SiC-Based High-Density Charger Pile Power Module Design

Abstract:
With more charger stations being built in urban commercial area, the physical size of charger piles becomes a main concern. Efficiency and power density of charger modules directly impact the charger stations investment capital and operation cost. This paper proposes a new AC/DC power conversion architecture, which uses a resonant DC transformer fed by a three-phase current-source PFC for battery charging. By eliminating DC bulk capacitors at the PFC output and employing SiC MOSFETs to simplify the power topologies and operate at higher switching frequency, both efficiency and density are improved. A 20kW charger module prototype was built to validate the concept and benchmark existing design.