Applied Integrated Active Filter Auxiliary Power Module for Electrified Vehicles With Single-Phase Onboard Chargers

In single-phase onboard chargers for electrified vehicles, second-order harmonic currents and corresponding ripple voltages exist on the dc bus. The low-frequency harmonic current is normally filtered using a bulk film capacitor or an additional active filter (AF) circuit. This presents an obstacle for improving the power density as well as reducing the cost. This paper proposes a simple and effective method that reduces the bulk capacitor in single-phase chargers and alleviates the low-frequency sinusoidal harmonic current in automotive applications. It applies the low-voltage (LV) battery charger auxiliary power module as an AF to filter the low-frequency harmonic currents in the high-voltage (HV) battery charger when the HV battery is charging. Hence, the integrated active filter auxiliary power module (AFAPM)-based dual-voltage charging system can achieve the AF function without extra power switches, heat sinks, and corresponding gate-drive circuits. In addition, the proposed AFAPM converter can obtain an almost unchanged switch rating to achieve 2.4-kW LV battery charging and 6.6-kW HV active filtering functions. Therefore, the proposed method can reduce the cost for the dual-voltage charging system in electrified vehicles. A 1.2-kW proof-of-concept prototype has also been built and experiments show promising results confirming the effectiveness of the proposed concept.