Design of electromagnetic components for EV battery chargers

This study focuses on the appropriate design of the inductive elements of the LLC converter based on a typical industrial approach, i.e. assuming to use standard parts available on the market from qualified manufacturers. At first, a methodology to select the passive components is presented, highlighting the difference between the external inductor solution and the magnetically integrated solution. Secondly the step-by-step procedure used for the design of the high frequency transformer is illustrated. The possibility to integrate the resonant inductors into the HF transformer is then analysed, presenting different solutions. Finally a comparison between a classical and an integrated design is then presented referring to a case study; thus permitting to endow the potential benefits of the integrated solution.