An Integrated Single-phase On-board Charger

With the growing demand for transportation electrification, plug-in electric vehicles (PEVs), and plug-in hybrid electric vehicles (PHEVs), cumulatively called electric vehicles (EVs) are drawing more and more attention. The on-board charger (OBC), which is the power electronics interface between the power grid and the high voltage traction battery, is an important part for charging EVs. Besides the OBC, every EV is equipped with another separate power unit called the auxiliary power module (APM) to charge the low voltage (LV) auxiliary battery, which supplies all the electronics on car including audio, air conditioner, lights and controllers. The main target of this work is a novel way to integrate both units together to achieve a charger design that is not only capable of bi-directional operation with high efficiency, but also higher gravimetric and volumetric power density, as compared with those of the existing OBCs and APMs combined. To achieve this target, following contributions are made: (i) a three-port integrated DC/DC converter, which combines OBC and APM together through an innovative integration method; (ii) an innovative zero-crossing current spike compensation for interleaved totem pole power factor correction (PFC) and (iii) a new phase-shift based control strategy to achieve a regulated power flow management with minimum circulating losses

A Bidirectional Soft-Switched DAB-Based Single-Stage Three-Phase AC–DC Converter for V2G Application

In vehicle-to-grid applications, the battery charger of the electric vehicle (EV) needs to have a bidirectional power flow capability. Galvanic isolation is necessary for safety. An ac-dc bidirectional power converter with high-frequency isolation results in high power density, a key requirement for an on-board charger of an EV. Dual-active-bridge (DAB) converters are preferred in medium power and high voltage isolated dc-dc converters due to high power density and better efficiency. This paper presents a DAB-based three-phase ac-dc isolated converter with a novel modulation strategy that results in: 1) single-stage power conversion with no electrolytic capacitor, improving the reliability and power density; 2) open-loop power factor correction; 3) soft-switching of all semiconductor devices; and 4) a simple linear relationship between the control variable and the transferred active power. This paper presents a detailed analysis of the proposed operation, along with simulation results and experimental verification

Review of Electric Vehicle Charging Technologies, Configurations, and Architectures

Electric Vehicles (EVs) are projected to be one of the major contributors to energy transition in the global transportation due to their rapid expansion. The EVs will play a vital role in achieving a sustainable transportation system by reducing fossil fuel dependency and greenhouse gas (GHG) emissions. However, high level of EVs integration into the distribution grid has introduced many challenges for the power grid operation, safety, and network planning due to the increase in load demand, power quality impacts and power losses. An increasing fleet of electric mobility requires the advanced charging systems to enhance charging efficiency and utility grid support. Innovative EV charging technologies are obtaining much attention in recent research studies aimed at strengthening EV adoption while providing ancillary services. Therefore, analysis of the status of EV charging technologies is significant to accelerate EV adoption with advanced control strategies to discover a remedial solution for negative grid impacts, enhance desired charging efficiency and grid support. This paper presents a comprehensive review of the current deployment of EV charging systems, international standards, charging configurations, EV battery technologies, architecture of EV charging stations, and emerging technical challenges. The charging systems require a dedicated converter topology, a control strategy and international standards for charging and grid interconnection to ensure optimum operation and enhance grid support. An overview of different charging systems in terms of onboard and off-board chargers, AC-DC and DC-DC converter topologies, and AC and DC-based charging station architectures are evaluated

Highly Efficient SiC Based Onboard Chargers for Plug-in Electric Vehicles

Grid-enabled plug-in electrified vehicles (PEVs) are deemed as one of the most sustainable solutions to profoundly reduce both oil consumption and greenhouse gas emissions. One of the most important realities, which will facilitate the adoption of PEVs is the method by which these vehicles will be charged. This dissertation focuses on the research of highly efficient onboard charging solutions for next generation PEVs. This dissertation designs a two-stage onboard battery charger to charge a 360 V lithium-ion battery pack. An interleaved boost topology is employed in the first stage for power factor correction (PFC) and to reduce total harmonic distortion (THD). In the second stage, a full bridge inductor-inductor-capacitor (LLC) multi-resonant converter is adopted for galvanic isolation and dc/dc conversion. Design considerations focusing on reducing the charger volume, and optimizing the conversion efficiency over the wide battery pack voltage range are investigated. The designed 1 kW Silicon based charger prototype is able to charge the battery with an output voltage range of 320 V to 420 V from 110 V, 60 Hz single-phase grid. Unity power factor, low THD, and high peak conversion efficiency have been demonstrated experimentally. This dissertation proposes a new technique to track the maximum efficiency point of LLC converter over a wide battery state-of-charge range. With the proposed variable dc link control approach, dc link voltage follows the battery pack voltage. The operating point of the LLC converter is always constrained to the proximity of the primary resonant frequency, so that the circulating losses and the turning off losses are minimized. The proposed variable dc link voltage methodology, demonstrates efficiency improvement across the wide state-of-charge range. An efficiency improvement of 2.1% at the heaviest load condition and 9.1% at the lightest load condition for LLC conversion stage are demonstrated experimentally. This dissertation proposes a novel PEV charger based on single-ended primary-inductor converter (SEPIC) and the maximum efficiency point tracking technique of an LLC converter. The proposed charger architecture demonstrates attracting features such as (1) compatible with universal grid inputs; (2) able to charge the fully depleted battery pack; (3) pulse width modulation and simplified control algorithm; and (4) the advantages of Silicon Carbide MOSFETs can be fully manifested. A 3.3 kW all Silicon Carbide based PEV charger prototype is designed to validate the proposed idea

A SiC-based neutral leg for the three-phase four-wire inverter

SiC-based inverters can operate at high switching frequency with high efficiency, which can reduce the size of passive components and heat sinks to achieve high power density. However, in three-phase four-wire inverters supplying unblanced loads, the second-order ripples in the DC bus need to be mitigated by large DC capacitance, which increases the size of the converter. The conventional neutral leg is widely used in three-phase four-wire inverters to provide neutral currents for the unbalanced loads. In this paper, an improved neutral leg is proposed, which can provide neutral currents and reduce the second-order ripples in the DC bus simultaneously. The DC bus ripples can be reduced without adding any hardware components. Furthermore, the proposed neutral leg can save 50% DC capacitance comparing to the conventional neutral leg. The proposed neutral leg was built with SiC MOSFETs and tested with a three-phase four-wire inverter in the laboratory. The experimental results verified the effectiveness of the proposed neutral leg

A GALLIUM NITRIDE INTEGRATED ONBOARD CHARGER

Compared to Silicon metal–oxide–semiconductor field-effect transistors (MOSFETs), Gallium Nitride (GaN) devices have a significant reduction in gate charge, output capacitance, and zero reverse recovery charge, enabling higher switching frequency operation and efficient power conversion. GaN devices are gaining momentum in power electronic systems such as electric vehicle (EV) charging system, due to their promises to significantly enhance the power density and efficiency. In this dissertation, a GaN-based integrated onboard charger (OBC) and auxiliary power module (APM) is proposed for EVs to ensure high efficiency, high frequency, high power density, and capability of bidirectional operation. The high switching frequency operation enabled by the GaN devices and the integration of OBC and APM bring many unique challenges, which are addressed in this dissertation. An important challenge is the optimal design of high-frequency magnetics for a high-frequency GaN-based power electronic interface. Another challenge is to achieve power flow management among three active ports while minimizing the circulating power. Furthermore, the impact of circuit layout parasitics could significantly deteriorate the system interface, due to the sensitivity of GaN device switching characteristics. In this work, the aforementioned challenges have been addressed. First, a comprehensive analysis of the front-end AC-DC power factor correction stage is presented, covering a detailed magnetic modeling technique to address the high-frequency magnetics challenge. Second, the modeling and control of a three-port DC-DC converter, interfacing the AC-DC stage, high-voltage traction battery and low-voltage battery, are discussed to address the power flow challenge. Advanced control methodologies are developed to realize power flow management while maintaining minimum circulating power and soft switching. Furthermore, a new three-winding high-frequency transformer design with improved power density and efficiency is achieved using a genetic-algorithm-based optimization approach. Finally, a GaN-based integrated charger prototype is developed to validate the proposed theoretical hypothesis. The experimental results showed that the GaN-based charging system has the capability of achieving simultaneous charging (G2B) of both HV and LV batteries with a peak efficiency of 95%

A V2G Integrated Battery Charger Based on an Open End Winding Multilevel Configuration

A new approach to obtain an integrated battery charger is described in this paper, based on the Asymmetrical Hybrid Multilevel Converter topology. Such a particular open-end winding motor configuration, which has proved to be more efficient than conventional inverter topologies in EV motor drive applications, can be turned in an on-board battery charger only by acting on the control system. Thus, no circuit reconfiguration through electro-mechanical switches is required. Moreover, by introducing a single extra power switch, a bilateral power flow can be managed enabling vehicle to grid operations. The obtained integrated battery charger can be supplied either by a standard ac single-phase grid, either by a dc power source for direct connection to domestic energy resources. The proposed approach enables a new remarkable function to the asymmetrical hybrid multilevel converter at a marginal extra cost, thus mitigating the larger complexity and cost of such an inverter if compared with conventional topologies

Analysis and Design of High Efficiency Grid-to-Vehicle (G2V) Plug-in Chargers for Local e-Transportation

Electric transportation worldwide has witnessed a tremendous increase in the use of electric vehicles (EV's) due to increased awareness of environmental issues. Road EV's compromise a broad spectrum of vehicles right from two-wheelers three-wheelers (rickshaws/Auto/Trio), cars and electric buses. E-Rickshaw has gained popularity in the Asian market post-2010 because of their symbolic resemblance with traditional auto-rickshaw. The fast growth of the market is principally pushed by the low ownership cost of electric three-wheelers, falling battery prices, and favorable government policies and support. These EVs run on low-cost 48 V, 120 Ah lead acid battery packs having low depth-of-discharge (DOD). Hence, frequent battery charging becomes essential for such EVs. Conventional battery chargers available in the market utilize flyback converter based topologies in order to charge such battery packs. On one hand such battery chargers are easy to implement, these topologies fail to achieve unity power factor (UPF) operation leading to high total harmonic distortion (THD) and poor input power quality at the input. Thus active power factor correction (PFC) becomes a vital constituent in AC-DC converters. By understanding the constraints posed by continuous current mode (CCM) based battery chargers, the proposed converters are designed to operate in discontinuous current mode (DCM) because of its evident benefits such as inherent PFC, zero current turn-on and zero diode reverse recovery losses. By omitting sensors at the input and utilizing only the output sensors, regulated voltage or current can be obtained which makes the system cost-effective and improves its reliability and robustness to high frequency noise. This thesis presents both isolated and non-isolated battery charger for local e-transportation EVs utilizing 48 V lead acid battery pack. At first, a non-isolated single-stage interleaved buck-boost float charger is proposed by considering the advantages such as reduced current stresses, minimum number of semiconductor devices and absence of bulky high frequency transformer. DCM operation of the proposed converter ensure UPF operation for variable input voltage and utilizing just a single sensor makes this charger configuration economical and easy to implement. However, such a configuration had high current stress on the semiconductor devices leading to increased thermal requirement and reduced efficiency at light loads. Thus addressing these problems, a high efficiency two-stage battery charger is proposed. The battery charger uses an interleaved DCM buck-boost converter in order to achieve PFC at variable input voltage, whereas the second stage is an unregulated half-bridge LLC resonant converter which provides isolation as well as soft-switching for the primary switches. Synchronous rectification (SR) along with only capacitive filter is used on center tapped transformer secondary to improve converter efficiency. Due to DCM of the front-end AC-DC converter achieves zero current turn-on of the switches and DC-DC converter switches achieve zero voltage turn-on because of the LLC resonant. The proposed battery charger implements constant current (CC) and constant voltage (CV) method of charging using simple PI controllers, thus making it suitable for commercial use. Small signal models for both the battery charger configurations are developed using the current injected equivalent circuit approach and a detailed controller design is illustrated. Simulation results using PSIM11.1 software and experimental results from proof-of-concept laboratory hardware prototypes are provided in order to validate the reported analysis and design which demonstrates their performance

SiC-based improved neutral legs with reduced capacitors for three-phase four-wire EV chargers

An electric vehicle (EV) charger can operate in an autonomous mode to create its own grid by utilizing the EV batteries during grid blackouts. This requires three-phase four-wire inverters as the grid-side ac/dc port of the EV charger to supply unbalanced loads. Although silicon carbide (SiC) MOSFETs can be adopted to increase the power density of these inverters, the second order ripples exhibited on the dc bus caused by unbalanced loads need to be mitigated by a large dc capacitance—increasing the size of inverters. In this paper, an improved neutral leg for three-phase four-wire inverters is presented, which not only provides the neutral current for unbalanced loads like a conventional neutral leg, but also reduces the second order ripples on the dc bus without the need for additional hardware components. Furthermore, it can reduce by 50% the dc capacitance compared to its conventional counterpart. A control strategy featuring power decoupling capability is included for the improved leg. It was built with SiC MOSFETs and experimentally assessed with a three-phase inverter, with results verifying its effectiveness. For completeness, the performance of the improved neutral leg is also evaluated through simulations in PLECS and compared to a conventional neutral leg