[cts_casemod]

For 144V I plan to use buck PFC. This only works from a 230VAC supply, basically were aiming at a reduction of the peaks on a normal rectifier to the whole portion of the sine wave where the voltage is greater than 144V. This can typically achieve PFC of about 0.9, with current proportional to voltage (resistive behaviour). A Google search will reveal solutions from Texas instruments and others.

The PFC converter can regulate to a DC voltage very well. Its just overcomplicated because the easiest approach, discontinuous mode, results on high harmonic content and that would likely not pass IEC certification ( USA must have something similar) On a DC supply this does not apply, so assuming there are no sensitive equipments on board one can be more relaxed with the design.

The charger does not provide 6KW at 48V. But it does work down to some 10V. That's a requirement of the PFC.

Operating from DC the supply voltage will set the current limit. If the limit is 10A, then 10*48= 480W, for example. The switches are not being overdriven.

The one currently on my vehicle charges at 1.5KW from a 250V supply, 1350W from a 220V supply and 1KW from a 150VDC supply, but it can operate at lower voltages.

Interleaved is just a way to make sure when one converter is 'charging' the other is supplying the load. With this logic the input and output power is more or less constant rather than pulsating. There is no line synchronization with the AC Mains. AC line synchronization is only used for the outer loop that regulates voltage, but that's a bit of a long subject to describe here.

I can easily charge my LIFEPO4 at 1C up to 70% capacity. Most EVSE's here are rated for at least 7KW (Some for 22). So for a quick 30 minute stop at the grocery shop with an empty battery I could potentionally put 3KW on the battery (15 miles).