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IEEE TRANSACTIONS ON VEHICULAR TECHNOLOGY, VOL. 63, NO. 4, MAY 2014 1581 Design Methodology of LLC Resonant Converters for Electric Vehicle Battery Chargers Junjun Deng, Student Member, IEEE, Siqi Li, Sideng Hu, Chunting Chris Mi, Fellow, IEEE, and Ruiqing Ma, Member, IEEE Abstract—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 con- siderations are studied thoroughly. The worst-case conditions for primary-side zero-voltage switching (ZVS) operation are analyt- ically identified based on fundamental harmonic approximation when a constant maximum power (CMP) charging profile is imple- mented. 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 experi- ments 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%. Index Terms—Battery charger, DC–DC converter, electric ve- hicle (EV), LLC resonant converter, plug-in hybrid EV(PHEV), zero-current switching (ZCS), zero-voltage switching (ZVS). I. I NTRODUCTION R ECENTLY, there is a growing interest in plug-in hy- brid electric vehicles (PHEVs) and pure electric vehicles (EVs) because of the threat of fossil fuel depletion and global warming [1]–[4]. Most current PHEVs and EVs are equipped with a lithium-ion battery pack. A single-phase 3–6 kW on- board charger is usually installed on passenger cars, and a three- phase 30–200 kW battery charger is installed for buses and trucks; therefore, the high power traction battery pack can be charged through a utility power outlet [5]. High-voltage, high-current, and sophisticated charging algo- rithms are involved in quick charging of high-capacity lithium- Manuscript received July 22, 2013; revised October 7, 2013; accepted October 19, 2013. Date of publication October 25, 2013; date of current version May 8, 2014. The review of this paper was coordinated by Prof. A. Khaligh. J. Deng is with the School of Automation, Northwestern Polytechnical University, Xi’an 710072, China, and also with the Department of Electrical and Computer Engineering, University of Michigan, Dearborn, MI 48109 USA (e-mail: [email protected]). S. Li, S. Hu, and C. C. Mi are with the Department of Electrical and Computer Engineering, University of Michigan, Dearborn, MI 48109 USA (e-mail: [email protected]; [email protected]; [email protected]). R. Ma is with the School of Automation, Northwestern Polytechnical Uni- versity, Xi’an 710072, China (e-mail: [email protected]). Color versions of one or more of the figures in this paper are available online at http://ieeexplore.ieee.org. Digital Object Identifier 10.1109/TVT.2013.2287379 Fig. 1. Typical power architecture of a battery charger. ion battery packs [6]. Moreover, high efficiency with high power density, high reliability, small size, and low cost are the basic requirements for an onboard charger. All these factors make the design of an onboard charger complicated and costly, which has been regarded as one of the barriers that keeps PHEVs from wide acceptance [5]. The size, cost, and mechanical packaging are well discussed from a practical aspect in [6] and [7]. A comprehensive topolog- ical survey of the currently available charging solutions has also been presented in [8] and [9]. The most common charger archi- tecture consists of a boost-type ac–dc converter for active power factor correction, and an isolated dc–dc converter as the second stage [6], as shown in Fig. 1. The characteristic of this type of charger is mainly dependent on the dc–dc stage since the output voltage and current are regulated in this stage [10], [11]. Among different solutions, an inductor–inductor–capacitor (LLC) res- onant converter becomes the most attractive topology due to its high efficiency, low electromagnetic interference (EMI) emis- sions, a wide operation range, and the ability to achieve high power density [12]. Such features excellently fit the demand of PHEV and EV charger applications. However, the LLC topol- ogy is difficult to analyze and design because of its multiple resonant components and various operation modes [13]. Many design methodologies have been proposed for this type of converter in the past decades. Exact analysis of LLC resonant converters [14] ensures accuracy but cannot be easily used to get a handy design procedure due to the complexity of the model. The methodologies based on first harmonic approxima- tion (FHA) analysis [15], [16] are much simpler to handle. The FHA approach gives acceptable accurate results for operating points at and above the resonance frequency of the resonant tank [17]. Therefore, it has been widely used in constant output voltage applications where the LLC converter is designed to resonate at nominal condition. Designing a wide-output-range LLC resonant converter based on FHA is investigated in [18], and the expanded range is mainly designed in frequencies above the resonant frequency. However, zero-current switching (ZCS) for output rectifier diodes is lost in this region, which causes 0018-9545 © 2013 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
12

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Page 1: Design Methodology of LLC Resonant Converters for Electric …chrismi.sdsu.edu/publications/2014_TVT_63_4_Deng_junjun... · 2015-11-18 · DENGet al.: DESIGN METHODOLOGY OF LLC RESONANT

IEEE TRANSACTIONS ON VEHICULAR TECHNOLOGY, VOL. 63, NO. 4, MAY 2014 1581

Design Methodology of LLC Resonant Convertersfor Electric Vehicle Battery Chargers

Junjun Deng, Student Member, IEEE, Siqi Li, Sideng Hu, Chunting Chris Mi, Fellow, IEEE, andRuiqing Ma, Member, IEEE

Abstract—In this paper, an inductor–inductor–capacitor (LLC)resonant dc–dc converter design procedure for an onboardlithium-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 relatedto the charging profiles. Based on the features of an LLC converterand the characteristics of the charging profiles, the design con-siderations are studied thoroughly. The worst-case conditions forprimary-side zero-voltage switching (ZVS) operation are analyt-ically identified based on fundamental harmonic approximationwhen a constant maximum power (CMP) charging profile is imple-mented. Then, the worst-case operating point is used as the designtargeted point to ensure soft-switching operation globally. To avoidthe inaccuracy of fundamental harmonic approximation approachin the below-resonance region, the design constraints are derivedbased on a specific operation mode analysis. Finally, a step-by-stepdesign methodology is proposed and validated through experi-ments on a prototype converting 400 V from the input to an outputvoltage range of 250–450 V at 3.3 kW with a peak efficiency of98.2%.

Index Terms—Battery charger, DC–DC converter, electric ve-hicle (EV), LLC resonant converter, plug-in hybrid EV(PHEV),zero-current switching (ZCS), zero-voltage switching (ZVS).

I. INTRODUCTION

R ECENTLY, there is a growing interest in plug-in hy-brid electric vehicles (PHEVs) and pure electric vehicles

(EVs) because of the threat of fossil fuel depletion and globalwarming [1]–[4]. Most current PHEVs and EVs are equippedwith a lithium-ion battery pack. A single-phase 3–6 kW on-board charger is usually installed on passenger cars, and a three-phase 30–200 kW battery charger is installed for buses andtrucks; therefore, the high power traction battery pack can becharged through a utility power outlet [5].

High-voltage, high-current, and sophisticated charging algo-rithms are involved in quick charging of high-capacity lithium-

Manuscript received July 22, 2013; revised October 7, 2013;accepted October 19, 2013. Date of publication October 25, 2013; dateof current version May 8, 2014. The review of this paper was coordinated byProf. A. Khaligh.

J. Deng is with the School of Automation, Northwestern PolytechnicalUniversity, Xi’an 710072, China, and also with the Department of Electricaland Computer Engineering, University of Michigan, Dearborn, MI 48109 USA(e-mail: [email protected]).

S. Li, S. Hu, and C. C. Mi are with the Department of Electrical andComputer Engineering, University of Michigan, Dearborn, MI 48109 USA(e-mail: [email protected]; [email protected]; [email protected]).

R. Ma is with the School of Automation, Northwestern Polytechnical Uni-versity, Xi’an 710072, China (e-mail: [email protected]).

Color versions of one or more of the figures in this paper are available onlineat http://ieeexplore.ieee.org.

Digital Object Identifier 10.1109/TVT.2013.2287379

Fig. 1. Typical power architecture of a battery charger.

ion battery packs [6]. Moreover, high efficiency with highpower density, high reliability, small size, and low cost are thebasic requirements for an onboard charger. All these factorsmake the design of an onboard charger complicated and costly,which has been regarded as one of the barriers that keepsPHEVs from wide acceptance [5].

The size, cost, and mechanical packaging are well discussedfrom a practical aspect in [6] and [7]. A comprehensive topolog-ical survey of the currently available charging solutions has alsobeen presented in [8] and [9]. The most common charger archi-tecture consists of a boost-type ac–dc converter for active powerfactor correction, and an isolated dc–dc converter as the secondstage [6], as shown in Fig. 1. The characteristic of this type ofcharger is mainly dependent on the dc–dc stage since the outputvoltage and current are regulated in this stage [10], [11]. Amongdifferent solutions, an inductor–inductor–capacitor (LLC) res-onant converter becomes the most attractive topology due to itshigh efficiency, low electromagnetic interference (EMI) emis-sions, a wide operation range, and the ability to achieve highpower density [12]. Such features excellently fit the demand ofPHEV and EV charger applications. However, the LLC topol-ogy is difficult to analyze and design because of its multipleresonant components and various operation modes [13].

Many design methodologies have been proposed for this typeof converter in the past decades. Exact analysis of LLC resonantconverters [14] ensures accuracy but cannot be easily used toget a handy design procedure due to the complexity of themodel. The methodologies based on first harmonic approxima-tion (FHA) analysis [15], [16] are much simpler to handle. TheFHA approach gives acceptable accurate results for operatingpoints at and above the resonance frequency of the resonanttank [17]. Therefore, it has been widely used in constant outputvoltage applications where the LLC converter is designed toresonate at nominal condition. Designing a wide-output-rangeLLC resonant converter based on FHA is investigated in [18],and the expanded range is mainly designed in frequencies abovethe resonant frequency. However, zero-current switching (ZCS)for output rectifier diodes is lost in this region, which causes

0018-9545 © 2013 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.

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1582 IEEE TRANSACTIONS ON VEHICULAR TECHNOLOGY, VOL. 63, NO. 4, MAY 2014

Fig. 2. Relationship between battery OCV and SOC for a single lithium-ionbattery cell.

additional diode reverse recovery losses compared with theregion below resonance [19]. The FHA is still valid but lessaccurate in the below-resonance region; therefore, it is usefulfor qualitative analysis but not for optimal design procedure.Optimal design methods are developed based on the operationmode analysis in [20] and [21]. These approaches can givequite good design results but call for utilizing sophisticatedcalculation tools. A simple yet accurate design-oriented modeland a step-by-step design procedure that ensure most merits ofan LLC converter are presented in [22], but the wide outputvoltage range has not been discussed.

In the previous studies, the load is usually assumed to be aresistor. Taking the characteristics of lead–acid batteries intoaccount, a design procedure and practical design considerationsfor the LLC converter in battery charger applications are pre-sented in [23]. The optimization of burst-mode operation foroccasionally deep discharged lead–acid battery pack has beendiscussed in [24]. However, the characteristic of lithium-ionbattery load and its impact on the design of LLC converterare not well researched. For a high-voltage lithium-ion batterycharger, the design requirements are greatly different and chal-lenging compared with passive load applications and lead–acidbattery applications.

First of all, nonlinear load I–V characteristics exist in thedesign of a resonant converter for battery charger applications.The properties of the resonant converter are nonlinearly af-fected by the load current [25]. For an LLC converter connectedwith a passive load, the output voltage is largely determined bythe load current, whereas for battery load, the output voltage isrelated to the battery state-of-charge (SOC) and the chargingprofile. The nonlinear properties affected by nonlinear loadmake it harder to frame design constraints and objects into thedesign procedure.

Second, the load voltage significantly varies in the wholecharging process. The voltage range of a single cell lead–acidbattery is generally 1.75–2.4 V. By contrast, for a single-celllithium-ion battery (4.2 V/cell), the open-circuit voltage (OCV)increment could be more than 1 V per cell as the SOC reachesthe full level from zero, as shown in Fig. 2 [26]. This meansthat there is nearly a 100-V increment for a battery packageapplied for a 400-V PHEV drive system. As a result, the LLCconverter should be able to handle a widely adjustable regulatedoutput voltage range even when the load current varies. More-over, lithium-ion battery has better weight-to-energy densityratio, which calls for higher power rating requirements for thechargers.

Fig. 3. Charge profile for a single lithium-ion battery cell.

Third, the charge process for a lithium-ion battery usuallycontains two main stages: a constant-current (CC) chargingstage and a constant-voltage (CV) charging stage, as shown inFig. 3. Moreover, a trickle charging stage before the CC stageis necessary for deeply depleted cells [27]. The design require-ments are not the same in the different stages. For the benefitsof saving charging time, in the CC charging stage, a presetmaximum charging current is controlled by the charger whilemonitoring the battery voltage. In the trickle charging stageor the CV charging stage, the charge current is much smallerthan that in the CC stage. Hence, the light-load efficiency andovercharging issues are more critical in this stage.

Based on the given analysis, the design requirements foran LLC-resonant-converter-based PHEV lithium-ion batterycharger are significantly different from those for regular passiveload applications. In this paper, some general design guidelinesfor resistive load are discussed based on the FHA analysisof the LLC converter in Section II. The impacts of batteryload characteristics that relate to the charging profiles on thedesign considerations of LLC converters are investigated inSection III. The design constraints for realizing soft-switchingunder all operating conditions are derived in Section IV. Then,the design procedure is proposed in Section V. Experimentalresults are presented in Section VI, and conclusions are drawnin Section VII.

II. MAIN FEATURES OF LLC RESONATE CONVERTERS

The LLC topology can be implemented as a half-bridge typeor a full-bridge type. The full-bridge type is preferable in PHEVcharger applications due to its high power rating. A typicalschematic of a full-bridge LLC multiresonant dc–dc converteris shown in Fig. 4, where Cr is the resonant capacitor, Lm

is the magnetizing inductor, and Lr is the leakage inductorreflected in the primary side. These reactive components formthe resonant tank. In the switch network shown in Fig. 4, S1

and S4, and S2 and S3 are grouped, respectively. Each group isturned on and off with a 50% duty cycle at frequency fs with180◦ out-of-phase between groups, to generates a symmetricalsquare waveform with amplitude Vin, as shown in Fig. 5. This

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DENG et al.: DESIGN METHODOLOGY OF LLC RESONANT CONVERTERS FOR EV BATTERY CHARGERS 1583

Fig. 4. LLC resonant full-bridge converter.

Fig. 5. AC equivalent circuit of the LLC resonant converter.

voltage is applied to the resonant tank so that energy can betransferred to the load, which is coupled to the resonant tank byan ideal transformer [28].

The ac equivalent circuit of an LLC resonant converter basedon FHA analysis is shown in Fig. 5. In this circuit, Req,ac isequivalent to the load and rectifier stage defined as follows [6],[18], [25], [29]:

Req,ac = n2 8π2

Vout

Iout= n2 8

π2

V 2out

Pout(1)

where n is the transformer turns ratio between the primary sideand the secondary side, and Vout, Iout, and Pout denote theoutput voltage, current, and power, respectively. In addition, theoutput voltage is clamped by the battery and is consideredthe same while the charging is carried out.

The dc voltage gain of LLC converters is obtained based onFHA equivalent circuit analysis [17], i.e.,

M(fn, l, Q) =1√(

1 + l − lf2n

)2

+Q2 ·(fn − 1

fn

)2(2)

with the following parameter definitions:

voltage conversion ratio: M =nVout

Vin

resonance frequency: fr1 =1

2π√LrCr

characteristic impedance: Z0 =

√Lr

Cr

= 2πfr1Lr =1

2πfr1Cr

quality factor: Q =Z0

Req,ac=

π2

8IoutVout

1n2

Z0

=π2

8Pout

(nVout)2Z0

inductance ratio: l =Lr

Lm

normalized frequency: fn =fsfr1

where fs in the last definition denotes the switching frequency.

Fig. 6. DC gain characteristics of the LLC resonant converter based on FHA.

The normalized input impedance of the resonant tank can bederived as follows:

Zn(fn, l, Q) =Zin(fn, l, Q)

Z0

= j

(fnl

l2 + f2nQ

2− 1 − f2

n

fn

)+

f2nQ

l2 + f2nQ

2. (3)

A second resonant frequency corresponds to the conditionsof no load, or the secondary winding(s) being open can befound. It is defined as

fr2 =1

2π√(Lr + Lm)Cr

= fr1

√l

1 + l. (4)

From (2), we can see that the voltage conversion ratio ofan LLC converter is not only related to fs but also related tothe load situation and the inductance ratio. A family of plotsof the voltage gain versus normalized frequency for differentvalues of Q, with l = 0.2 is shown in Fig. 6. It is visiblethat a load-independent operation with unity gain happens atthe resonant frequency fr1, where all the curves are tangent.Step-up operation is available below the resonance frequency,whereas buck mode operates above the resonance frequency.Moreover, a shrinking effect [17] of increasing l values can beobserved by plotting voltage gain curve for different values ofl with Q = 0.7 in Fig. 7, which implies that a higher l valueleads to a higher voltage gain within a smaller frequency rangeat the cost of increasing the circulating current due to smallerinput impedance.

Soft-switching is the most desirable advantage of a resonantconverter due to its capability to reduce switching loss andEMI. The LLC topology possesses the soft-switching featureas the ZVS for input inverting choppers and the ZCS for outputrectifiers [30], which minimizes the switching losses of theMOSFET-based inverter. However, FHA provides only a nec-essary condition for ZVS operation of the primary switches butdoes not guarantee the secondary rectifiers to work in ZCS [17].For the primary side, ZVS occurs when the input impedanceof the resonant tank is inductive, whereas ZCS occurs when

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1584 IEEE TRANSACTIONS ON VEHICULAR TECHNOLOGY, VOL. 63, NO. 4, MAY 2014

Fig. 7. Shrinking effect of increasing the inductance ratio.

the input impedance is capacitive. From (3), we can tell thatthe imaginary part of the normalized impedance Zn is alwayspositive when fn ≥ 1, which promised inductive mode abovethe resonance. For fn < 1, the borderline condition betweencapacitive and inductive mode can be found by imposing thatthe imaginary part of (3) is zero [17]. The analytical results arethe following:

fnZ(l, Q) =

√√√√Q2 − l(1 + l) +√

[Q2 − l(1 + l)]2 + 4Q2l2

2Q2

(5)

QZ(fn, l) =

√l

1 − f2n

−(

l

fn

)2

(6)

where the normalized frequency should be limited by√l/(1 + l) < fn < 1 for (6) to be true.By substituting (6) into (2), the critical voltage gain available

in the ZVS condition can be expressed by

MZ(fn, l) =fn√

f2n(1 + l)− l

. (7)

Moreover, by letting Q = 0, the no-load voltage gain can beobtained as follows:

MNL(fn, l) =1∣∣∣1 + l − l

f2n

∣∣∣ . (8)

According to (7) and (8), the boundary between capacitiveand inductive mode in the region between the two resonantfrequencies (below-resonance operating region) and the no-load gain are both shown in Fig. 6 with l = 0. 2.

Achieving the primary-side ZVS operation from full load tozero load is the most important target in selecting the resonanttank circuit parameters. To attain this purpose, some generaldesign guidelines for different types of applications can beconcluded based on the earlier analysis. For constant outputvoltage with various load applications, there is no better choice

Fig. 8. Charging profile of a 410-V lithium-ion battery pack.

than designing the converter to operate at resonant frequencywhen the input is at nominal value since this load-independentpoint occurs in the ZVS region. As for widely adjustable outputwith variable resistive load, there are two design choices. First,the maximum output voltage with full-load occurs in region 2(below resonance region), as shown in Fig. 6. This is thepreferable operation mode of an LLC converter according tooperation mode analysis [19], [21], [31] because primary ZVSand secondary ZCS operations can be realized at the same timeas long as the operation point does not go across the borderlineof capacitive mode and inductive mode in Fig. 6. However, itis also harder to obtain an optimum design because the FHAmodel is not very accurate in this region, and no closed-formsolution can be found in the exact model. Second, the full-load operation occurs in region 1 (above resonance region)while the boost capability of the resonant tank is left to handlethe minimum input during mains dips. This mode is easier tohandle since the input impedance is always inductive, and theerrors caused by the FHA approach are minor in this region[32]. However, the ZCS operation of the secondary rectifieronly appears in light-load conditions [14], [19].

Moreover, no matter which mode has been targeted, thecommon issue for optimization is achieving required voltagegain in the worst-case scenario while minimizing the circulatingreactive energy, which is a necessary condition to ensure soft-switching operation and to reduce conduction losses.

Applications adopting the aforementioned LLC topologyhave been discussed in a number of publications and applicationnotes in the industry. However, these analyses do not coverwide-adjustable-range output voltage with lithium-ion batteryload applications; therefore, the impacts of the charging profileon design considerations need to be investigated.

III. IMPACTS OF BATTERY LOAD PROPERTY ON THE

DESIGN CONSIDERATIONS OF LLC CONVERTERS

As in Section I, the charge rate of a lithium-ion batterycharger should be controlled according to the charging profileand the battery condition. A typical charging profile of a400-V battery pack is shown in Fig. 8. Similar to Fig. 3, atrickle charge stage with a CC of 0.1 C.1 I0 is performed when

1C-rate is referred to the charge rate of a battery in terms of its rated capacity.For example, if a battery is rated at 20 Ah, 1 C means the battery is charged ata current of 20 A, and 0.1 C means charging the battery at 2 A.

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DENG et al.: DESIGN METHODOLOGY OF LLC RESONANT CONVERTERS FOR EV BATTERY CHARGERS 1585

the battery is deeply depleted. A bulk charge follows after thevoltage has risen above the trickle charge threshold. A full-rate charge may not be able to be maintained during the wholebulk-charge stage due to limitations of the maximum outputpower of the charger. Moreover, the charging actions maybe modified as a response to the battery condition variation.Therefore, different CC (in the range of 0.2–1 C) charge stagesmay exist in the bulk-charge stage [33]. After the CC chargeends, the CV stage begins when the battery voltage reachesa certain value. Furthermore, all the preset charging currents(I0, I1, I2) and threshold voltages (U0, U1, U2) should be ableto be modified by users to match different battery packages.Therefore, it is particularly important for an LLC-converter-based lithium-ion battery charger to realize current or voltageregulation in any point of the highlighted area marked as “work-ing region” in Fig. 6 as the operating conditions and load varywidely [24].

From a designer’s point of view, the key is to incorporatethe design constraints related to achieving soft-switching un-der all operating conditions and zero-load operation capabil-ity. Therefore, the worst-case scenario in different operationmodes with a battery load should be identified to get theconstraints.

A. Full-Load Operation in Boost Mode (M > 1)

It is intuitive that, for a resistive load in the boost mode,the worst-case scenario occurs when the output voltage isregulated at its maximum value, and the input voltage dropsto its minimum under a full-load condition. However, for thecharger applications, the load characteristic varies nonlinearlyduring the whole charge process depending on the chargingprofile. It is not so easy to identify the worst-case operationpoint.

Unlike a resistive load, the quality factor Q and the requiredconversion gain M are coupled according to the chargingprofile. For example, as shown in Fig. 8, the output power of thecharger hits the limitation twice during the bulk-charge stage. Itis hard to see directly which operation point is closer to theedge of the inductive region because Q and M vary in reversedirection and affect the characteristic inversely.

On the other hand, all kinds of charging profiles are neededfor different battery packs, but all the profiles should be com-promised with the maximum output power of the converter.Therefore, maintaining the maximum power output during thewhole charge process at minimal input voltage is reasonable tobe seen as the overall heaviest load for the charger, althoughit may not be practical due to safety and cycle life consid-eration [34].

In short, the target is to distinguish the worst-case scenariofor achieving soft-switching from the constant maximum power(CMP) charging profile. Under the circumstances, the qualityfactor and the required conversion gain are related by thefollowing equation, which can be obtained according to thedefinition of these two parameters in Section II:

QCMP(Z0,M) =π2

8Pout,max

(MVin,min)2Z0. (9)

Fig. 9. Operation trajectories of CMP charge and ZVS boundaries for differ-ent Z0 and l values.

On the other hand, the maximum quality factor QZ,max

that allows the required voltage gain at the boundary betweencapacitive and inductive modes can be obtained by solving forfn in (7) and then substituting into (6), resulting into

QZ,max(l,M) =l

M

√1l+

M2

M2 − 1. (10)

The variation of the quality factor during the constant powercharge is implied in (9), whereas the limitation for achievingprimary-side ZVS is indicated in (10). It is clear that the operat-ing trajectory mainly depends on the characteristic impedanceZ0, and the ZVS boundary relies on the inductance ratio l. Afew operating trajectories (solid line) and boundaries (dash line)are shown by the swap voltage gain and the quality factor fordifferent values of Z0 and l in Fig. 9.

A lifting effect of increasing the l value can be observed inboundary curves, which means a higher inductance ratio bringshigher capability for the same required voltage gain. The pricefor higher capability is a higher circulating current in the reso-nant tank because of relatively smaller magnetizing inductance.The lifting effect is consistent with the shrinking effect, as pre-viously mentioned in Section II, because it is actually the samephenomenon presented from different views. In addition, thevertical asymptote of QZ,max is M = 1, which again illustratesthat the unity gain is the load-independent point.

On the other hand, the operating trajectories are pushed to-ward the boundaries by increasing the characteristic impedanceZ0. The motivation is to reduce the circulating current.

Thus, the intent to reduce the circulating reactive energy forminimizing the conduction losses during the optimal designprocedure will eventually make the operating trajectory to touchthe boundary at a certain point, and this touching point isactually the worst-case operation point in boost mode that weare trying to identify. This condition can be mathematicallydescribed by{

QZ,max(l,M)−QCMP(Z0,M) = 0∂(QZ,max(l,M)−QCMP(Z0,M))

∂M = 0.(11)

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1586 IEEE TRANSACTIONS ON VEHICULAR TECHNOLOGY, VOL. 63, NO. 4, MAY 2014

Substituting (9) and (10) into (11), we have⎧⎪⎪⎪⎨⎪⎪⎪⎩

lM

√1l +

M2

M2−1 − π2

8Z0

M2

Pout,max

V 2in,min

= 0

−l

√1l +

M2

M2−1

M2 + 12

l

(2M

M2−1− 2M3

(M2−1)2

)M

√1l +

M2

M2−1

+ 14π2Z0Pout,max

M3V 2in,min

=0.

(12)

The analytical results can be found as follows:⎧⎪⎨⎪⎩

Mcrit =

√1 +

√l

1+l

Z0,max = 8π2

V 2in,min

Pout,max

(√l(1 + l) + l

).

(13)

The results indicate that, during the CMP charging process,the LLC resonant converter is running at the boundary ofcapacitive and inductive modes (the critical operating point)when the characteristic impedance is designed to be the allowedmaximal value Z0,max and the required voltage gain equals thecritical value Mcrit. Both Z0,max and Mcrit are related to designparameter l.

In conclusion, the worst case for primary-side ZVS operationin boost mode is found using charging profile specificationsand FHA-based analysis of boundaries between capacitive andinductive modes. Many traditional design procedures can beused by seeing the worst-case operation point found here as thefull-load operation point.

B. Zero-Load Operation in Buck Mode (M < 1)

Zero-load operation occurs when the voltage developedacross Lm and reflected to the secondary side is lower than thebattery voltage so that the output rectifiers cannot be conductedover an entire switching cycle. There is no difference from aninfinite resistive load since the battery has been cut off from theresonant tank circuit. The design issues related to this mode arepresented in the following.

IV. DESIGN CONSTRAINTS

The most important object in designing the LLC converter isto achieve soft-switching operation in the whole working range.To attain this purpose, design constraints in different modes arediscussed respectively.

A. Zero-Load ZVS Operation Capability in Buck Mode

The worst-case scenario for ZVS operation in buck mode oc-curs when the output voltage is regulated at its minimum value,and the maximum input voltage is applied to the converterunder the no-load condition [35]. In this case, the switchingfrequency is adjusted to its maximum value to step down the in-put voltage. The zero-load operation, regarded as cutoff mode,has been discussed in [14]. The normalized cutoff frequency atminimum conversion gain can be expressed as

fnco =π

2

√l

1 + l

1

cos−1[

1Mmin(1+l)

] (14)

with the minimum voltage conversion defined as

Mmin =nVout,min

Vin,max(15)

and the normalized cutoff frequency defined as

fnco =fcofr1

. (16)

Mathematically, a necessary condition for the cutoff fre-quency to exist is

Mmin ≥ 11 + l

. (17)

Moreover, (14) can be rewritten as

1Mmin (1 + l)

= cos

2

√l

1 + l

1fnco

). (18)

Expanding the cosine function in MacLaurin series tothe second order and assigning value for fnco = fnmax =(fsmax/fr1), the resulting equation can be solved for l [22] is

l =

(1

Mmin− 1

)8f2

nmax

8f2nmax − π2

. (19)

To be noted, the junction capacitance of the rectifier diodehas not been taken into account in the given analysis. Therefore,the maximum switching frequency should be limited to 1.5–2.5times the resonant frequency to avoid the effect of this parasiticparameter at a higher frequency range [6], [36].

The peak value of the tank current in cutoff mode is alsoprovided [14] as follows:

Imco =Vin,max

2πfr1Lm0

√(1 +

1l

)M2

min − 1l (1 + l)

. (20)

In order to guarantee ZVS in this mode, the current Imco mustbe large enough to discharge the MOSFETs junction capacitorswithin the dead time, which can be represented by [12]

Imco ≥ 4CossVin,max

td(21)

where Vin,max is the maximum input voltage, Coss is theMOSFET junction capacitance, and td is the dead time.

Substituting (20) into (21) and solving for Lm0 yields

Lm0 ≤ td8πfr1Coss

√(1 +

1l

)M2

min − 1l (1 + l)

. (22)

B. Full-Load ZVS Operation Capability in Boost Mode

The worst-case operating point has been recognized fromthe CMP charging profile in Section III. The full-load ZVSoperation can be promised globally in the boost mode as longas the worst case is designed properly.

As previously mentioned, there is a preferable operationmode featured with primary ZVS and secondary ZCS capabilityin the boost-mode operation, which is referred to as DCMB2

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DENG et al.: DESIGN METHODOLOGY OF LLC RESONANT CONVERTERS FOR EV BATTERY CHARGERS 1587

Fig. 10. Simulation waveforms of the LLC resonant full bridge operated inDCMB2 mode.

mode in [14] and [21] or PO mode in [19]. However, thismode is complicated by nonlinear equation solving. To avoidthe complexity, a special operating point characterized by anearly flat tank current during the interval of multiresonancein this mode is targeted [22]. The simulation waveforms of thisoperating point are shown in Fig. 10.

As shown in Fig. 10, in the interval (TZ , Ts/2), when themagnetizing inductor joins the resonance, the tank current looksflat. Therefore, it is reasonable to assume

iLr(TZ) = iLm(TZ) = Im = iLr(Ts/2) = iLm(Ts/2) = Is.(23)

This equality holds true if the peak of the multiresonant cur-rent occurs exactly at the midpoint Tx of the interval (TZ , Ts/2)[22], i.e.,

Tx =12

(TZ +

Ts

2

). (24)

Moreover, for this to occur, the voltage across the resonantcapacitor at this moment must equal the minimal input voltagefor the worst case, i.e.,

VCr(Tx) = Vin,min. (25)

Based on assumption (23) and the symmetry of tank current,we have

−iLr(0) = iLr(Ts/2) = iLr(TZ) = Is. (26)

Because during the interval (0, TZ), the converter actuallyworks as a series resonant converter, and the tank current isexpressed by a sine function with series resonant period Tr1.Therefore, (26) implies

TZ =12Tr1 =

12fr1

. (27)

With all the given characteristics, a required magnetizinginductance TZ = (1/2)Tr1 = (1/2fr1) may be found and ex-

pressed by other design parameters and the critical operatingconditions (see Appendix)

Lm =n2

fr1

Vout,crit

4nIin,crit + (π2lMcrit − 4)Iout,crit. (28)

According to the discussion above, the maximum value ofmagnetizing inductance is limited by inequality (22) to guaran-tee no-load ZVS operation in buck mode, while (28) providesthe value of the magnetizing inductor that makes the converteroperate in the desired DCMB2 boost mode and ensures theworst-case full-load ZVS operation capability. Therefore, if thevalue resulting form (28) fulfills (22), soft-switching is ensuredthroughout the whole operating range [22].

V. DESIGN PROCEDURE

The proposed design procedure for the PHEV battery chargerapplication based on the analysis presented earlier can beoutlined in eight steps, starting from the design specificationdetailed in Table I.

Step 1) Select transformer turns ratio n. The minimal trans-former turns ratio should be selected at unity gainwhen the input voltage and the output voltage areboth at a minimum value, i.e.,

n =Vin,min

Vout,min. (29)

In this case, the converter operates at a load-independent point that ensures full-load operationcapability at minimal input voltage. The step-downoperation can be implemented to regulate the outputwhen the input is back to the nominal level or goesto the maximum. The step-up mode is targeted whenthe output voltage rises.

Step 2) To make sure the output is always under regulation,the minimum dc voltage gain Mmin should be cal-culated by using (15).

Step 3) Calculate inductance ratio l by (19). The resultsfrom Steps 2 and 3 ensure that the converter entersthe cutoff mode at minimum output and maximuminput when the switching frequency is regulated tothe maximum value.

Step 4) Use (13) to calculate the worst-case conversion gainMcrit and the maximum characteristic impedanceZ0,max. Then, calculate the other critical operatingcondition

Iout,crit =Pout,max

Vout,crit=

Pout,max

McritVin,min/n(30)

Iin,crit =Pout,max

ηVin,min. (31)

Step 5) Calculate the magnetizing inductance Lm requiredfor operating in DCMB2 mode at a critical pointusing (28).

Step 6) Check that the value of Lm fulfills the no-loadZVS condition (22). If not, try either reducing the

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1588 IEEE TRANSACTIONS ON VEHICULAR TECHNOLOGY, VOL. 63, NO. 4, MAY 2014

TABLE IDESIGN SPECIFICATION FOR THE LLC RESONANT CONVERTER

maximum operating frequency fsmax or increasingresonant frequency fr1 or else increasing dead timetd and go back to Step 2. In addition, adjust one ormore of the above parameters also if Lm is muchlower than the minimum needed for ZVS [22].

Step 7) Calculate the value of resonant capacitor Cr andresonant inductance Lr by (17A) and (18A). Then,check that the value of Z0 is smaller than the allowedmaximum value of Z0,max. If not, try either reducingthe maximum operating frequency fsmax or increas-ing resonant frequency fr1 slightly and go back toStep 2.

Step 8) Calculating the minimum operating frequencyfsmin. The switching current at maximum conver-sion gain Is,max can be obtained by assigning valuefor Vout = Vout,max in (20A). The other maximumoutput voltage operating conditions can be calcu-lated according to (30) and (31). Finally, the mini-mum operating frequency can be calculated by (8A).

VI. EXPERIMENTAL RESULTS

A prototype of the full-bridge LLC resonant converter hasbeen built to verify the theoretical analysis, which is based onthe specification given in Table I. The key parameters resultingfrom the proposed design procedure are given in Table II, wherethe actual measured values are also shown. It is noted that themagnetic integration is adopted to make the system more com-pact [28]. The primary and secondary windings are distributedin two asymmetrical separate slots of the core bobbin to formthe relatively large leakage inductance. The circuit componentsused in the prototype converter are provided in Table III.

To verify the whole range ZVS capability, the FHA-basedcharacteristic of the designed LLC tank has been plotted versusnormalized frequency fn and quality factor Q in Fig. 11.The borderline between the capacitive mode and the inductivemode, and the CMP charging profile are also shown in Fig. 11.As shown in this figure, the CMP operating trajectory keeps areasonable safe distance from the ZVS/ZCS boundary, whichconfirms the soft-switching operation for the whole operationrange.

The performance of the CMP charge is tested. An electronicload is used to simulate the load characteristics of the lithium-

TABLE IIRESONANT TANK PARAMETER DESIGN RESULTS

TABLE IIICOMPONENTS USED IN THE PROTOTYPE CONVERTER

Fig. 11. Verification of a design result by FHA analysis.

ion battery pack in the experiments. Experimental waveformsof the voltage across resonant tank vAB , voltage across resonantcapacitor vCr, resonant tank current iLr, and magnetizingcurrent iLm are shown in Fig. 12 at Vin = 390 V and Pout =Pout,max = 3.3 kW. In this figure, the capability for primary-side ZVS turn-on is noted since the resonant tank current lags

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DENG et al.: DESIGN METHODOLOGY OF LLC RESONANT CONVERTERS FOR EV BATTERY CHARGERS 1589

Fig. 12. Experimental waveforms. (a) CMP charge at Vout = 300 V, Iout = 11 A, and fs = 118.6 kHz. (b) CMP charge at Vout = 410 V, Iout = 8 A, andfs = 86 kHz. (c) CMP charge at Vout = 450 V, Iout = 7.3 A, and fs = 81.69 kHz.

Fig. 13. Measured efficiency versus output voltage at Po = 3.3 kW andVin = 390 V.

the voltage across the resonant tank. It is also proven thatthe desired DCMB2 mode operation is ensured for a wideoutput range because the features of these waveforms match thedesired features discussed in Section IV. The efficiency of theconverter as a function of output voltage for the CMP chargeis shown in Fig. 13. It is observed that the efficiency increaseswith the output voltage and achieves 98.2% at Vout = 450 V. Inaddition, the charging profile shown in Fig. 8 is implemented inthe prototype. The efficiency curve of the bulk-charge stage isprovided in Fig. 14. It is shown that the efficiency is higher than98% during the whole bulk-charge stage. Finally, the efficiencycurves of the CV charge stage at outputs of 250 and 410 Vare given in Figs. 15 and 16, respectively. The conversionperformance at light load condition can be evaluated accordingto these two curves. It can be seen that the efficiency is mostlyabove 95.5% during the CV charge stage. The light load effi-ciency is about 90.5% when the charge current drops to 0.1 C.

VII. CONCLUSION

This paper analyzed the wide-adjustable-range LLC resonantconverter applied in lithium-ion battery charger systems andproposed a step-by-step design methodology. The differentdesign requirements for resistive load and battery load areinvestigated based on the FHA approach. Considering thecharging profiles, the worst-case scenarios for the primary-side ZVS operation under full-load and no-load conditions areidentified, respectively. Then, the design constraints for achiev-ing soft-switching operation under all working conditions are

Fig. 14. Measured efficiency versus output voltage of multiple CC chargestage. CC1 stage: Io = 10 A and Vo = 300 ∼ 330 V. CC2 stage: Io = 8 Aand Vo = 330 ∼ 410 V.

Fig. 15. Measured efficiency versus output current at Vo = 250 V and Vin =390 V.

Fig. 16. Measured efficiency versus output current at Vo = 410 V and Vin =390 V.

analytically derived based on specific operating mode analysis.Finally, all the discussion has led to the design procedure thatensures soft-switching under all operating conditions, and the

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1590 IEEE TRANSACTIONS ON VEHICULAR TECHNOLOGY, VOL. 63, NO. 4, MAY 2014

preferable boost operation mode under full load conditions.A 3.3-kW 400-V-input 250–450-V-output LLC converter isbuilt using the proposed method, which achieves 98.2% peakefficiency.

APPENDIX

MODEL ANALYSIS OF DCMB2 OPERATION IN

BOOST-MODE OPERATION

In a half switching period, the operation model of the LLCconverter presented in Section IV-B can be approximatelydescribed by the following equations.

The resonant tank current is{iLr(t) =

Issin θ1

sin(2πfr1t− θ1), 0 ≤ t ≤ Tr1

2

iLr(t) = Is,Tr1

2 ≤ t ≤ Ts

2 .(1A)

The magnetizing current is{iLm(t) = Is(4fr1t− 1), 0 ≤ t ≤ Tr1

2

iLm(t) = Is,Tr1

2 ≤ t ≤ Ts

2 .(2A)

The voltage across the resonant capacitor is⎧⎪⎨⎪⎩

vCr(t) = vCr(0) + 1Cr

t∫0

iLr(t)dt, 0 ≤ t ≤ Tr1

2

vCr(t) = vCr

(Tr1

2

)+ Is

Cr

(t− Tr1

2

), Tr1

2 ≤ t ≤ Ts

2 .(3A)

The secondary current, flowing through rectifier D1 is

iD1(t) = n [iLr(t)− iLm(t)] . (4A)

It is now necessary to relate the unknown quantities in (1A),(2A), θ1, Is, and fs to the operating conditions Vin,min, Iin, andIout.

The converter’s dc output current is

Iout =2Ts

Tr1/2∫0

iD1(t)dt. (5A)

Substituting (4A) in (5A), taking (1A) and (2A) into consid-eration and developing the integral, we have

Iout =2nIs

π tan θ1

Tr1

Ts. (6A)

The converter’s dc input current is expressed as

Iin =2Ts

Ts/2∫0

iLr(t)dt = Is

[(2

π tan θ1− 1

)Tr1

Ts+ 1

].

(7A)

The simultaneous solution of (6A) and (7A) provides

fs =

(1 − nIin − Iout

nIs

)fr1 (8A)

tan θ1 =2π

(1 − n

Iin − IsIout

). (9A)

The value of vCr(Ts/2) is given by

vCr

(Ts

2

)= vCr(0) +

1Cr

Ts/2∫0

iLr(t)dt = vCr(0) +IinTs

2Cr.

(10A)

By symmetry, we have

vCr

(Ts

2

)= −vCr(0). (11A)

Substituting (11A) in (10A), we find

vCr(0) = −TsIin4Cr

. (12A)

By substituting (12A) in (3A), it is possible to find

vCr

(Tr1

2

)=

IsCr

(Tr1

2π tan θ1+

Tr1 − Ts

4

). (13A)

Considering (27), (24) can be rewritten

Tx =14(Tr1 + Ts). (14A)

By combining (3A), (13A), and (14A), the expression ofvCr(Tx) becomes

vCr(Tx) =IsCr

Tr1

2π tan θ1. (15A)

Substituting (25) and (9A) in (15A) and solving for Is

Is =4CrVin,min(Iout − nIin)

Tr1Iout − 4nCrVin,min. (16A)

From the definition of inductance ratio and resonant fre-quency, we have

Lr = lLm (17A)

Cr =1

Lr(2πfr1)2=

1lLm(2πfr1)2

. (18A)

By substituting (18A) into (16A), Is can be rewritten as

Is =Vin,min(Iout − nIin)

π2lLmfr1Iout − nVin,min. (19A)

Note that, in the interval (0, TZ), when the secondary rec-tifiers are conducting, the magnetizing inductor is clamped bythe output voltage; therefore, the switching current Is can bealso expressed by

Is = Im =nVout

4Lmfr1. (20A)

Finally, solving for Lm from (19A) and (20A) and introduc-ing the critical voltage gain discussed in Section III, a constraintmay be found on the magnetizing inductance for the converteroperating in this targeted mode

Lm =n2

fr1

Vout,crit

4nIin,crit + (π2lMcrit − 4)Iout,crit. (21A)

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Junjun Deng (S’13) received the B.S. and M.S.degrees in electrical engineering from Northwest-ern Polytechnical University, Xi’an, China, in 2008and 2011, respectively. He is currently working to-ward the Ph.D. degree in electrical engineering withNorthwestern Polytechnical University and with theUniversity of Michigan, Dearborn, MI, USA (sup-ported by the China Scholarship Council), where heis involved in the modeling and design of ac/dc anddc/dc converters.

His research interests include resonant power con-version and high-performance battery chargers for electric vehicles.

Siqi Li received the B.S. and Ph.D. degrees in elec-trical engineering from Tsinghua University, Beijing,China, in 2004 and 2010, respectively.

He is currently a Postdoctoral Fellow with theUniversity of Michigan, Dearborn, MI, USA. His re-search interests include battery management systemsand high-performance contact and wireless batterychargers for electric vehicles.

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1592 IEEE TRANSACTIONS ON VEHICULAR TECHNOLOGY, VOL. 63, NO. 4, MAY 2014

Sideng Hu received the Ph.D. degree from TsinghuaUniversity, Beijing, China in 2011.

From August 2011 to August 2013, he was a Post-doctoral Researcher with the University of Michi-gan, Dearborn, MI, USA. Since September 2013,he has been with the College of Electrical En-gineering, Zhejiang University, Hangzhou, China.His research interests include high-frequency dc/dcconverters, soft-switching techniques, and vehicleelectrification.

Chunting Chris Mi (S’00–A’01–M’01–SM’03–F’12) received the B.S. and M.S. degrees fromNorthwestern Polytechnical University, Xi’an,China, and the Ph.D. degree from the Universityof Toronto, Toronto, ON, Canada, all in electricalengineering.

Previously, he was an Electrical Engineer withGeneral Electric Canada, Inc. He is currently a Pro-fessor of electrical and computer engineering and theDirector of the newly established Department of En-ergy GATE Center for Electric Drive Transportation,

University of Michigan, Dearborn, MI, USA. He is the author of more than 100articles. His research interests include electric drives, power electronics, electricmachines, renewable-energy systems, and electrical and hybrid vehicles.

Dr. Mi was the Vice Chair and the Chair of the IEEE Southeastern MichiganSection from 2006 to 2007 and from 2008 to 2009, respectively. He was theGeneral Chair of the Fifth IEEE Vehicle Power and Propulsion Conferenceheld in Dearborn on September 6–11, 2009. He was a Guest Editor for theInternational Journal of Power Electronics and an Associate Editor for theJournal of Circuits, Systems, and Computers from 2007 to 2009. He has beenan Associate Editor for the IEEE TRANSACTIONS ON VEHICULAR TECHNOL-OGY, the IEEE TRANSACTIONS ON POWER ELECTRONICS LETTERS, andthe IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, and a Senior Editorfor IEEE Vehicular Technology Magazine. He serves on the Editorial Board ofthe International Journal of Electric and Hybrid Vehicles and the Institution ofEngineering and Technology Electrical Systems in Transportation. He receivedthe Distinguished Teaching Award and the Distinguished Research Award fromthe University of Michigan, Dearborn; the 2007 IEEE Region 4 Outstand-ing Engineer Award; the IEEE Southeastern Michigan Section OutstandingProfessional Award; and the Society of Automotive Engineers EnvironmentalExcellence in Transportation Award.

Ruiqing Ma (M’05) received the B.S. and M.S. de-grees in electrical engineering and the Ph.D. degreefrom Northwestern Polytechnical University, Xi’an,China, in 1985, 1988, and 2007, respectively.

He is currently a Professor of electrical engineer-ing and an Associate Director of the Institute ofREPM Electrical Machines and Control Technology,Northwestern Polytechnical University. Since 1993,he has been teaching and conducting research onelectric machines and power converters with North-western Polytechnical University. His research in-

terests include rare-earth permanent-magnet electric machines drives, powerconverters, and renewable energy systems.