Closed-Form Formulas for Automated Design of SiC-Based Phase-Shifted Full Bridge Converters in Charger Applications

Phase-Shifted Full Bridge (PSFB) topology in its four-diode variant is the choice with lowest part count applications that demand high power, voltage, and galvanic isolation, such as Electric Vehicle (EV) chargers. Even though prevalent power electronics applications, no single, unified analytical model has been proposed for design process of PSFB converters. As a result, engineers must rely on simulations empirical results obtained from previously built converters when selecting components to properly match DC source voltage level load requirements. In this work, authors provide design-oriented analysis approach obtaining output semiconductor current values, ready implementation spreadsheet- or MATLAB-type software automate optimization. The formulas account all first-order nonlinear dependencies by considering impact each following eight parameters: DC-link resistance, phase-shift ratio, switching frequency, transformer turns magnetizing inductance, series inductance. are verified through experiments at 10 kW 800 V using grid simulator SiC-based two-level Active Front End (AFE) DC–DC stage based topology. accuracy formula determined be around 99.6% 100.0% simulations. Based exact model, an automated procedure high-power high-voltage developed. By providing desired ripple factor, maximum temperatures, heatsink databases, algorithm calculates set feasible designs points one losses, dimensions, cost.