Non-Isolated Three-Phase Current DC-Link Buck-Boost EV Charger with Virtual Output Midpoint Grounding and Ground Current Control

Non-isolated three-phase AC/DC converter concepts facilitate more compact and more efficient realizations of future EV chargers. However, without the galvanic isolation and/or high common-mode (CM) impedance provided by an isolation transformer, non-isolated chargers must employ other means to suppress CM leakage currents to ground sufficiently and to prevent nuisance tripping of mandatory residual current devices (RCDs). Typically, the required EMI filters reduce high-frequency (HF) CM leakage currents to uncritical values. However, low-frequency CM voltages, e.g., generated by third-harmonic injection, may drive significant LF CM currents through the parasitic capacitances of the DC output (including the battery pack) to protective earth (PE). Therefore, considering a non-isolated three-phase buck-boost current DC-link PFC rectifier system that consists of a buck-type current-source rectifier (CSR) stage and a three-level boost-type DC/DC-stage, this paper first proposes a virtual grounding control (VGC) of the DC output voltage midpoint. VGC employs the DC/DC-stage to compensate the LF (third-harmonic) CM voltage inherently generated by the CSR-stage, and thus controls the LF CM voltage between the DC output midpoint and PE to zero. This enables further a direct connection of the DC output midpoint to PE, where an additionally proposed ground current control (GCC) ensures near-zero LF CM leakage current. The proposed concepts are verified with a 10kW hardware demonstrator (power density of 6.4 kW/dm3 or 107.5 W/in3, full-load peak efficiency of 98.5%) considering TT (Terra-Terra) and TN (Terra-Neutral) grounding systems. With a direct connection of the DC output midpoint to PE, GCC limits the LF CM leakage current to < 6mA RMS, i.e., significantly below typical RCD trip levels, and, using the human-body impedance model according to UL 2202, achieves a test voltage of 110mV that is clearly below the most stringent limit (250 mV) of the standard.