Novel Single-Stage Flying Capacitor DC Charging Module

doi:10.16628/j.cnki.2095-8188.2025.10.009

Abstract

Abstract:

Abandoning the DC bus design in the traditional two-stage charging architecture, a novel single-stage flying capacitor DC charging module scheme is proposed.The flying capacitor is used to achieve AC/DC power decoupling and construct a pulsating three-level topology to replace the traditional two-stage structure.The main power conversion and active pulsating power buffering(PBB)functions are integrated into the isolated DC/DC converter—dual-active bridge(DAB)converter, which not only provides isolation between the input and output sides but also effectively reduces voltage stress.Finally, a 1 kW prototype is constructed to validate the theoretical analysis and the feasibility of the design.A simplified topology solution for new energy charging stations is offered, and a reference for the innovative single-stage topologies is provided.

Key words: single-stage, DC charging module, flying capacity, pulsating three-level, active pulsating power buffering(PBB)

CLC Number:

TM46

YANG Qixin, MAO Xingkui. Novel Single-Stage Flying Capacitor DC Charging Module[J]. LOW VOLTAGE APPARATUS, 2025, 0(10): 61-71.

Figures/Tables 21

References 19

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工作模态	S1/S4	S2/S3	S5/S6	Q1/Q2	u_L	电流变化斜率
模态1	S4	S2	S6	Q1	U_c+U_out	k₁
模态2	S4	S3	S6	Q1	U_out	k₂
模态3	S4	S3	S6	Q2	-U_out	k₃
模态4	S1	S3	S6	Q2	U_in-U_c-U_out	k₄
模态5	S1	S3	S5	Q2	-U_c-U_out	-k₁
模态6	S1	S2	S5	Q2	-U_out	-k₂
模态7	S1	S2	S5	Q1	U_out	-k₃
模态8	S4	S2	S5	Q1	U_c-U_in+U_out	-k₄

参数	数值
输入电压有效值/V AC	220/50 Hz
输出直流电压/V	400
输出电流/A	2.5
额定功率/kW	1
开关频率f_s/kHz	50

工作模态	S1	S4	S2	S3
模态1	U_in-U_c	0	0	U_c
模态2	U_in-U_c	0	U_c	0
模态3	U_in-U_c	0	U_c	0
模态4	0	U_in-U_c	U_c	0
模态5	0	U_in-U_c	U_c	0
模态6	0	U_in-U_c	0	U_c
模态7	0	U_in-U_c	0	U_c
模态8	U_in-U_c	0	0	U_c
最大电压	S1/S4-上管	S1/S4-下管	U_A	U_A
最大电压	U_B+	U_B-	U_A	U_A

参数	数值和型号
输入电压有效值/V AC	220(50 Hz)
输出直流电压/V	400
满载输出功率/kW	1
MOS管	lPP60R060P7XKSA1
开关频率/kHz	50
主控制器	STM32G474RET6
飞跨电容	MC3D706K500V×5
输出滤波电容	C372S565K9SC000×8
输入EMI滤波器	MPP205J2G2411198LC CBB21-400V/305JP20 65125-10 μH 90125-220 μH