Reliability Enhancement of Isolated Full-Bridge DC-DC Power Converter for Fast Charging of Electric Vehicles

In the realm of electric mobility, fast chargers for electric vehicles (EVs) play a critical role in mitigating range anxiety while driving. The converter in these chargers usually has a load profile consisting of a high-current pulse to swiftly recharge the EV battery, followed by a cooling-off phase when the charging process is over. This pattern results in thermal cycles on the devices resulting in mechanical fatigue that leads to gradual deterioration of the power electronic components. Consequently, evaluating the power electronic converters reliability is critical to facilitating fast EV charging. This paper focuses on the reliability analysis of the phase-shifted full-bridge DC/DC converter within EV fast chargers, with a specific emphasis on the battery charging profile. The primary objective is to demonstrate how the charger load characteristics and number of charging sessions influence device reliability and, consequently, overall system reliability. Additionally, the investigation explores the effects of altering devices heatsinks and current ratings on system reliability. It was observed that in worst-case scenarios, increasing devices current rates extended the system lifetime from 0.7 to about 23 years, with 3p.u. ratings achieving 10.8 years, meeting industry targets, while reducing heatsink thermal resistance improves that to around 2 years.