Isolated Chargers for EVs Incorporating Six-Phase Machines

This paper considers two isolated solutions for fast charging of electric vehicles (EVs). The isolation is located on the grid side (off board), whereas the rest of the charging apparatus is placed on board the EV, and it entirely consists of the existing power electronics components that would be otherwise used only for propulsion. Thus, substantial savings on space, weight, and cost are achieved. The considered configurations fully incorporate either a symmetrical or an asymmetrical six-phase machine, as well as a six-phase inverter, into the charging process. Due to the nature of the connections, torque production is avoided during the charging/vehicle-to-grid (V2G) modes of operation. Thus, the machines do not have to be mechanically locked, and their rotors naturally stay at standstill. Control schemes for both configurations are elaborated, and theoretical results are validated by experiments for the two configurations in both charging and V2G modes

Integrated on-board EV battery chargers: New perspectives and challenges for safety improvement

Thanks to the heavy reduction of cost and volume, integrated On-Board Chargers (OBCs) represent an effective solution to provide a versatile and powerful charging system on board of electric and plug-in electric vehicles, combining the charging function with the traction drivetrain. Such integration foresees the use of the traction motor windings as reactive elements and the traction inverter as AC/DC converter. However, this integration brings several challenges on the table. At first, shaft torque production must be avoided to reduce the losses and mechanical stress. A second challenge is to improve the filtering capability of the motor windings in order to meet the grid standards in terms of current distortion and power factor correction. At last, the most critical issue is to meet the safety standards in terms of leakage current, since it represents a risk to human operators and could also hamper the smooth operation of the charger. Therefore, this paper aims at giving a comprehensive review of the challenges in designing integrated chargers. After reviewing the architectures available in literature, an exemplifying structure of integrated OBC will be analysed in terms of leakage current generation and compliance with the relevant standards, along with an introduction to those solutions which use the machine as isolation transformer. Conclusions are given on the prospect for making integrated on-board chargers safer and more reliable

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

Single-Phase On-Board Integrated Battery Chargers for EVs Based on Multiphase Machines

The paper considers integration of multiphase (more than three phases) machines and converters into a single-phase charging process of electric vehicles (EVs) and, thus, complements recently introduced fast charging solutions for the studied phase numbers. One entirely novel topology, employing a five-phase machine, is introduced and assessed jointly with three other topologies that use an asymmetrical nine-phase machine, an asymmetrical six-phase machine, and a symmetrical six-phase machine. In all topologies, both charging and vehicle-to-grid (V2G) mode are viable. Moreover, all are capable of unity power factor operation. A torque is not produced in machines during charging/V2G process so that mechanical locking is not required. Hardware reconfiguration between propulsion and charging/V2G mode is either not required or minimized by using a single switch. Theoretical analysis of operating principles is given, and a control scheme, applicable to all topologies and which includes current balancing and interleaving strategy, is developed. Finally, operation of all topologies is compared by means of experiments in both charging and V2G mode, with a discussion of influence of current balancing and interleaving strategy on the overall performance

Onboard Integrated Battery Charger for EVs Using an Asymmetrical Nine-Phase Machine

This paper considers an integrated onboard charger for electric vehicles that incorporates an asymmetrical nine-phase machine and an inverter into the charging process. The charging is from three-phase mains, and it employs exclusively the power electronic components that already exist on board the vehicle and that are mandatory for the propulsion. No new elements are introduced. Moreover, the charging is achieved without any hardware reconfiguration since the existing elements and their connections are not altered during the transfer from propulsion to the charging mode. Instead, the operating principle is based on additional degrees of freedom that exist in nine-phase machines. These degrees of freedom are employed to avoid electromagnetic torque production in the machine during the charging process, although currents flow through its stator windings. The configuration operates with a unity power factor and is capable of vehicle to grid (V2G) operation as well. A detailed theoretical analysis is given, and the control for the charging/V2G and propulsion modes is discussed. Theoretical analysis is validated by experiments for charging, V2G, and propulsion operating regimes

Integration of Six-Phase EV Drivetrains into Battery Charging Process with Direct Grid Connection

The paper proposes two novel topologies for integrated battery charging of electric vehicles (EVs). The integration is functional and manifests through re-utilization of existing propulsion drivetrain components, primarily a six-phase inverter and a six-phase machine, to serve as components of a fast (three-phase) charging system. An important feature of the proposed charging systems is that they are with direct grid connection, thus non-isolated from the mains. Torque is not produced in machines during the charging process. The paper provides a comprehensive evaluation of the novel systems, together with an existing topology. Various aspects of the considered chargers are detailed and elaborated, including current balancing, interleaving modulation strategy, and influence of rotor field pulsation on control and overall performance. A control strategy is proposed and the theory and control scheme are verified by experiments

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

Efficiency Evaluation of Fully Integrated On-board EV Battery Chargers with Nine-Phase Machines

A fully integrated on-board battery charger for future electric vehicles (EVs) has been recently introduced. It re-utilizes all the propulsion components of an EV in charging/vehicle-to-grid (V2G) modes, it does not require any additional components or hardware reconfiguration, and charging/V2G modes are realized with zero electromagnetic torque production. Both fast (three-phase) and slow (single-phase) charging are possible, with unity power factor operation at the grid side. The solution is based on the use of a triple three-phase machine and a nine-phase inverter/rectifier. This paper reports on the results of efficiency evaluation for the said system. Testing is performed using both a nine-phase induction machine and a nine-phase permanent magnet (PM) machine for a range of operating conditions in charging/V2G modes, with both three-phase and single-phase grid connection. Additionally, the impact of converter interleaving on the losses and efficiency is also studied. Losses are separated for different subsystems, thus providing an insight into the importance of optimization of different EV power train components from the efficiency point of view. Promising efficiencies, in the order of 90%, are achieved although none of the system components have been optimized

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

Vehicle electrification: technologies, challenges and a global perspective for smart grids

Nowadays, due to economic and climate concerns, the private transportation sector is shifting for the vehicle electrification, mainly supported by electric and hybrid plug-in vehicles. For this new reality, new challenges about operation modes are emerging, demanding a cooperative and dynamic operation with the electrical power grid, guaranteeing a stable integration without omitting the power quality for the grid-side and for the vehicle-side. Besides the operation modes, new attractive and complementary technologies are offered by the vehicle electrification in the context of smart grids, which are valid for both on-board and off-board systems. In this perspective, this book chapter presents a global perspective and deals with challenges for the vehicle electrification, covering the key technologies toward a sustainable future. Among others, the flowing topics are covered: (1) Overview of power electronics structures for battery charging systems, including on-board and off-board systems; (2) State-of-the-art of communication technologies for application in the context of vehicular electrification, smart grids and smart homes; (3) Challenges and opportunities concerning wireless power transfer with bidirectional interface to the electrical grid; (4) Future perspectives about bidirectional power transfer between electric vehicles (vehicle-to-vehicle operation mode); (5) Unified technologies, allowing to combine functionalities of a bidirectional interface with the electrical grid and motor driver based on a single system; and (6) Smart grids and smart homes scenarios and accessible opportunities about operation modes.Fundação para a Ciência e Tecnologia (FCT