RESEARCH ARTICLE

SAM RIDDHI Volum e 13, Issue 2, 2021 Print ISSN : 2229-7111 Online ISSN : 2454-5767

Design and Simulation of PFC based CUK Converter for

Electric Vehicles Battery Charger
Balram Singh Yadav* 1, Sudhanshu Tripat hi2, Nmaita Jaiswal3
1.
* Depar t m ent of Elect r ical Engineer ing, Sam Higginbott om Universit y of Agr icult ure,Technology & Sciences, Prayagraj, U.P.,
India; e-m ail : bsyadav3966@gm ail.com .
2 ,3
Departm ent of Electrical Engineering, Sam Higginbottom University of Agriculture, Technology & Sciences, Prayagraj, U.P., India.

A B ST R A CT
This paper describes a bat t ery charger for plugin electric vehicles based on power fact or conversion and CUK convert er
in t he design of elect ric vehicles.. The int egrat ed bat t ery charger is supplied from t he convent ional t hree-phase
invert er for elect ric vehicle, w hich is a pow er fact or-correct ing buck boost convert er. The PFC cont roller changes
batt ery voltage and m onit ors t he convert er's pow er supply t o achieve a fast and high out put unit pow er fact or. The
proposed pow er fact or cont rolling w hich is alt ernat ive t o t he relat ionship bet w een t he input volt age rect ified and t he
bat t ery volt age. Sim ulat ion has been used t o assess t he pract icalit y and efficiency of t he bat t ery charger of t he
proposed convert er t opology.
Keywords: CUK Convert er, Elect ric Vehicle Batt er Charger, PFC, PI Cont rol.
SAM RIDDHI : A Journal of Physical Sciences, Engineering and Technology, (2021); DOI : 10.18090/ samriddhi.v13i02.7

I N T R O D U CT I O N
Corre sp onding Aut hor : Bal ram Si ngh Yadav,

A very alarming rate of depletion of fossil fuels

occurs as a result of t heir constant use in energy
Department of Electrical Engineering, Sam Higginbottom
Universit y of Agricult ure, Technology & Sciences,
Prayagraj, U.P., India; e-mail : [email protected]
production, vehicles, factories, etc. About time for
How t o cite t his art icle : Yadav, B.S., Tripat hi , S.,
these outlet s to disappear. So, the origins of electric
Jaisw al, N. (2021). Design and Simulation of PFC based
cars have gained a new level of att ention. A new
generation of batteries for electric cars is on its w ay CUK Converter for Electric Vehicles Battery Charger.
t o m eet i ng fut ure ener gy dem ands w it hout t he SAM RIDDHI : A Journal of Physical Sciences, Engineering
need for gasoline or diesel. Lit hium-ion, lead acid, and Technology, Volume 13, Issue (2), 98-103.
nickel zinc and ot her types of battery chargers are Source of support : Nil
available for electric vehicles. In addition t o being Conflict of interest : None
plentiful, these electric car outlets have a significant
im pact on our clim ate. This is anot her important mode to the battery packs to send the pow er DC on
reason w hy so many countries are sw it ching from the load side.
fossil fuels to electric car technology. The cu r r ent i n p ut qu al i t y p r o f i l e and t h e
The new technologies used today t o move t he harm onic range are required t o ensure opt im um
t r an sp o r t w o r l d w i d e t o a gr eener an d m or e energy consum pt ion and long l ife of t he bat t ery
affordable w ay is a batt ery-pow ered elect ric car. w hen transmitt ing t hese recharging signals. Since
For t hese cars, large bat tery packs are used w it h DBR has a negative effect on the input pow er profile
final energy pow er, usually recharged by a batt ery due to its non-linear nature, it also uses a PFC based
ch ar ger based on t he AC-DC conver t er. Th ese independent DC-DC t ransform er. A PFC converter
charger s are essent ially buil t f rom a DBR-Diode hi gh-f requency separ at i on i s usef ul i n or der t o
Bridge Rect ifier (CC-DC) converter to communicate optimise charging propert ies by blocking harmonics
t he charge si gnal s i n const ant t ension, const ant or unwanted signals from penet rat ing the battery.
curr ent or const ant cont i nuous vol t age (CC/ CV) Convent i onal EV-bat t ery chargers are based on

The Aut hor (s). 2021 Open Access This art icle is dist ribut ed under t he t erm of t he Creat ive Com mons At t ribut ion 4.0 Int ernat ional License (ht t p:/ / cr eat ivecommons.or g/
licenses/ by/4.0/ ), w hich perm it s unrest rict ed use, dist ribut ion, and non-comm er cial r eproduct ion in any medium, pr ovided you give appropriat e credit t o t he original
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98 SAM RIDDHI : A Jour nal of Physical Sciences, Engineer ing and Technology, Volum e 13, Issue 2 (2021)
 Reconfigurable Successive Approxim at ion Regist er ADC and SAR-Assist ed Pipeline ADC

convent ional AC-DC convert ers and have inherent charging a 12-V auxiliary bat t ery from t he 180-V
h ar m on i cal i nj ect i on i n con v en i en ces, v ol t age battery.
di st ort ion and very low PF curr ent (0.8-0.85). A For the entire ZVS range, as w ell as a synchronous
number of AC-DC converters, w ith or w ithout high resonant DC-DC transformer operating in DCM , the
f r eq uen cy i sol at i o n, ar e al so def i n ed i n t h e app r op r i at e dead t i m e an d r ev er se cur r en t
literat ure t o increase the real pow er ut ilisation of specificat ions can be det erm ined in [4]. W it hout
charging circuit s. emulation or experimental verification, parameters
Like convent ional CUK Convert or diode bridge can be co l l ect ed f r om co m p o nen t d at ash eet s
rectifier, Bridgeless SEPIC, Bridgeless Zeta Convert er, w ithout emulation or experimental verification. DC
et c., m any f orm s of convert ers in charge. In t he mot ors can be pow ered by a variety of PFC topologies,
charging syst em, t he Bridgeless Cuk Converter is including Diode Bridge, Buck, Buck-Boost and SEPIC
used t o ov er com e t he di sadvant ages o f t hese at t he init ial stage..
conver t er. This paper desi gns and advances t he Simulat ing and analysing various t opologies is
proposed im proved bridge-f ree, high pow er and r equi r ed i n [ 5]. PFC t opol ogi es based on diode
enhanced per form ance Cuk Conver t er -based EV bridge rectifiers are the better option for low pow er
batt ery charger. It offers a low cost and high capacity applications, according to a this study. When the DC
EV-based recharge solution. This loader incorporates volt age out put is great er t han t he desired input ,
less com ponent s, avoids t he input and output of boosting the PFC t opology can help. Buck-based PFC
rip-offs, sw it ch voltage and current volt age, body topologies are acceptable if the DC out put voltage
d i o des and no i se conduct i vi t y. Thi s i ncreases is less t han RM S. It is im port ant t o know t he AC
performance. The additional benefit of the topology volt age of the source.
proposed is t hat unw ant ed capacitive connect ion
is eliminat ed and unw anted conduction through the The exper i m ent al val i dat i on of t he pr oposal
inactive sw it ch diode is st opped. concept is performed w ith 100 W of pow er w ith a
90 V supply. The design of a Buck convert er w it h
L I T ER AT U R E R EV I EW continuous on-tim e control is recomm ended in[6].
A level 2 charger incorporating PFC converter w ith With m axim um voltage and universal service, the
a bridge-free boost and an isolated full-pitch transient effectiveness is m easured as 0,96. The key draw back
step transducer, and isolated DC-DC t ransducer w ith of t he Buck st yle PFC convert er, w hich requires a
total bridge change is provided in [1]. Power sw itches large philtre at the input, is the discontinous input
ar e used t o ach i ev e h i gh d ensi t y an d h i gh present .
performance silicon carbide. At a frequency of 200 In[ 7] , Th e engi neer ed co nv er t er has an
kHz, m aximum efficiencies of 95%, and m inimum advant age of less pow er st r ain on sw it ches and
THD 4.2% are reached.[2] Smart homes and sm art decreased conduction loss in sw itches and inducers
gr i d s ar e t h e m ost com m on m o d es of p o w er w it h sm aller dim ensi ons. In addit ion, t he sw it ch
dist ribution betw een elect ric vehicles and the grid. provides an ext ra tw o-sw it ch boosted buck boost
In t he literature, there are tw o more modes, grid to topology. The universal line voltage input w ith low
vehicle and home t o vehicle, w hich are described THD achieves an efficiency of 93 percent.
in detail. You should run your car at home. With a
P R O P O SED W O RK
charger that runs from a home t o an aut om obile,
the charging current is adjusted based on household From t he last section w e have seen t he change in
pow er usage and in-house appliances, allow ing for output volt age due to changes in input voltage, low
more efficient charging. Vehicle to grid is intended po w er fact or and l ar ger i n pu t To t al Har m on i c
to compensate in-house reactivity through the use Dist ortion as both the normal diode bridge rectifier
of t he vehicle charger. and the open band correct or. The method used here
is cont rolled by t he average current . The out put
In [3], t he elect ric scoot er is designed w it h an
voltage is regulated by changing the actual amplitude
on-board battery charger. A plumbing battery of 180
signal and its mean value in average current control
V, 12 Ah and 110 V, 60 Hz, single phase outlet, can be
mode. The voltage at the terminal is regulat ed by
charged. The adapt er also has the abilit y to charge
the operation of t he output voltage cont roller, and
batt eries. The DC-DC low voltage converter idea is
the input side current is controlled by the input side
suggest ed . A DC-DC adap t er i s su ggest ed f o r
SAM RIDDHI : A Jour nal of Physical Sciences, Engineer ing and Technology, Volum e 13, Issue 2 (2021) 99
 Design and Sim ulat ion of PFC based CUK Conver t er for Elect ric Vehicles Bat t ery Charger

error compensat or. The input voltage variat ion is

cont rolled by the voltage transm ission compensator
so t hat t he out put of t he vol t age t r ansm it t er is
increased and vice versa if the input voltage is low ered
[8].
PW M signals are produced by com pari ng t he
out put of t he proport ional int egral device to t he
output of the SAW.
M ost electronic equipment connected to the grid Figure 2: Isolated Cuk Convert er
draw s the non-sinusoidal line current discontinuous
rather than the sm ooth w ave current. This current
includes a range of harm onics t hat flow t hrough
bot h the pow er grid and t he m achinery. A single-
phase AC-DC bridge corrective system follow ed by
a broad-condensing system draw s a non-sinusoidal
peak curr ent discont i nuousl y and t her ef or e t he
presence of harm onic current s in both t he AC-DC
rect ifier circuit and in t he pow er grid connected to
that converter. Figure 3: Waveforms of open loop CUK convert er

S I M U LAT I O N R ESU LT S
The proposed Single phase CUK converter show n in
Figure 2. The cont rol technique used here changes
the charging of the battery in constant voltage mode
in w hi ch st at e of char ging is m axi m i zed. As t he
batt ery is fully charged at the end of this mode, the
source current also decreases. Because very lit tle
current is coming from the source, only the voltage
Figure 1: Simulink Diagram of Proposed Control loop is active in t his mode. In this mode of charging,
a pow er fact or convert er is not possi ble. Voltage
The tradit ional approach for PFC controllers w ith and current of the battery are sensed independently
a single phase is an internal loop that controls the to enforce the control syst em. They are compared
current input w hile an external loop cont rols t he w ith t he reference values and given t o t he tw o PI
DC-link volt age[9]. cont rol ler s as descr ibed i n t he cont rol sect i ons
In addit i on t o t he sensed out put current and [11-15].
output of the outer loop, the internal loop reference PW M sw i t chi n g sy st em , t he o u t p u t of t h e
is mult iplied. This problem can be rest rict ed and present PI corresponds to a saw tooth carrier w ave
b et t er execu t ed u si n g t h e cl o sed l o op Cu k in the sw itching block of the PWM sw itch. The high
controller-based AC-DC converter in Figure 1 [10]. frequency switch is driven by the pulses acquired at
t he out put of t he pul se w i dt h bl ock. W i t h t h i s
Bat t er i es ar e usual l y char ged w i t h const ant
technique, the out put voltage has few er harmonics
volt age and current. A const ant current is applied
and a more uniform sw itching met hod.
to the battery unt il a predeterm ined volt age level
Therefor e, t he dut y rat i o for t his convert er is
is reached.It then sw it ches t o a const ant volt age
controlled by tw o PI cont rollers, w hich produce a
m ode in w hi ch t he bat t er y curr ent i s gr aduall y
sinusoidal input current w ith a low t otal harmonic
reduced along w ith its state of charge. An isolated
di st ort i on val ue, and provide enhanced bat t er y
CUK convert er is show n in figure 2, and the voltage
f eat ur es i n t w o d i f f er ent t y pes o f b at t er i es.
w avef o r m s on bo t h si des of a h i gh f r equ en cy
Controlling DC-DC convert ers w ith PI is one of the
transformer are show n in figure 3.
standard methods. Previously for pulse control and

100 SAM RIDDHI : A Jour nal of Physical Sciences, Engineer ing and Technology, Volum e 13, Issue 2 (2021)
 Design and Sim ulat ion of PFC based CUK Conver t er for Elect ric Vehicles Bat t ery Charger

syst em performance improvement, a proportional

(P) controller is used. It is impossible to stabilise a
process of higher order. A proport ional i nt egral
controller is obtained by combining proportional and
i n t egr al con t r ol st rat egi es. Th e PI co nt ro l l er ’s
output is equal to the sum of the proportional and
integral error signals. This controller can eliminate
forced oscillations and stable state errors by using
a proport ional integral.

Figure 5: Cuk converter output voltage

Figure 4: PI Cont roller General Representation

The simulation parameters are show n in given table Figure 6: Output of input Inductor and Output induct or
I. current

Table I: Sim ulat ion Param et ers

PARAM ETRS RATING

Transformer volt age V1 220V
Transformer volt age V2 220V
Induct or L1 and L2 6 mH 4 M h
Sw it ching Frequency 25 kHz
Transformer Turns Rat io 1:1
Capacitor C1 and C2 0.88uF, 15uF
Bat t ery Rat ing 100 Ah, 60V
DC Link Capacit or 4.7mH Figure 7: show the cont rol voltage of the Cuk convert er is
Filt er induct or 3 mH compared w ith the reference volt age of 200V and error is
given PI cont roller.

Case 1: Working of CUK Converter in Open Loop

Supply Voltage Vi = 270V, Capacitance C1 = 0.66 uF ,
C2 = 2200uF , L1 = 2.5 mH , L2 = 4.3 mH , R = 114.2ohm,
Constant Voltage = 200V and KP =0.01, KI =1. The input
voltage of 270V has been taken, the output voltage is
(compared with the reference voltage of 200V and the
error is given to the PI controller, the output of the PI
controller is used t o provide sw it ching t o t he CUK
converter. The simulation result shows that the output
voltage is tracked in a correct way.
Figure 8: Output Voltage of PI Controller using CUK
Converter
SAM RIDDHI : A Jour nal of Physical Sciences, Engineer ing and Technology, Volum e 13, Issue 2 (2021) 101
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 Design and Sim ulat ion of PFC based CUK Conver t er for Elect ric Vehicles Bat t ery Charger

Figure 9: CUK Converter Control Voltage

Figure 12: Waveforms of constant voltage at the output
t erm inal

Using a PI controller, the output voltage of the CUK

convert er is show n and com pared t o t he out put
current of the sawtooth wave in Figure 8. The converter
output voltage is determined by its performance.
Case 2: Working of CUK Converter in Closed Loop
Figure to Figure 12 show s the simulation results for
this project. As a result, w e have plot ted the input
rectified voltage, output voltage and an Fast Fourier
Transform analysis of the input current.
This is done by com paring the CUK convert er ’s
output voltages with the reference voltage, giving an Figure 13: Batt ery Voltage Charact erstics
error to the PI converter’s output, comparing the CUK
conver t er ’s out put cur rent t o t he PI cont roll er ’s
output, comparing the PI controller’s output to the PI
form, and using that form’s output to sw itch to the
CUK converter.

Figure 14: Battery Discharge Characteristics

Figure 10: Waveforms of PI output voltage
A power factor of 1 is achieved when the source
voltage and the source current are both in phase.

C O N CLU S I O N
This paper proposes the unitary pow er factor CUK
converter w ith the support of a CC-CV m ode bat tery
charger for isolation of high frequency t ransform ers.
Th e m odel l i ng, an al y si s and si m ul at i o n o f t he
batt ery charger for the electric vehicle based on an
i so l at ed CUK co n ver t er w as do n e. Th e m aj o r
advant age of t he PI doubl e-l oop cont r oll er i s a
Figure 11: Output of input induct or current
102 SAM RIDDHI : A Jour nal of Physical Sciences, Engineer ing and Technology, Volum e 13, Issue 2 (2021)
 Design and Sim ulat ion of PFC based CUK Conver t er for Elect ric Vehicles Bat t ery Charger

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