A Novel Design for a 22kW Transformer for a 3 Phase Full Bridge LLC EV Onboard Charger for Smaller Size, Lower Cost and Improved Performance

Conference: PCIM Europe 2022 - International Exhibition and Conference for Power Electronics, Intelligent Motion, Renewable Energy and Energy Management
05/10/2022 - 05/12/2022 at Nürnberg, Germany

doi:10.30420/565822242

Proceedings: PCIM Europe 2022

Pages: 5Language: englishTyp: PDF

Authors:
Healy, Gerard; Wang, Tyler (Pulse Electronics, Ireland)

Abstract:
As power levels increase, powertrain system engineers are already moving to a three-phase full bridge LLC topology but this in turn brings challenges for heat dissipation and symmetrical operation of the transformer. These challenges have limited the performance of existing magnetic integrations. A novel transformer construction for symmetrical operation is presented that also reduces the size and cost compared to the multi transformer approach. This paper introduces the concept and presents the finite element modelling (FEM) and SPICE results used to optimize the design. Finally, the concept is validated through prototyping and evaluation in a 22kW on-board charger (OBC).