High-Efficiency Design and Control of a Single-Stage 400 V/800 V EV Charging Station Using a Dual-Output LF Transformer with an ATS | Zendy

Jin-Su Jang | Zendy; Elysee Malon Harerimana | Zendy; Myeong-Jun Cha | Zendy; Rae-Young Kim | Zendy

Open Access

High-Efficiency Design and Control of a Single-Stage 400 V/800 V EV Charging Station Using a Dual-Output LF Transformer with an ATS

Author(s) -

Jin-Su Jang,

Elysee Malon Harerimana,

Myeong-Jun Cha,

Rae-Young Kim

Publication year - 2025

Publication title -

ieee access

Language(s) - English

Resource type - Magazines

SCImago Journal Rank - 0.587

H-Index - 127

eISSN - 2169-3536

DOI - 10.1109/access.2025.3598033

Subject(s) - aerospace , bioengineering , communication, networking and broadcast technologies , components, circuits, devices and systems , computing and processing , engineered materials, dielectrics and plasmas , engineering profession , fields, waves and electromagnetics , general topics for engineers , geoscience , nuclear engineering , photonics and electrooptics , power, energy and industry applications , robotics and control systems , signal processing and analysis , transportation

The escalating global demand for high-power electric vehicle (EV) charging has driven manufacturers to adopt 800 V battery systems. However, the prevalent 400 V-centric existing EV charging infrastructure requires substantial modifications or additional conversion stages for 800 V EVs, leading to increased complexity, cost, and efficiency losses. This paper proposes a novel EV charging system architecture comprising a dual-output low-frequency (LF) transformer, an automatic transfer switch (ATS), an LCL filter, and a Vienna rectifier, operating under three-phase 380 V/60 Hz grid input. The system offers a unified, single-stage solution, efficiently supporting both 400 V and 800 V EVs without additional DC/DC conversion. Within this architecture, the LF transformer provides dual 380 V and 180 V outputs; the ATS selects the appropriate output, fed via the LCL filter into the Vienna rectifier for wide-range DC outputs. The Vienna rectifier strategically controls DC output current/power and AC input current/DC output voltage. Experimental results from a 100 kW prototype demonstrate a peak efficiency of about 97.8%, with total harmonic distortion (THD) performance maintained below 3.9% (current THD). Compared to conventional multi-stage systems, this proposed system offers demonstrably superior efficiency, stability, and flexibility, making it ideally suited for comprehensive EV battery systems due to its simplified structure and optimized control algorithm.

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