Super twisting sliding mode control for high-efficiency and fast charging of electric vehicles using current-fed resonant converter: 400 V and 800 V validation

A high-performance AC-DC single-stage current-fed resonant converter is presented in this research to cater the rising demands for sustainable, low-emission, efficient electric vehicles (EVs) charging solutions enhanced by a super-twisting sliding mode controller (ST-SMC) for power factor correction (PFC) and DC output voltage regulation. The proposed EV charging solution introduces a converter design operating at high frequencies with a fixed 50% duty cycle for primary switches, effectively reducing input current ripples and enhancing efficiency. As v c c = 2 v g , the voltage stress on the primary side remains consistent for both 400 V and 800 V, on same input voltage. Additionally, an advanced control strategy utilizing ST-SMC is implemented to ensure precise PFC and voltage regulation by controlling the secondary-side bidirectional switches, maintaining consistent performance across varying grid voltages and loads. Furthermore, the design incorporates zero-voltage switching (ZVS), with primary switches achieving ZVS during turn-on and secondary-side bidirectional switches exhibiting near-ZVS during turn-off, significantly reducing switching losses. For comparative analysis, the system's performance is also evaluated using a conventional PI controller. The proposed system is validated through simulations in MATLAB/Simulink and PSIM software, and Hardware-in-Loop (HIL) based experimental validation using the Delfino F28369D dual-core microcontroller. Results demonstrate near-unity power factor (0.998), low input current THD (2.8%), peak efficiency of 96.48%, and precise output voltage regulation for both 400 V and 800 V EV battery configurations, with ZVS operation at turn-on and turn-off instants, underscoring the converter's adaptability, robustness, and high performance. • Development of a dual-voltage EV charger compatible with both 400 V and 800 V. • Design of model-free ST-SMC that ensures PFC, output voltage regulation, and 2.8% THD performance. • Simplified PWM control, unlike frequency modulation used in resonant converters. • Achieving ZVS/ZCS for all switches and assuring a peak efficiency of 96.48%. • Comparative assessment with a conventional PI controller and robustness under HIL-based validation.