Analysis and Performance Evaluation of a Two-Stage Resonant Converter for Wide Voltage Range Operation

This paper proposes a two-stage isolated dc-dc converter for electric vehicle charging applications, where high efficiency over a wide range of battery voltages is required. It employs a first pre-regulation stage and a second half-bridge LLC stage, integrated with the first. The second stage is always operated at resonance, ensuring very high efficiency. The first pre-regulation stage is responsible for the desired input-to-output voltage conversion ratio and the zero-voltage switching operation of all the switches. This allows low conversion losses even with voltages that may vary over a wide range. The conversion structure is shown considering a first experimental prototype that interfaces a 750-V dc-link with an output bus with nominal voltage range 250V-500V. The implemented module is rated 5kW and achieves a peak efficiency of 98.0% at 3kW output power.