Loss Analysis and Improvements of Battery Charging System for Light Electric Vehicles

The paper presents loss analysis and improvements of a battery charging system for light electrical vehicles. Possible solutions and design approaches are presented for reducing weight and improving efficiency of the system. The charger system (1500W) consists of rectifier with inrush current limiting, PFC and resonant DC/DC converter. Presented loss analyses leads to selection of proper switches (SiC) to minimize the switching and conduction losses. Comparative study of using different magnetic materials, wires and winding arrangements is presented, aimed at reducing losses, weight and volume of magnetic components. Design conclusions and recommendations are derived to optimize the charger.