Hardware Design and Testing of a 50 kW T-Type Active Rectifier

The thesis analyses the schematic and PCB design process of the active rectifier for an ultrafast battery charger for electric vehicles. Ultrafast chargers are and will increasingly be a key technology, being at the heart of the transportation electrification. Therefore, the goal of this work is the design, assembly and testing of an Active Front End prototype for an off-board battery fast charger. The work has been carried out in collaboration with the interdepartmental Power Electronics Innovation Center (PEIC) at the Politecnico di Torino and it deals with the detailed hardware design of a 50 kW AFE, from its schematics to the final printed circuit boards (PCBs) and the testing of the converter. The hardware development of this prototype is a work carried out in sequential stages and has required transversal engineering skills, both electrical, electronic and mechanical. In fact, the process started from the theoretical study phase of the active rectifiers, going through the design of the schematic and PCBs, until the assembly and testing of the boards.