AC-DC on a battery board

he project focuses on developing a modular AC-DC onboard battery charger designed for 120Vac input, supporting 400Vdc and 48Vdc batteries.

Our project focuses on designing an AC-DC onboard battery charger for applications such as electric vehicles and portable electronics. The charger supports input power from a 120Vac source and outputs to 400Vdc and 48Vdc batteries. This system uses a bidirectional topology designed for plug-in electric vehicles (PEVs), which allows power flow in both directions when needed.

The input power from the grid is first stabilized using an AC filter to reduce fluctuations. It is then converted to DC using an AC-DC converter. The DC voltage is further stepped down or boosted using a DC-DC converter, specifically a Class C chopper, which operates in both buck and boost modes.

To handle high power and medium frequencies efficiently, we chose Insulated Gate Bipolar Transistors (IGBTs). These components ensure reliability and performance in the system. To address thermal challenges, we performed thermal modeling and introduced heat sinks as cooling mechanisms.

We also analyzed the components, developed circuit diagrams, and designed waveforms to validate the system. The result is a robust, modular charger capable of efficiently meeting the energy demands of modern applications while maintaining stability and durability.