近年来，由于环境污染和能源危机问题日益突出，各国开始加大对新能源产业的推广，新能源汽车的产量和销量迎来了巨大飞跃。车载充电机作为电动汽车关键充电设备，关系着电动汽车的动力来源。本文聚焦于高效率车载充电机电路和控制设计，研制了一台数字控制的宽范围、高效率和高功率因数的车载充电机样机。

针对车载充电机宽输出电压范围、高效率和高功率因数等要求，设计了前级Boost-PFC和后级全桥LLC谐振变换器的两级式电路结构作为车载充电机的主功率电路。分析了Boost-PFC变换器和全桥LLC谐振变换器的工作原理和电路特性，针对锂电池负载条件下LLC谐振变换器软开关特性不稳定问题，根据ZVS/ZCS边界推导了软开关约束条件，提出了谐振参数优化设计方法，可使LLC谐振变换器全局软开关。根据技术指标完成主电路参数设计和器件选型，并对电路关键器件进行了详细的损耗计算，做出理论条件下电路损耗分布图，为降低电路损耗提升效率提供参考。

对PFC和LLC变换器控制策略进行分析并设计了其电压电流控制环路。通过对Boost-PFC变换器小信号模型分析完成了电压环和电流环PI补偿器的设计，实现了前级PFC变换器电压电流双闭环控制。根据锂电池充电策略确定了后级LLC谐振变换器电压电流双单环竞争的控制方案，并使用PFM+Burst混合控制方法提高LLC谐振变换器轻载效率。采用等效电路法简化LLC谐振变换器的小信号建模，推导出频率到输出电压传递函数，基于此设计了2p2z型补偿器用于LLC谐振变换器闭环控制。随后设计了车载充电机控制电路和软件程序，并给出了控制电路的硬件原理图和软件流程图。

根据上述设计方案搭建了一台500W的车载充电机试验样机，在实验室条件下对样机进行测试。结果表明：试验样机整机最高效率可达94.36%，且在满载工况下功率因数PF值为0.996，电流THD为3.2%，满足高效率、高功率因数、低谐波等技术指标。并且测试的关键波形和实验数据与理论分析一致，证明了本文设计方案的正确性。

In recent years, due to the increasingly prominent problems of environmental pollution and energy crisis, countries have begun to increase the promotion of new energy industries, and the output and sales of new energy vehicles have ushered in a huge leap. As the key charging equipment of electric vehicles, on-board chargers are related to the power source of electric vehicles. This paper focuses on the circuit and control design of high-efficiency on-board chargers, and develops a digitally controlled on-board charger prototype with wide range, high efficiency and high power factor.

In order to meet the requirements of wide output voltage range, high efficiency and high power factor of the vehicle charger, the two-stage circuit structure of the front-stage Boost-PFC and the post-stage full-bridge LLC resonant converter is designed as the main power circuit of the on-board charger. The working principle and circuit characteristics of Boost-PFC converter and full-bridge LLC resonant converter are analyzed, aiming at the problem of unstable soft switching characteristics of LLC resonant converter under lithium battery load conditions, combined with ZVS/ZCS boundary to derive the soft switching constraints, a set of resonant parameter optimization design methods are proposed to ensure the global soft switching of LLC resonant converter. According to the technical indicators, the main circuit parameter design and device selection are completed, and the loss calculation of the key components of the circuit is carried out in detail, and the circuit loss distribution diagram under theoretical conditions is given, which provides a reference for reducing circuit loss and improving efficiency.

The control strategies of PFC and LLC converters were analyzed and their voltage and current control loops were designed. Through the analysis of the small signal model of the Boost-PFC converter, the design of the voltage loop and current loop PI compensator is completed, and the voltage and current double closed-loop control of the PFC converter is realized. According to the lithium battery charging strategy, the control scheme of voltage and current double single-loop competition of post-stage LLC resonant converter was determined, and the PFM+Burst hybrid control method was proposed to improve the light load efficiency of LLC resonant converter. Based on the equivalent circuit method to simplify the small-signal modeling of LLC resonant converter, and derive the frequency-to-output voltage transfer function, a 2p2z compensator is designed for closed-loop control of LLC resonant converter. Subsequently, the control circuit and software program of the vehicle charger were designed, and the hardware schematic diagram and software flow chart of the control circuit were given.

According to the above design scheme, a 500W on-board charger test prototype was built and tested under laboratory conditions. The results show that the maximum efficiency of the test prototype can reach 94.36%, and the power factor PF value is 0.996 and the current THD is 3.2% under full load conditions, which meets the technical indicators of high efficiency, high power factor and low harmonics. Moreover, the key waveforms and experimental data of the test are consistent with the theoretical analysis, which proves the correctness of the design scheme in this paper.

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