A Method for Suppressing Leakage Current of Non-isolated Integrated On-board EV Battery Charger

Abstract

The integrated on-board battery chargers (IOBCs) can be used to repurpose the existing high-rated power electronic devices in electric vehicles (EVs) for charging, thereby cutting costs. However, non-isolated IOBCs face significant common-mode (CM) leakage currents owing to the lack of current isolation and coupling between the AC and DC side CM filters. A method that combines topology and modulation to suppress the CM leakage currents in a non-isolated integrated charger is proposed. The touch current can be suppressed below a reaction threshold of 1 MIU. This enhancement enables the safe usage and commercialization of transformer-less chargers, presenting superior charger efficiency, power density, and cost-effectiveness. The CM model of the proposed system is derived to guide the design of the circuit topology and modulation schemes. The simulation results are used to determine the feasibility of these techniques. Finally, a prototype of the 6.6 kW experimental charger is proposed, and the experimental results demonstrate the effectiveness of the proposed solution.