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Usually battery chargers have two stages and DC charging current is considered to by necessary for a proper charging. To decrease the charger volume, a single stage LLC battery charger is investigated in this paper. PFC stage is eliminated, therefore no bulky capacitor is necessary any more, and battery is charged with a sinusoidal-like charging current. However, previous studies show that such a pulsating charging current has only minimal impact on battery life and efficiency. Design considerations of the resonant tank and optimal transformer design are presented. A 360W single stage LLC converter prototype for e-bike charger achieves a power factor of 0.98, efficiency of 0.93 and power density of 1,8kW/dm³.
We present a compact battery charger topology for weight and cost sensitive applications with an average output current of 9A targeted for 36V batteries commonly found in electric bicycles. Instead of using a conventional boost converter with large DC-link capacitors, we accomplish PFC-functionality by shaping the charging current into a sin²-shape. In addition, a novel control scheme without input-current sensing is introduced. A-priori knowledge is used to implement a feed-forward control in combination with a closed-loop output current control to maintain the target current. The use of a full-bridge/half bridge LLC converter enables operation in a wide input-voltage range.
A fully featured prototype has been built with a peak output power of 1050W. An average output power of 400W was measured, resulting in a power density of 1.8 kW/dm³. At 9A charging current, a power factor of 0.96 was measured and the efficiency exceeds 93% on average with passive rectification.
The impact of pulse charging has been evaluated on a 400Wh battery which was charged with the proposed converter as well as CC-CV-charging for reference. Both charging schemes show similar battery surface temperatures.
The Dual Active Bridge (DAB) is a very promising topology for future power converters. However, careless operation can lead to a DC component in the transformer current. The problem is further exacerbated when the phase shift changes during operation. This work presents a study of DC bias effects on the DAB with special regard to transient effects introduced by sudden shifts in the output load. We present a simple yet effective approach to avoid DC bias entirely.