This article reviews the design and evaluation of different DC-DC converter topologies for Battery Electric Vehicles (BEVs) and Plug-in Hybrid Electric Vehicles (PHEVs). The design and evaluation of these converter topologies are presented, analyzed and compared in terms of output power, component count, switching frequency, electromagnetic interference (EMI), losses, effectiveness, reliability and cost. This paper also evaluates the architecture, merits and demerits of converter topologies (AC-DC and DC-DC) for Fast Charging Stations (FCHARs). On the basis of this analysis, it has found that the Multidevice Interleaved DC-DC Bidirectional Converter (MDIBC) is the most suitable topology for high-power BEVs and PHEVs (> 10kW), thanks to its low input current ripples, low output voltage ripples, low electromagnetic interference, bidirectionality, high efficiency and high reliability. In contrast, for low-power electric vehicles (<10 kW), it is tough to recommend a single candidate that is the best in all possible aspects. However, the Sinusoidal Amplitude Converter, the Z-Source DC-DC converter and the boost DC-DC converter with resonant circuit are more suitable for low-power BEVs and PHEVs because of their soft switching, noise-free operation, low switching loss and high efficiency. Finally, this paper explores the opportunity of using wide band gap semiconductors (WBGSs) in DC-DC converters for BEVs, PHEVs and converters for FCHARs. Specifically, the future roadmap of research for WBGSs, modeling of emerging topologies and design techniques of the control system for BEV and PHEV powertrains are also presented in detail, which will certainly help researchers and solution engineers of automotive industries to select the suitable converter topology to achieve the growth of projected power density.

This paper introduces a novel concept for implementing constant current (CC) and constant voltage (CV) charges of batteries for electric vehicles using a dual full-bridge LLC (FBLLC) resonant converter, which shares its primary switches. In the proposed concept, the CC and CV charges are implemented using the inherent characteristics of an LLC converter as a current source and a voltage source. One FBLLC resonant converter operates with a fixed-resonant network whereas the other operates with a variable resonant network for the CC and CV charge operations. The proposed converter can achieve zero voltage switching (ZVS) and nearly zero current switching (ZCS) for all of the primary switches in the CC charge operation, and ZVS for all of the primary switches in the CV charge operation, which lead to a high efficiency. In addition, fixed switching frequency operation is possible in both the CC and CV charges thanks to the variable resonant network. A 3.3-kW prototype converter is implemented to verify the feasibility and validity of the proposed converter and a maximum efficiency of 98% was achieved.

A novel Pulse-Width-Modulation (PWM) quasi-resonant active-clamp phase-shifted full-bridge converter is presented and analyzed in this paper. In the proposed topology, an active-clamp switch and a clamp capacitor that resonates with the leakage inductance of transformer are employed at the secondary side. The active-clamp circuit helps all of the primary switches in achieving both zero-voltage switching (ZVS) turn-on and nearly zero-current switching (ZCS) turn-off over the entire load range, and resets the primary current during the freewheeling interval. The operation of the active-clamp circuit eliminates voltage ringing across the rectifier. In addition, the secondary diodes can achieve ZCS turn-off, which removes the reverse recovery problem of diodes, and the active-clamp switch can achieve ZCS turn-on. A 3.5-kW prototype was built to verify the performance of the proposed converter. A maximum efficiency of 97.6% was achieved under a 2-kW load, and an efficiency of more than 96% was achieved even under a light load.