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Performance improvement of front-end PFC controller with small DC-link capacitance for light EV charger applications

Author

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  • Israr, Majhrul
  • Samuel, Paulson

Abstract

PFC converters in EV chargers produce DLF (double line frequency) ripple voltage due to mismatch between input and output power, requiring large DC-link capacitors. A small DC-link capacitance results in increased voltage ripple, adversely affecting supply power quality and introducing DLF ripple at secondary stage output. In traditional ACM methods, enhancing source power quality with small DC-link capacitance involves low-pass filters (LPF). Nonetheless, LPF in voltage loop has a limited bandwidth problem, which results in degraded dynamic response and compromised stability margins. This article proposes cascaded control strategy that integrates voltage PIR controller and model predictive current control (MPCC) to improve power quality in single-phase PFC converters. This approach utilizes supply voltage and output current, using power balancing equations, to produce high-quality reference current, effectively addressing the constraints of low-bandwidth voltage loops and enhancing dynamic performance. The outer voltage PIR controller effectively suppresses DLF ripples and reduces distortion in the reference signal. Simultaneously, MPCC ensures precise reference tracking and reduces zero-crossing distortion (ZCD) through cost-function minimization and improved power quality. The proposed controller effectiveness has been validated through comprehensive MATLAB simulations and supported by hardware testing on a 500W Boost PFC converter prototype using a dSPACE DS 1104 digital controller.

Suggested Citation

  • Israr, Majhrul & Samuel, Paulson, 2025. "Performance improvement of front-end PFC controller with small DC-link capacitance for light EV charger applications," Energy, Elsevier, vol. 324(C).
    • Handle: RePEc:eee:energy:v:324:y:2025:i:c:s0360544225015725
    DOI: 10.1016/j.energy.2025.135930
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