V Vin = 240 V 91 3500 3000 Output Power (W) 2500 2000 1500 1000 500 90 0 A. Experimental Results of Interleaved Boost Converter An experimental prototype was built to verify the operation of the interleaved boost PFC converter. The components used to build the prototype are listed in Table II. Figure 6 shows the input voltage, input current and PFC bus voltage of the converter under the following test conditions: Vin = 240 V, Iin = 15 A, Po = 3.4 kW, Vo = 400 V, fsw = 70 kHz. Figure 7. Efficiency versus output power at different input voltages for an interleaved boost converter. IV. PHASE SHIFTED SEMI-BRIDGELESS BOOST CONVERTER 2 Input Voltage Vin The bridgeless boost PFC topology avoids the need for the rectifier input bridge yet maintains the classic boost topology [12-19], as shown in Figure 8. Output Voltage Vo Figure 8. Bridgeless PFC boost converter. Input Current Iin Figure 6. Input current, input voltage and output voltage of an interleaved boost converter at Vin = 240 V. Y-axis scales: Iin 10 A/div, Vin 100 V/div and Vo 100 V/div. It is an attractive solution for applications >1 kW, where power density and efficiency are important. This converter solves the problem of heat management in the input rectifier diode bridge inherent to the conventional boost PFC, but it introduces increased EMI [20, 21]. Another disadvantage of this topology is the floating input line with respect to the PFC ground, making it impossible to sense the input voltage without a low frequency transformer or an optical coupler. Also, in order to sense the input current, complex circuitry is needed to sense the current in the MOSFET and diode paths
  • 4. separately, since the current path does not share the same ground during each half-line cycle [14, 22]. In order to address these issues, a phase shifted semi-bridgeless boost converter, shown in Figure 9 was introduced in [23]. However, this topology does not achieve high full load efficiency since there is high power stress in the main MOSFETs due to high intrinsic body diode losses. B. Performance Evaluation of the Semi-bridgeless Boost Converter Figure 11 shows the efficiency of phase shifted semibridgeless boost converter at input voltages ranging from 90 V to 240 V. As it can be noted from this graph, the efficiency is significantly improved at light load. 99 Efficiency (%) 98 97 96 95 Vin = 90 V Vin = 120 V 93 Vin = 240 V Vin = 220 V TABLE III. COMPONENT USED IN THE SEMI-BRIDGELESS BOOST CONVERTER PROTOTYPE Phase Shifted Semi-bridgeless PFC Boost Converter Topology Components Used in Prototype Unit Device Part # / Value # of Devices Regular Diode 25ETS08S 2 Fast Diode IDB06S60C 2 MOSFET IPB60R099CP 2 Inductors 400 μH 2 Input Voltage Vin Input Current Iin Figure 10. Input current, input voltage and output voltage of a phase shifted semi-bridgeless boost converter at Vin = 240 V. Y-axis scales: Iin 10 A/div, Vin 100 V/div and Vo 100 V/div. 3500 3000 2500 2000 1500 Output Power (W) Figure 11. Efficiency versus output power at different input voltages for a phase shifted semi-bridgeless boost converter. These results show that the phase shifted semi-bridgeless PFC boost converter is ideally suited for automotive level I residential charging applications in North America where the typical supply is limited to 120 V and 1.44 kVA. As an example, for 120 V input voltage and 1700 W load the efficiency is 95 %, which is the same efficiency achieved with an interleaved boost converter operating with the same conditions. But at lighter loads, the semi-bridgeless converter achieves much higher efficiency. This is critical for converters used in applications such as battery chargers. In battery chargers, the converter is fully loaded for only one third of the total charging time (i.e. during the bulk charging stage). However, during the absorption and float stages, which are two thirds of the total charging time, the charger is only partially loaded, so light load efficiency is an important consideration. V. Output Voltage Vo 1000 A. Experimental Results of the Phase Shifted Semibridgeless Boost Converter An experimental prototype was built to verify the operation of the phase shifted semi-bridgeless boost PFC converter. The components used to build the prototype are listed in Table III. Figure 10 shows the input voltage, input current and PFC bus voltage of the converter under the following test conditions: Vin = 240 V, Iin = 15 A, Po = 3.4 kW, Vo = 400 V, fsw = 70 kHz. 500 92 0 Figure 9. Phase shifted semi-bridgeless PFC boost converter. 94 BRIDGELESS INTERLEAVED BOOST CONVERTER The bridgeless interleaved topology, shown in Figure 12, was proposed as a solution to operate at power levels at and above 3.5 kW. In comparison to the interleaved boost PFC, it introduces two MOSFETs and also replaces four slow diodes with two fast diodes. The gating signals are 180 ° out of phase, similar to the interleaved boost. A detailed converter description and steady state operation analysis are given in [24, 25]. This converter topology shows a high input power factor, high efficiency over the entire load range and low input current harmonics. Since the proposed topology shows high input power factor, high efficiency over the entire load range, and low input current harmonics, it is a potential option for single phase PFC in high power level II battery charging applications.
  • 5. Q3 Q4 Figure 12. Bridgeless interleaved PFC boost converter. A. Experimental Results Bridgeless Interleaved Boost Converter An experimental prototype was built to verify the operation of the bridgeless interleaved boost PFC converter. The components used to build the prototype are listed in Table IV. Figure 13 shows the input voltage, input current and PFC bus voltage of the converter under the following test conditions: Vin = 240 V, Iin = 15 A, Po = 3.4 kW, Vo = 400 V, fsw = 70 kHz. TABLE IV. BRIDGELESS INTERLEAVED BOOST CONVERTER PROTOTYPE COMPONENTS Bridgeless Interleaved PFC converter Topology Components Used in Prototype Unit Device Part # / Value IDB06S60C IPB60R099CP 4 Inductors 400 μH 4 97 96 Vin = 90 V Vin = 120 V 95 Vin = 220 V Vin = 240 V 94 4 MOSFET 98 # of Devices Fast Diode 99 Input Voltage Vin Output Voltage Vo Input Current Iin Figure 14. Efficiency versus output power at different input voltages for a bridgeless interleaved boost converter. VI. BRIDGELESS INTERLEAVED RESONANT BOOST CONVERTER The bridgeless interleaved resonant topology operating in BCM was first introduced by Infineon Technologies [26] and proposed for front end ac-dc stage of level II on-board chargers. The topology is illustrated in Figure 15. Compared to the bridgeless interleaved boost converter, it replaces the four fast diodes with four slow diodes; however it requires two high side drivers for MOSFETs – Q1 and Q2 as well as two low side drivers for Q3 and Q4. The other drawbacks with this topology include the need for at least two sets of current sensors, two snubbers and a complex digital control scheme. D1 Figure 13. Input current, input voltage and output voltage of a bridgeless interleaved boost converter at Vin = 240 V. Y-axis scales: Iin 10 A/div, Vin 100 V/div and Vo 100 V/div. B. Performance Evaluation of the Bridgeless Interleaved Boost Converter Figure 14 shows the efficiency of the bridgeless interleaved boost converter at input voltages ranging from 90 V to 240 V. In general, this converter achieves higher efficiency than both the phase shifted semi-bridgeless converter and interleaved boost at the same power levels. In addition, due to the improved efficiency, greater output power can be achieved for a given input current. For Output Power (W) 4500 Q2 4000 Q1 3500 L4 L O A D 3000 Co 2500 L2 2000 L3 Vin example, at 240V input, the maximum output power increases from 3.4kW for the phase shifted semi-bridgeless converter up to 4.2kW for the bridgeless interleaved boost converter. These results demonstrate that the bridgeless interleaved boost converter is ideally suited for automotive level II residential charging applications in North America and Europe where the typical supply is limited to input voltages of 120/240/250 V, and power levels up to approximately 8kVA - depending on the input supply breaker limitation. 1500 D4 1000 D3 500 D2 0 D1 Efficiency (%) L1 D4 LB1 Q1 Q2 LB2 Vin D2 D3 Co Q3 Q4 Figure 15. Bridgeless interleaved resonant PFC boost converter. L O A D
  • 6. # of Devices Fast Diode - 4 MOSFET IPW60R045CP 4 Inductors - 2 98 Efficiency (%) 97.5 97 96.5 Vin = 230 V 3500 3000 2500 2000 1500 1000 96 Output Power (W) Figure 16. Efficiency versus output power at 230 V input voltages for a bridgeless interleaved resonant boost converter by Infineon Technologies AG [26]. VII. TOPOLOGY COMPARISON Prototypes of the converter presented in sections II-V were built to provide data for a qualitative and quantitative performance comparison. Loss analysis modeling was also performed to gain insight into the noted qualitative advantages/disadvantages of each prototype in comparison to the measured efficiency. Figure 17 shows the modeled loss distribution within the semiconductors for these topologies at Vin = 240 V, Po = 3400 W, Vo = 400 V and fsw = 70 kHz. The regular diode losses consist of only conduction losses in bridge rectifier diodes, i.e. reverse recovery losses were neglected due to the low frequency mains input. Due to the low reverse recovery characteristics of SiC, these diodes were selected for the boost diodes. Therefore reverse recovery losses were neglected for these diodes, so that only conduction losses were considered. Switching loss, conduction loss, gate charge loss and ½ CV2 loss are 48.7 35.7 48.7 39.6 7.8 0.0 0.0 7.8 16.6 19.1 0.0 0.0 10 8.3 20 8.3 12.9 12.7 12.9 11.3 27.6 27.6 30 Bridgeless Interleaved Boost FETs 0 Devices / Total Losses Total Losses Part # / Value Interleaved Boost 40 Intrinsic Body Diodes Bridgeless Interleaved Resonant PFC converter Device Phase Shifted Semi-Bridgeless Boost 50 Fast Diodes Components Used in Prototype Unit Topology Conventional Boost Regular Diodes TABLE V. BRIDGELESS INTERLEAVED RESONANT BOOST CONVERTER PROTOTYPE COMPONENTS 60 Power Losses (W) A. Experimental Results and Performance Evaluation of Bridgeless Interleaved Resonant Boost Converter The operation of this converter and efficiency was reported in [26]. The components used for the prototype are listed in Table V. Figure 16 shows the reported efficiency (reproduced) of the converter under the following test conditions: Vin = 230 V, Iin = 16 A, Po = 3.6 kW, Vo = 400 V. This converter achieves a peak efficiency of 97.9% at 2.7kW load, but the efficiency degrades rapidly beyond 2.7kW of output power, so based on the reported data, it is not an ideal candidate for automotive level II charging. Figure 17. Loss distribution in semiconductors at Vin = 240 V, Vo = 400 V, Po = 3.4 kW and fsw = 70 kHz. included in the MOSFET losses. The inductor losses were neglected in the comparison. The regular diodes in input bridge rectifiers have the largest share of losses among the topologies with the input bridge rectifier. The bridgeless topologies eliminate this large loss component (~27.6 W). However, the tradeoff is that the MOSFET losses are higher and the intrinsic body diodes of MOSFETs conduct, producing new losses (~7.8 W). The fast diodes in the bridgeless interleaved PFC have slightly lower power losses, since the boost diode average current is lower in these topologies. Overall the MOSFETs have increased current stress in the bridgeless topologies, but the total semiconductor losses for the bridgeless interleaved boost are 37% lower than the benchmark conventional boost and 37% lower than the interleaved boost. Since the bridge rectifier losses are so large, it was expected that bridgeless interleaved boost converter would have the lowest power losses among the topologies studied in section II-V. Also, it was noted that the losses in the input bridge rectifiers were 56% of total losses in the conventional PFC converter and in the interleaved PFC converter. Therefore eliminating the input bridges in PFC converters is justified despite the fact that new losses are introduced. Figure 18 illustrates the measured efficiency as a function of output power for all five topologies studied under the following operating conditions: fsw = 70 kHz, Vin = 240 V and Vo = 400 V. All semiconductor and magnetic devices used in prototype units were the same. Limited information was available for Infineon bridgeless interleaved resonant converter. Notably it was measured at 230 V input voltage. Table VI demonstrates an overall overview and comparison of all candidate topologies discussed for the front end ac-dc stage of a PHEV battery charger. The phase shifted semi-bridgeless PFC converter was the topology of choice for level I chargers and the bridgeless interleaved PFC converter is an optimal topology for level II chargers.
  • 7. 99 REFERENCES [1] Efficiency (%) 98 97 [2] Bridgeless Interleaved PFC Converter Vin = 240 V 96 [3] Phase Shifted Semi-Bridgeless Converter Vin = 240 V Interleaved PFC Converter Vin = 240 V 95 Infineon Bridgeless Resonant Converter Vin = 230 V Conventional PFC Vin = 240 V [4] 4500 Output Power (W) 4000 3500 3000 2500 2000 1500 1000 500 0 94 [5] Figure 18. Efficiency versus output power for different PFC boost converters. [6] Conventional PFC boost converter Phase shifted semibridgeless PFC boost Interleaved PFC boost converter Bridgeless interleaved PFC boost converter Bridgeless interleaved resonant PFC converter TABLE VI. TOPOLOGY OVERVIEW/COMPARISON < 1 kW < 3.5 kW < 3.5 kW > 5 kW > 5 kW Poor Fair Fair Best Best High Medium Low Low Low High Medium Low Low Low Large Medium Small Small Small Driver 2 LS 2 LS 2 LS 2 LS 2LS+2HS Efficiency Poor Best Fair Best Fair Cost Low Medium Medium High [7] Highest Topology Power Rating EMI / Noise Capacitor Ripple Input Ripple Magnetic Size [8] [9] [10] [11] [12] [13] VIII. CONCLUSIONS A topology survey aimed at evaluating topologies for use in front end ac-dc converters for PHEV battery chargers is presented in this paper. The potential converter solutions have been analyzed and their performance characteristics are presented. Several prototype converter circuits were built to verify the proof-of-concept. The results show that the phase shifted semi bridgeless converter is ideally suited for automotive level I residential charging applications in North America where the typical supply is limited to 120 V and 1.44 kVA. 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