Level-2 On-board 3.3 kW Battery Charger for EV

In this design example, Level-2 on-board 3.3kW EV battery charging system is explained. The design example is patterned after the first generation Nissan Leaf as there was ample public data available to build the model. In this design example, Li-ion 24 kWh 32.5Ah battery is charged from single phase 230 V 50Hz AC supply. The AC voltage from electric grid is passed to full bridge diode rectifier to convert AC voltage to DC. The rectified AC voltage is converted to 400V DC voltage using interleaved boost converter. Power Factor Correction (PFC) controller is used to make the power factor close to unity that further improves the input power quality. The PFC controller is designed based on the application note of UCC28070, Interleaving Continuous Conduction Mode PFC Controller available from Texas Instrument. The design example illustrates the methods to achieve optimal efficiency for battery charging designs. Reliability study is also performed using stress analysis to identify any overstressed components. The Li-ion battery, Power MOSFET and Schottky diodes are created using characterization tools in SaberRD.

How to use the example:

Download the attached "EV_Battery_charging_system.zip" and unzip to a local folder. Open the Battery_Charging_System.ai_dsn in SaberRD and run the experiments listed in the Experiment Analyzer.

For more details of the design, how to run the design, etc., refer to the README.pdf file in the attachments.

Note: This design example works only in SaberRD commercial edition 2017.12-1 and above.

Circuit Diagram:

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