A Single-Phase Single-Stage Charger for High Voltage Batteries

The automotive industry is currently undergoing a profound transition from gasoline-powered vehicles to electric mobility, resulting in a change in battery voltage ratings from 400 V to 800 V. This increase in battery voltage leads to a decrease in the amplitude of battery current, resulting in reduced weight and volume of required wiring in electric vehicles. However, this transition also poses a significant challenge for charging equipment manufacturers to design chargers capable of charging both 400 V and 800 V batteries. In this paper, a solution to this problem through the development of a single-phase, single-stage bidirectional battery charger specifically designed for high-voltage batteries, is presented. This topology is designed to operate bidirectionally, allowing for efficient charging and discharging of batteries. The single-stage design of the charger enables high efficiency throughout the bidirectional operation, and a notable advantage of the developed charger is its high power factor operation. Furthermore, the presented charger adheres to the IEC 61000-3-2 power quality standard, ensuring reliable and compliant operation. Simulation analysis is conducted to validate the performance of the developed charger at a rated power of 6.6 kW, confirming its efficiency and power factor performance. Experimental verification is also demonstrated to verify the charger's performance in accordance with the IEC standards of power quality.