Analysis and design of synchronous-rectified LLC DC–DC converter for LDC of electric vehicles

In electric vehicles (EVs), the low voltage dc-dc converter (LDC) with synchronous rectifier switches (SRs) can be used to reduce conduction loss caused by the high load current and improve the efficiency. Therefore, it is important to design a proper turn-on time of SRs. As a popular driving strategy for the SRs, the drain–source voltage across the SRs is sensed to generate the gate driving signal. However, when LLC dc–dc converter operates at O mode, there will be a voltage ringing across the SRs. If the ringing voltage reaches to the threshold voltage −V_th,on, it would make SRs turn-on early and results in abnormally working of the converter. The novelty and contribution of this paper lie in: (1) elaborating on the voltage ringing across the SRs, (2) the accurate ringing model is established during O mode, and (3) a simple, lossless, and low-cost filter circuit is used to solve the negative effect of the ringing voltage for LLC converter at high load current. A 1.26 kW experimental prototype with ≈250–430 V wide input voltage and ≈9–16 V wide output voltage is implemented, 96.7% peak efficiency and 96% full load efficiency are achieved with a 3.12 kW/L power density. The theoretical analysis has been validated by the simulated and experimental results, and the SR LLC dc–dc converter with the SR works efficiently and reliably with the proposed solution at a high load current.