A review on integrated battery chargers for electric vehicles

Electric vehicles (EVs) contain two main power electronics systems, namely, the traction system and the battery charging system, which are not used simultaneously since traction occurs when the EV is travelling and battery charging when the EV is parked. By taking advantage of this interchangeability, a single set of power converters that can perform the functions of both traction and battery charging can be assembled, classified in the literature as integrated battery chargers (IBCs). Several IBC topologies have been proposed in the literature, and the aim of this paper is to present a literature review of IBCs for EVs. In order to better organize the information presented in this paper, the analyzed topologies are divided into classical IBCs, IBCs for switched reluctance machines (SRMs), IBCs with galvanic isolation, IBCs based on multiple traction converters and IBCs based on multiphase machines. A comparison between all these IBCs is subsequently presented, based on both requirements and possible functionalities.This work has been supported by FCT - Fundação para a Ciência e Tecnologia within the R&D Units Project Scope: UIDB/00319/2020. T.J.C.S. is supported by the FCT scholarships SFRH/BD/134353/2017 and COVID/BD/151993/2021

Electric Vehicle Powertrain Integrated Charging

Batterieelektrische Fahrzeuge benötigen ein im Fahrzeug eingebautes Ladegerät, um die Energie aus dem Wechselstromnetz für die Gleichstrom- Batterie aufzubereiten. Integriertes Laden ist eine Methode der Integration von Ladefunktionalität in die Antriebsstrangkomponenten, welche während des Parkens außer Betrieb sind, mit dem Ziel, Kosten, Gewicht und Volumen des Ladegerät zu sparen. Das Laden ohne die Sicherheitsmaßnahme einer galvanischen Trennung im Ladegerät ist möglich mit zusätzlichen Maßnahmen gegen elektrischen Schlag, z.B. mit einer Fehlerstromerkennung und entsprechenden Trenneinrichtung. Im Stand der Technik wurden 33 integrierte Ladekonzepte gefunden und bezüglich Antriebsstrangnutzung, benötigte Komponenten, Drehmoment der elektrischen Maschine und Wirkungsgrad verglichen. Im Rahmen dieser Arbeit wird ein neues galvanisch getrenntes integriertes Ladekonzept beschrieben, mit dem Ziel, die Effizienz zu verbessern und gleichzeitig auftretendes Drehmoment in der Maschine zu vermeiden. Der Antriebsstrang wird als DC/DC-Wandler mit der elektrischen Maschine als Transformator im Stillstand genutzt. Berechnungen zeigen eine maximale Effizienz von 88%. Ansätze zur Verbesserung des Wirkungsgrads und zur Integration des Energieflusses im Bordnetz werden in dieser Arbeit vorgeschlagen und diskutiert. Allerdings muss der Rotorkäfig geöffnet werden, um ein Drehmoment während des Laden zu vermeiden. Dies stellt einen ähnlichen Aufwand dar wie die Darstellung eines separaten Ladegeräts. Somit ist dieses Konzept aus heutiger Sicht wegen niedriger Effizienz und hoher Kosten gegenüber einem separaten Ladegerät nicht konkurrenzfähig. Zwei Ladekonzepte ohne galvanische Trennung, die eine sechsphasige elektrische Maschine als in Serie geschaltete Hoch- und Tiefsetzsteller nutzen, werden im Rahmen der Arbeit vorgestellt und bezüglich der benötigten Komponenten, der Effizienz und des Drehmoments des Maschine ausgearbeitet. Die Antriebsstrangverluste werden für die Ladebedingungen mit Gleichströmen analysiert, basierend auf neuen Materialcharakterisierungen für die angewendete Belastung. Es wurden Wirkungsgrade bis zu 93% demonstriert und auch in theoretischen Berechnungen mit einer maximalen Abweichung von ±1% zum experimentellen Befund bestätigt. Zum Schutz gegen elektrischen Schlag bei nicht isolierten Ladekonzepten werden drei Konzepte für eine Fehlerstrommessung präsentiert und anhand von Messergebnissen analysiert. Siliziumkarbid-Inverter-Technologien zeigen in Kombination mit diesen Ladekonzepten Wirkungsgrade, die vergleichbar zu herkömmlichen separaten Ladegeräten sind, und weisen dabei deutlich geringere Kosten auf

Integrated on-board battery chargers for EVs based on multiphase machines and power electronics

The concept of integration of an electric vehicle (EV) drivetrain’s components into the charging process is not novel. It has been considered over the years in both industry and academia, which resulted in a number of published papers and patents in this area. Possibilities of charging from single-phase and three-phase mains were both considered. In the former group the charging power rating cannot exceed the limit set by the single-phase mains. Therefore, the topologies are characterised with low charging powers, leading to a long duration of the charging process. Although the topologies supplied form three-phase mains are capable of achieving fast charging, they were considered to a much lesser extent. The main reason is the undesirable torque production in machines integrated into the charging process during the battery charging, which is unavoidable when a three-phase machine of either synchronous or induction type is used. The thesis investigates integrated on-board battery chargers for electric vehicles (EVs) based on multiphase machines and multiphase power electronics. At present, EVs rely on three-phase systems for machine propulsion. However, recent advances in multiphase drive technology have firmly established their potential advantages over their three-phase counterparts for this application. One of the most notable features of multiphase drive systems is their excellent fault tolerance, which is highly desirable in EVs since it enables realisation of the requirement for “limp-home” operation in the propulsion mode, in case of a fault. The thesis demonstrates that multiphase drives have an additional major advantage over three-phase systems in vehicular applications, which is related to the aspect of battery charging. It shows a clear superiority of multiphase over three-phase systems in designing integrated charging topologies for EVs. In order to support the statement, the thesis provides a multitude of novel charging solutions that incorporate multiphase machines and multiphase power electronics into the charging process. The developed solutions could contribute to achieve significantly faster and cost-free (or at a minimum additional cost) on-board chargers in the near future. The thesis demonstrates how additional degrees of freedom that exist in multiphase systems can be conveniently utilised to achieve torque-free charging operation. Therefore, although three-phase currents flow through machines’ stator windings, they are not capable of producing a torque; thus the machines do not have to be mechanically locked. The principal advantage is that either very few or no new elements are required in order to realise the charging process. Thus savings are made with regard to cost and weight, and available spare space in the vehicle is increased. The novel integrated charging solutions, developed in the thesis, are based on primarily five-phase, asymmetrical and symmetrical six-phase, and asymmetrical and symmetrical nine-phase systems. Solutions with other phase numbers are also considered. Thus, in essence, all the possible phase numbers are encompassed by the research and the solutions are valid for both induction and synchronous machines. A common attribute of all discussed topologies is that they do not require a charger as a separate device since the charging function is performed by the drivetrain elements, predominantly a multiphase machine and an inverter. Further, each topology is capable of operating in both charging and vehicle-to-grid (V2G) mode. Three types of voltage sources are considered as a power supply for the charging process, namely single-phase, three-phase, and multiphase. For each supply type, and each phase number, viability of torque-free charging operation is theoretically assessed. Mathematical models of multiphase rectifiers are developed. For each topology equivalent scheme in the charging/V2G mode of operation is constructed. A control scheme, which aims at achieving unity power factor operation and complete suppression of the low order grid current harmonics, is designed for each solution. Finally, the validity of theoretical considerations and control algorithms for the developed solutions is experimentally assessed in charging, V2G, and propulsion mode of operation. Experimental performances of all discussed topologies are compared, and advantages and shortcomings of each solution are identified and discussed

On the Modeling, Analysis and Development of PMSM: For Traction and Charging Application

Permanent magnet synchronous machines (PMSMs) are widely implemented commercially available traction motors owing to their high torque production capability and wide operating speed range. However, to achieve significant electric vehicle (EV) global market infiltration in the coming years, the technological gaps in the technical targets of the traction motor must be addressed towards further improvement of driving range per charge of the vehicle and reduced motor weight and cost. Thus, this thesis focuses on the design and development of a novel high speed traction PMSM with improved torque density, maximized efficiency, reduced torque ripple and increased driving range suitable for both traction and integrated charging applications. First, the required performance targets are determined using a drive cycle based vehicle dynamic model, existing literature and roadmaps for future EVs. An unconventional fractional–slot distributed winding configuration with a coil pitch of 2 is selected for analysis due to their short end–winding length, reduced winding losses and improved torque density. For the chosen baseline topology, a non–dominated sorting genetic algorithm based selection of optimal odd slot numbers is performed for higher torque production and reduced torque ripple. Further, for the selected odd slot–pole combination, a novel star–delta winding configuration is modeled and analyzed using winding function theory for higher torque density, reduced spatial harmonics, reduced torque ripple and machine losses. Thereafter, to analyze the motor performance with control and making critical decisions on inter–dependent design parameter variations for machine optimization, a parametric design approach using a novel coupled magnetic equivalent circuit model and thermal model incorporating current harmonics for fractional–slot wound PMSMs was developed and verified. The developed magnetic circuit model incorporates all machine non–linearities including effects of temperature and induced inverter harmonics as well as the space harmonics in the winding inductances of a fractional–slot winding configuration. Using the proposed model with a pareto ant colony optimization algorithm, an optimal rotor design is obtained to reduce the magnet utilization and obtain maximized torque density and extended operating range. Further, the developed machine structure is also analyzed and verified for integrated charging operation where the machine’s winding inductances are used as line inductors for charging the battery thereby eliminating the requirement of an on–board charger in the powertrain and hence resulting in reduced weight, cost and extended driving range. Finally, a scaled–down prototype of the proposed PMSM is developed and validated with experimental results in terms of machine inductances, torque ripple, torque–power–speed curves and efficiency maps over the operating speed range. Subsequently, understanding the capabilities and challenges of the developed scaled–down prototype, a full–scale design with commercial traction level ratings, will be developed and analyzed using finite element analysis. Further recommendations for design improvement, future work and analysis will also be summarized towards the end of the dissertation

A fast on-board integrated battery charger for four-motor EVs

A novel type of fast on-board battery charger, applicable for four-motor electric vehicles (EVs), is presented in the paper. The charger consists exclusively of components that are already present on-board the vehicle. Having no new elements, it has a positive impact on the cost, weight and space saving in the vehicle. A three-phase grid is directly attached to the neutral points of three propulsion machines, so that hardware reconfiguration with respect to the propulsion mode of operation is not required. The charger operates with unity power factor and both charging and vehicle-to-grid (V2G) modes are feasible. The torque is not produced in the machines during the charging/V2G process. The charger is particularly suited for the interleaving process, which is used to improve the quality of the current that is taken/injected into the grid. A complete control algorithm for the charging/V2G operation is given, and performance of the charger, including torque-free operation feature, is validated by simulations

Technical Challenges and Solutions of a three-phase bidirectional two stage Electric Vehicle charger

The sustainability of the power grid owing to the building strain of the ever-growing demand for electrical energy urges innovative and more practical solutions that enable active participation of end-users in stable and reliable management of power systems. One of the emerging projections of such a two-way exchange of electrical power between the grid and consumers is the developing field of bidirectional energy trade between power providers and electric vehicle owners. A bidirectional, three-phase, two-stage off-board electric vehicle EV charger design is proposed in this research. The first stage acts as alternating current AC to direct current DC converter during charging operation and behaves as three phase inverter and power factor corrector when energy exchange is from vehicle to grid. The second stage is a bidirectional DC-DC level converter linked to the first stage by a DC bus. The grid side filter is designed to enable the grid interfacing without any significant power quality problems. The proposed design, topology and the devised control infrastructure are tested through simulations on MATLAB/Simulink platform by interfacing the charger to a three-phase AC microgrid and the results approve the performance of the proposed charging topology

An Isolated Integrated Charger for Electric or Plug-in Hybrid Vehicles

For electric and hybrid vehicles using grid power to charge the battery, traction circuit components are not normally engaged during the charging time, so there is a possibility to use them in the charger circuit to have an on-board integrated charger.In this Licentiate thesis, an isolated high power integrated charger is proposed, designed and constructed based on a special ac machine with a double set of stator windings called motor/generator.The charger is capable of unit power factor operation as well as bi-directional power operation for grid to vehicle application.The mathematical electromechanical model of the motor/generator is derived and presented. Based on the developed model, new controller schemes are developed and designed for the grid synchronization and charge control. The machine windings are re-arranged for the traction and charging by a controllable relay-based switching device that is designed for this purpose.A laboratory system is designed and implemented based on a $4$ pole $25~kW$ interior permanent magnet synchronous motor and a frequency converter considering the integrated charging features for winding re-configuration. The practical results will be added in the next step of the project. The charging power is limited to $12.5~kW$ due to the machine thermal limit (half of the motor full power in the traction mode) for this system.The whole system is simulated in Matlab/Simulink based on the developed model and controllers to verify the system operation for the charge control. Simulation results show that the system has good performance during the charging time for a load step change. The simulation results show also a good performance of the controllers leading to machine speed stability and smooth grid synchronization. Moreover, the unit power factor operation is achieved for battery charging in the simulations

An Isolated Integrated Charger for Electric or Plug-in Hybrid Vehicles

For electric and hybrid vehicles using grid power to charge the battery, traction circuit components are not normally engaged during the charging time, so there is a possibility to use them in the charger circuit to have an on-board integrated charger.In this Licentiate thesis, an isolated high power integrated charger is proposed, designed and constructed based on a special ac machine with a double set of stator windings called motor/generator.The charger is capable of unit power factor operation as well as bi-directional power operation for grid to vehicle application.The mathematical electromechanical model of the motor/generator is derived and presented. Based on the developed model, new controller schemes are developed and designed for the grid synchronization and charge control. The machine windings are re-arranged for the traction and charging by a controllable relay-based switching device that is designed for this purpose.A laboratory system is designed and implemented based on a $4$ pole $25~kW$ interior permanent magnet synchronous motor and a frequency converter considering the integrated charging features for winding re-configuration. The practical results will be added in the next step of the project. The charging power is limited to $12.5~kW$ due to the machine thermal limit (half of the motor full power in the traction mode) for this system.The whole system is simulated in Matlab/Simulink based on the developed model and controllers to verify the system operation for the charge control. Simulation results show that the system has good performance during the charging time for a load step change. The simulation results show also a good performance of the controllers leading to machine speed stability and smooth grid synchronization. Moreover, the unit power factor operation is achieved for battery charging in the simulations

Design and implementation of a transistorized bi-controlled based utility-connected battery charger for underdeveloped nations

This paper presents a transistorized bi-controlled based utility-connected battery charger to address the problem of erratic public power supply in underdeveloped nations. In this study, a utility battery charger was built by the integration of grid power supply, line frequency transformer, power electronic switches, alternating current-direct current bridge converter, regulator, and resistor-inductor-capacitor. The excess-voltage protection and battery monitoring were obtained by the bi-controlled technique. In contrast to other charging systems in underdeveloped nations, the proposed system is very simple, rugged, reliable and cheap to maintain due to simplicity and un-programmed nature of the system. The results showed that the proposed system is craggy and robust to resist voltage stress, highly reliable and relatively free from leakage currents due to the presence of a double controlled scheme using a common point of action and a line frequency transformer. In addition, the system can be used to charge batteries ranging from 50μA and above. The system can be utilized in communication companies, electric vehicles, drilling machines