Design Methodology of LLC Resonant Converters for Electric Vehicle Battery Chargers

In this paper, an inductor-inductor-capacitor (LLC) resonant dc-dc converter design procedure for an onboard lithium-ion battery charger of a plug-in hybrid electric vehicle (PHEV) is presented. Unlike traditional resistive load applications, the characteristic of a battery load is nonlinear and highly related to the charging profiles. Based on the features of an LLC converter and the characteristics of the charging profiles, the design considerations are studied thoroughly. The worst-case conditions for primary-side zero-voltage switching (ZVS) operation are analytically identified based on fundamental harmonic approximation when a constant maximum power (CMP) charging profile is implemented. Then, the worst-case operating point is used as the design targeted point to ensure soft-switching operation globally. To avoid the inaccuracy of fundamental harmonic approximation approach in the below-resonance region, the design constraints are derived based on a specific operation mode analysis. Finally, a step-by-step design methodology is proposed and validated through experiments on a prototype converting 400 V from the input to an output voltage range of 250-450 V at 3.3 kW with a peak efficiency of 98.2%.