DESC:FIELD OF THE INVENTION

The present disclosure relates to a hybrid charge controller rectifier system with composition of two technologies including solar and AC.

BACKGROUND OF THE INVENTION

From the point of view of reducing greenhouse gas emissions and conserving energy, hybrid vehicles with gasoline-fueled engines and electric motors have attracted attention in recent years as vehicles with less exhaust gas and better fuel efficiency. A hybrid vehicle is more complicated than a vehicle with only an internal combustion engine, but it has more components, like a motor and a battery.

A nickel metal hydride storage battery is the hybrid vehicle power source of choice right now. Nickel metal hydride batteries have good discharge characteristics and can cut carbon dioxide emissions and fuel consumption by half compared to cars with only gasoline engines. However, a power source for a hybrid vehicle with a higher energy density per unit volume and weight is required due to the need to achieve long distances using only a battery and the growing concern about the environment.

Lithium-ion secondary batteries with a high energy density are anticipated to be used as a power source for hybrid vehicles of the next generation, and developments for their practical application have been made by battery manufacturers and automobile manufacturers. However, there is a possibility of ignition at high temperatures due to the use of organic solvents in lithium ion batteries. The cathode active material deteriorates and the electrolyte decomposes severely when used as a motor power source for automobiles in environments with a high interior temperature, such as direct sunlight or high outdoor temperatures. increased danger of fire and leakage. The electrolyte may leak and cause an ignition or explosion if the battery ruptures as a result of an incident or similar circumstance. As a result, protecting oneself from these threats is essential.

In the view of the forgoing discussion, it is clearly portrayed that there is a need to have an improved hybrid charge controller rectifier system.

SUMMARY OF THE INVENTION

The present disclosure seeks to provide a hybrid charge controller rectifier system.

In an embodiment, a hybrid charge controller rectifier system is described. The system includes of a Hybrid System Control Command Unit (HCCU) configured to manage input sources from solar photovoltaic (PV) panels and AC power sources; a DC-DC converter utilizing a half-bridge LLC resonant topology, configured to convert high DC voltage input (380-500VDC) from solar PV panels and AC sources into a regulated 54V DC output for battery charging; an active power factor correction (PFC) circuit integrated on the AC input side, comprising a two-phase interleaved PFC topology with alternating switching devices operating in reverse polarity and a 180° phase difference; and a microcontroller to prioritize solar power over AC power for battery charging based on detected input voltage and current, and to regulate power output accordingly.

In another embodiment, the two-phase interleaved PFC circuit further comprises two interleaved boost converter stages synchronized to operate with a 180° phase difference, alternating between positive and negative half cycles of the input AC voltage; reactors (L1 and L2) in reverse phase configuration, wherein ripple currents cancel out to reduce input ripple current; MOSFETs configured for independent switching to simplify thermal management and reduce switching losses by operating at half the switching frequency of a single-phase PFC circuit.

In another embodiment, the DC-DC converter comprises MOSFETs arranged in a half-bridge topology with a voltage divider capacitor for zero voltage switching (ZVS) in the primary side and zero current switching (ZCS) in the secondary side; an LLC resonant network comprising inductors and capacitors to facilitate high-frequency switching and voltage transformation; a high-frequency step-down transformer to regulate the output voltage to 54V DC for battery charging.

In another embodiment, the microcontroller is configured to: monitor and adjust power output based on real-time detection of solar PV panel and AC power input characteristics, ensuring optimal battery charging efficiency; and to dynamically balance load between solar and AC power sources based on power availability and priority settings, and wherein the Hybrid System Control Command Unit (HCCU) includes: sensors for detecting input voltage and current from solar PV panels and AC power sources; and interface modules for communication with the microcontroller to relay input data and receive control signals for managing power sources and output.

In another embodiment, the system includes an EMI filter for mitigating electromagnetic interference from solar PV and AC power sources; a diode full-bridge rectifier for converting AC input voltage to a DC bus; and an output stage comprising output MOSFETs, capacitors, and filters to deliver a stable 54V DC output for battery charging.
In another embodiment, a method for operating a hybrid charge controller rectifier system is described. The method includes of receiving input from solar photovoltaic (PV) panels and AC power sources at a Hybrid System Control Command Unit (HCCU); converting high DC voltage input (380-500VDC) from the solar PV panels and AC sources into a regulated 54V DC output for battery charging using a DC-DC converter with a half-bridge LLC resonant topology; implementing an active power factor correction (PFC) circuit on the AC input side, comprising a two-phase interleaved PFC topology with alternating switching devices operating in reverse polarity and a 180° phase difference; and prioritizing solar power over AC power for battery charging based on detected input voltage and current said prioritizing including monitoring and adjusting power output based on real-time detection of solar PV panel and AC power input characteristics to ensure optimal battery charging efficiency; and dynamically balancing load between solar and AC power sources based on power availability and priority settings.

In another embodiment, implementing the two-phase interleaved PFC circuit further includes: synchronizing two interleaved boost converter stages to operate with a 180° phase difference, alternating between positive and negative half cycles of the input AC voltage; configuring reactors (L1 and L2) in reverse phase configuration to cancel out ripple currents and reduce input ripple current; independently switching MOSFETs to simplify thermal management and reduce switching losses by operating at half the switching frequency of a single-phase PFC circuit.

In another embodiment, converting the high DC voltage input from the solar PV panels and AC sources into a regulated 54V DC output includes configuring MOSFETs in a half-bridge topology with a voltage divider capacitor for zero voltage switching (ZVS) in the primary side and zero current switching (ZCS) in the secondary side; utilizing an LLC resonant network comprising inductors and capacitors to facilitate high-frequency switching and voltage transformation; and regulating output voltage to 54V DC for battery charging using a high-frequency step-down transformer.

In another embodiment, the method includes of detecting input voltage and current from solar PV panels and AC power sources using sensors integrated into the HCCU; and communicating input data to a microcontroller via interface modules to relay control signals for managing power sources and output.

In another embodiment, the method includes of mitigating electromagnetic interference from solar PV and AC power sources using an EMI filter; converting AC input voltage to a DC bus using a diode full-bridge rectifier; and delivering a stable 54V DC output for battery charging through an output stage comprising output MOSFETs, capacitors, and filters.

An object of the present disclosure is to develop a renewable energy system that uses solar photovoltaic (PV) panels to generate the energy to charge the battery.

Another object of the present disclosure is to operate in a wide power range with zero voltage switching in primary side and zero current switching in secondary side.

Yet another object of the present invention is to deliver an expeditious and cost-effective Hybrid Charge Controller Rectifier.

To further clarify advantages and features of the present disclosure, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF FIGURES

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates HCCU 1748 wiring diagram in accordance with an embodiment of the present disclosure;
Figure 2 illustrates HCCU 1748 main menu window in accordance with an embodiment of the present disclosure; and
Figure 3 illustrates Table 1 depicts specific values attributable in accordance with an embodiment of the present disclosure.
Figure 4 and 5 illustrate flow chart of the working of the invention;
Figure 6 illustrates a Hybrid Charge Controller Rectifier System Architecture in accordance with an embodiment of the present invention;
Figure 7 illustrates Schematic of interleaved PFC &DC -DC Half bridge LLC convertor.
Figure 8 and Figure 9 show the current paths in an interleaved PFC circuit while the input AC voltage is in the positive half cycle;
Figure 10 and Figure 11 show the current paths while it is in the negative half cycle;
Figure 12 illustrates a block diagram of hybrid charge controller rectifier system; and
Figure 13 illustrates a flow chart for a method for operating hybrid charge controller rectifier system

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present disclosure. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION:

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.

Reference throughout this specification to “an aspect”, “another aspect” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrase “in an embodiment”, “in another embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by "comprises...a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.

The present disclosure relates to a hybrid charge controller rectifier system with composition of two technologies including solar and AC.
Referring to Figure 1, a Hybrid System Control Command Unit (HCCU) 1748 wiring diagram is illustrated in accordance with an embodiment of the present disclosure. Hybrid Charge Controller Rectifier is a renewable energy system that uses solar photovoltaic (PV) panels to generate the energy to charge the battery. Also, it works with AC power source to charge the battery as well when Solar power is not available A hybrid solar system intelligently switches between solar power and Grid Power.

System is taking energy outside from Solar and Grid simultaneously by an algorithm implemented in a microcontroller. System detects the input voltage and current of Solar power and Grid power and makes decisions . Power source selection priority is Solar.

This system operates at high solar input voltage (380-500VDC) that converts High DC voltage Solar Input to Low voltage DC output by half bridge DC-DC converter .System provide 54V DC output to charge the battery. High DC voltage input is provided to Mosfets which is connected in half bridge configuration with voltage divider capacitor. Switched High voltage DC output is fed to LLC resonant network (Inductor+Inductor+ Capacitor) then fed to high frequency step down transformer to get 54V DC output for battery charging.

This system operates at AC input (170VAC- 260VAC) . In the front end, we used active power factor correction circuits for power factor improvements and Total harmonic distortion reduction. In this circuit, 2 - phase interleaved boost converter to get the high voltage DC . Power factor and THD improvement algorithm implemented in microcontroller.
High DC voltage input is provided to Mosfets which is connected in half bridge configuration with voltage divider capacitor. Switched High voltage DC output is fed to LLC resonant network (Inductor+Inductor+ Capacitor) then fed to high frequency step down transformer to get 54V DC output for battery charging.

This is an automatic process by algorithm we implemented in a microcontroller. System detects the input voltage and current from Solar and Grid and decides itself . In this design , solar power priority is over Ac power. If any case output power demand is more than Input solar power then the system provides additional power from AC input as well. If solar power is negligible then the system provides whole power from AC input.

In this design, we have used following stages -
EMI Filter-
Diode Full Bridge rectifier
PFC Boost Inductor
PFC Mosfet, PFC diode, Half bridge mosfet, resonant inductor , transformer, output mosfet, output capacitor, output filter

PFC is used extensively in AC-DC converters since it allows the converter to meet harmonic standards without the need for a bulky and costly input filter. Power Factor Correction aims at shaping input current to be as sinusoidal as possible, in order to reduce harmonic distortion and its associated losses, and bring power factor close to one in AC circuits. We have used Active power factor correction techniques using microcontroller. System meets the requirement of unity power factor and Total harmonic distortion at low and high line AC input.

1. Solar and AC converter is incorporated in a single design for low cost and efficiency
2. Converter selects intelligently the input source to charge the battery.

A half-bridge converter is a type of DC-DC converter can supply an output voltage either higher or lower than the input voltage and provide electrical isolation via a transformer.This converter have used Half Bridge LLC resonant converter topology. In this design, DC-DC converter mosfet is connected in half bridge configuration. Mosfet devices are switched to operate in a wide power range with zero voltage switching in primary side and zero current switching in secondary side.

Figure 2 illustrates HCCU 1748 main menu window in accordance with an embodiment of the present disclosure. We have used PFC (Power Factor Correction) circuits, AC input side to make 400V DC bus. After that High DC bus (400V) is converted by Half Bridge LLC topology to convert 48V DC output. Also solar power is converted by half bridge LLC converter to make 48V DC output. We have used the same DC-DC Half Bridge LLC converter for solar power source as well as AC power source. By this topology, we made the system more efficient by reducing the component counts in the solar section. This invention is specifically made for buyer adoption by reducing cost and size.
Figure 3 illustrates Table 1 depicts specific values attributable in accordance with an embodiment of the present disclosure. We have made this to charge the battery. This charger works on solar power source and AC power source separately or collectively.

By this technology, we incorporate solar and AC in a single charger by reducing components. It is marginal development change. In this Invention, we can use solar power sources with a higher voltage than 300V DC only, lower voltage will not support.
Figure 4 and 5 illustrate flow chart of the working of the invention;

In the present invention the system is taking energy outside from Solar and Grid simultaneously. The operation is below:
The Output of Grid rectifier (ie. PFC converter ) and solar input is coupled and feeded to the DC/DC Half bridge LLC converter.
DC/DC Converter sends a reference voltage to the PFC converter controller to dropdown its output voltage to a level at which solar MPPT Voltage point exists (which is tracked during full tracking cycle).
Now as per the load requirement if solar is capable of supporting full power then DC/DC draws most of the current solar as PFC Output Voltage is below solar MPPT point. But if Solar is not sufficient to what power is required by Load then solar voltage drops to a specific voltage level of PFC Output so that Both can share the Load current with having priority of solar over grid.
In case of either absent DC/DC converter works independently over source.

The present invention is advantageous in in detecting the input voltage and current of Solar power and Grid power and making decisions:
(a)The Dual Controller model helps us to sense and maintain the required Solar tracking point fixed.
(i) PFC Controllers take care of Input Voltage sensing, detection for Zero-crossing and drive mosfet with achieving valley switch for a partial ZVS, also regulated PFC Output BUS voltage.
(ii) DC/DC Controller Sense Solar Voltage and Current Calculating Current Solar Power and Tracks the MPPT point by rMMPT algorithm of UTL Solar simultaneously controlling final output voltage and current for the Load.

Figure 6 illustrates a Hybrid Charge Controller Rectifier System Architecture in accordance with an embodiment of the present invention. The present invention relates to the field of battery chargers, specifically hybrid charge controller rectifiers. More particularly, it pertains to a system and method for combining the power output from both Solar Photovoltaic (SPV) sources and AC sources to provide a unified and efficient charging solution for batteries. Hybrid Solar converters which are based on Half bridge LLC resonant converter to make a hybrid converter which works on AC power as well as SPV power. High DC Solar voltage terminated on High DC Voltage Solar and AC converter is incorporated in a single design for low cost and efficiency Converter intelligently selects the input source to charge the battery.
Figure 7 illustrates Schematic of interleaved PFC &DC -DC Half bridge LLC convertor.
Figure (8) and Figure (9) show the current paths in an interleaved PFC circuit while the input AC voltage is in the positive half cycle whereas Figure (10) and Figure (11) show the current paths while it is in the negative half cycle.

In the present invention Interleaved PFC Switching is sued that helps to minimize input high frequency current ripple for smoothen Input current waveform, Initial Both PWM of Interleaved Mosfets are 180* Out of phase and next pulse of mosfet occurs at the valley of Vds and this signal is captured at microcontroller pins respectively to gate drive and PWM signals sink to signal to achieve continuous valley switching or complete ZVS.
To Achieve a greater PF > 0.99 we imply a reverse sine modulation graph in duty cycle of the PWM of PFC controller which improves PF as well as THD by running into variable frequency mode.

Medium and large power supplies with a capacity greater than 500 W are now widely used. In principle, a multi-phase interleaved PFC may be used for such power supplies, but a large majority of them use a two-phase interleaved PFC circuit like the one shown in Figure 8,9,10,11. With two-phase interleaved PFC, two switching devices switch alternately so that two PFC circuits operate in reverse polarity (with a 180° phase difference). Therefore, the switching frequency of each switching device is half the circuit frequency. Figure (8)and Figure (9) show the current paths in an interleaved PFC circuit while the input AC voltage is in the positive half cycle whereas Figure (10) and Figure (11) show the current paths while it is in the negative half cycle. Figure (11)shows the current waveforms of this circuit. The input current is always equal to the sum of the currents flowing through two reactors (L1 and L2). Since the ripple currents of the reactors in reverse phase cancel each other out, the input ripple current due to the reactors becomes small. Since power losses are dispersed across two devices as is the case with a PFC circuit using parallel MOSFETs, an interleaved PFC circuit also simplifies thermal design. Since each MOSFET switches independently, delicate consideration is unnecessary for the selection of MOSFETs. Since the switching frequency of one MOSFET is half that of the circuit, the switching loss is half. On the other hand, the disadvantage of interleaved PFC circuits is that they have higher conduction losses, because they have a peak current that is twice that of a PFC circuit using parallel MOSFETs.

Figure 12 illustrates a block diagram of hybrid charge controller rectifier system. The system 100 includes of a Hybrid System Control Command Unit (HCCU) 102 configured to manage input sources from solar photovoltaic (PV) panels and AC power sources; a DC-DC converter 104 utilizing a half-bridge LLC resonant topology, configured to convert high DC voltage input (380-500VDC) from solar PV panels and AC sources into a regulated 54V DC output for battery charging; an active power factor correction (PFC) circuit 106 integrated on the AC input side, comprising a two-phase interleaved PFC topology 106a with alternating switching devices operating in reverse polarity and a 180° phase difference; and a microcontroller 108 to prioritize solar power over AC power for battery charging based on detected input voltage and current, and to regulate power output accordingly.

In another embodiment, the two-phase interleaved PFC circuit 106a further comprises two interleaved boost converter stages synchronized to operate with a 180° phase difference, alternating between positive and negative half cycles of the input AC voltage; reactors (L1 and L2) in reverse phase configuration, wherein ripple currents cancel out to reduce input ripple current; MOSFETs configured for independent switching to simplify thermal management and reduce switching losses by operating at half the switching frequency of a single-phase PFC circuit.

In another embodiment, the DC-DC converter 104 comprises MOSFETs arranged in a half-bridge topology with a voltage divider capacitor for zero voltage switching (ZVS) in the primary side and zero current switching (ZCS) in the secondary side; an LLC resonant network comprising inductors and capacitors to facilitate high-frequency switching and voltage transformation; a high-frequency step-down transformer to regulate the output voltage to 54V DC for battery charging.

In another embodiment, the microcontroller 108 is configured to: monitor and adjust power output based on real-time detection of solar PV panel and AC power input characteristics, ensuring optimal battery charging efficiency; and to dynamically balance load between solar and AC power sources based on power availability and priority settings, and wherein the Hybrid System Control Command Unit (HCCU) 102 includes: sensors 102a for detecting input voltage and current from solar PV panels and AC power sources; and interface modules 102b for communication with the microcontroller to relay input data and receive control signals for managing power sources and output.

In another embodiment, the system 110 includes an EMI filter 110 for mitigating electromagnetic interference from solar PV and AC power sources; a diode full-bridge rectifier 112 for converting AC input voltage to a DC bus; and an output stage comprising output MOSFETs, capacitors, and filters to deliver a stable 54V DC output for battery charging.

Figure 13 illustrates a flow chart for a method for operating a hybrid charge controller rectifier system. The method 200 includes of:
Step 202 discloses about receiving input from solar photovoltaic (PV) panels and AC power sources at a Hybrid System Control Command Unit (HCCU);
Step 204 discloses about converting high DC voltage input (380-500VDC) from the solar PV panels and AC sources into a regulated 54V DC output for battery charging using a DC-DC converter with a half-bridge LLC resonant topology;
Step 206 discloses about implementing an active power factor correction (PFC) circuit on the AC input side, comprising a two-phase interleaved PFC topology with alternating switching devices operating in reverse polarity and a 180° phase difference;
Step 208 discloses about prioritizing solar power over AC power for battery charging based on detected input voltage and current said prioritizing including monitoring and adjusting power output based on real-time detection of solar PV panel and AC power input characteristics to ensure optimal battery charging efficiency; and
Step 210 discloses about dynamically balancing load between solar and AC power sources based on power availability and priority settings.

In another embodiment, implementing the two-phase interleaved PFC circuit further includes: synchronizing two interleaved boost converter stages to operate with a 180° phase difference, alternating between positive and negative half cycles of the input AC voltage; configuring reactors (L1 and L2) in reverse phase configuration to cancel out ripple currents and reduce input ripple current; independently switching MOSFETs to simplify thermal management and reduce switching losses by operating at half the switching frequency of a single-phase PFC circuit.

In another embodiment, converting the high DC voltage input from the solar PV panels and AC sources into a regulated 54V DC output includes configuring MOSFETs in a half-bridge topology with a voltage divider capacitor for zero voltage switching (ZVS) in the primary side and zero current switching (ZCS) in the secondary side; utilizing an LLC resonant network comprising inductors and capacitors to facilitate high-frequency switching and voltage transformation; and regulating output voltage to 54V DC for battery charging using a high-frequency step-down transformer.

In another embodiment, the method 200 includes of detecting input voltage and current from solar PV panels and AC power sources using sensors integrated into the HCCU; and communicating input data to a microcontroller via interface modules to relay control signals for managing power sources and output.

In another embodiment, the method 200 includes of mitigating electromagnetic interference from solar PV and AC power sources using an EMI filter; converting AC input voltage to a DC bus using a diode full-bridge rectifier; and delivering a stable 54V DC output for battery charging through an output stage comprising output MOSFETs, capacitors, and filters.

The drawings and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples. Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible. ,CLAIMS:1. A hybrid charge controller rectifier system, comprising:
a Hybrid System Control Command Unit (HCCU) configured to manage input sources from solar photovoltaic (PV) panels and AC power sources;
a DC-DC converter utilizing a half-bridge LLC resonant topology, configured to convert high DC voltage input (380-500VDC) from solar PV panels and AC sources into a regulated 54V DC output for battery charging;
an active power factor correction (PFC) circuit integrated on the AC input side, comprising a two-phase interleaved PFC topology with alternating switching devices operating in reverse polarity and a 180° phase difference; and
a microcontroller to prioritize solar power over AC power for battery charging based on detected input voltage and current, and to regulate power output accordingly.

2. The hybrid charge controller rectifier system as claimed in claim 1, wherein the two-phase interleaved PFC circuit further comprises:
two interleaved boost converter stages synchronized to operate with a 180° phase difference, alternating between positive and negative half cycles of the input AC voltage;
reactors (L1 and L2) in reverse phase configuration, wherein ripple currents cancel out to reduce input ripple current;
MOSFETs configured for independent switching to simplify thermal management and reduce switching losses by operating at half the switching frequency of a single-phase PFC circuit.

3. The hybrid charge controller rectifier system as claimed in claim 1, wherein the DC-DC converter comprises:
MOSFETs arranged in a half-bridge topology with a voltage divider capacitor for zero voltage switching (ZVS) in the primary side and zero current switching (ZCS) in the secondary side;
an LLC resonant network comprising inductors and capacitors to facilitate high-frequency switching and voltage transformation;
a high-frequency step-down transformer to regulate the output voltage to 54V DC for battery charging.
4. The hybrid charge controller rectifier system as claimed in claim 1, wherein the microcontroller is configured to: monitor and adjust power output based on real-time detection of solar PV panel and AC power input characteristics, ensuring optimal battery charging efficiency; and to dynamically balance load between solar and AC power sources based on power availability and priority settings, and wherein the Hybrid System Control Command Unit (HCCU) includes: sensors for detecting input voltage and current from solar PV panels and AC power sources; and interface modules for communication with the microcontroller to relay input data and receive control signals for managing power sources and output.

5. The hybrid charge controller rectifier system as claimed in claim 1, further comprising: an EMI filter for mitigating electromagnetic interference from solar PV and AC power sources; a diode full-bridge rectifier for converting AC input voltage to a DC bus; and an output stage comprising output MOSFETs, capacitors, and filters to deliver a stable 54V DC output for battery charging.

6. A method for operating a hybrid charge controller rectifier system, comprising:
receiving input from solar photovoltaic (PV) panels and AC power sources at a Hybrid System Control Command Unit (HCCU);
converting high DC voltage input (380-500VDC) from the solar PV panels and AC sources into a regulated 54V DC output for battery charging using a DC-DC converter with a half-bridge LLC resonant topology;
implementing an active power factor correction (PFC) circuit on the AC input side, comprising a two-phase interleaved PFC topology with alternating switching devices operating in reverse polarity and a 180° phase difference; and
prioritizing solar power over AC power for battery charging based on detected input voltage and current said prioritizing including:
monitoring and adjusting power output based on real-time detection of solar PV panel and AC power input characteristics to ensure optimal battery charging efficiency; and
dynamically balancing load between solar and AC power sources based on power availability and priority settings.

7. The method as claimed in claim 6, wherein implementing the two-phase interleaved PFC circuit further includes:
synchronizing two interleaved boost converter stages to operate with a 180° phase difference, alternating between positive and negative half cycles of the input AC voltage;
configuring reactors (L1 and L2) in reverse phase configuration to cancel out ripple currents and reduce input ripple current;
independently switching MOSFETs to simplify thermal management and reduce switching losses by operating at half the switching frequency of a single-phase PFC circuit.

8. The method as claimed in claim 6, wherein converting the high DC voltage input from the solar PV panels and AC sources into a regulated 54V DC output includes:
configuring MOSFETs in a half-bridge topology with a voltage divider capacitor for zero voltage switching (ZVS) in the primary side and zero current switching (ZCS) in the secondary side;
utilizing an LLC resonant network comprising inductors and capacitors to facilitate high-frequency switching and voltage transformation; and
regulating output voltage to 54V DC for battery charging using a high-frequency step-down transformer.

9. The method as claimed in claim 6, further comprising:
detecting input voltage and current from solar PV panels and AC power sources using sensors integrated into the HCCU; and
communicating input data to a microcontroller via interface modules to relay control signals for managing power sources and output.

10. The method as claimed in claim 6, further comprising:
mitigating electromagnetic interference from solar PV and AC power sources using an EMI filter;
converting AC input voltage to a DC bus using a diode full-bridge rectifier; and
delivering a stable 54V DC output for battery charging through an output stage comprising output MOSFETs, capacitors, and filters.