Three-Level Reduced Switch AC/DC/AC Power Conversion System for High Voltage Electric Vehicles

Two of the main challenges of recent electric vehicles (EVs) are the charging time and high initial cost. To solve the problem associated with long charging time, the car manufacturers are moving from 400 V battery EV (BEV) to 800 V BEV, which enables the utilization of multi-level converters in EV applications. This paper presents a power conversion system consisting of a Vienna rectifier and a two/three level hybrid inverter as a machine-side inverter to drive a permanent-magnet synchronous motor (PMSM). The Vienna rectifier improves the quality of the grid-side current and provides a regulated DC-link voltage. The proposed inverter, known as a 10-switch inverter, offers high output current quality with a lower number of active switches, making it compact and cost-effective. The field-oriented control (FOC), along with the SPWM modulation, is implemented to control the system. A reliable and cost-effective PMSM drive system demands sensorless control; therefore, a sliding mode observer (SMO) is used to estimate the rotor position and velocity. The accuracy of the proposed system was proved through the simulation results from MATLAB/Simulink.© 2022 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).fi=vertaisarvioitu|en=peerReviewed

Integrated battery charger for electric scooter

The paper deals with a battery charger integrated into the traction hardware of an electric scooter, for recharging the scooter batteries by means of a single-phase AC source. A mechanical switch and a rectifier bridge are the only additional components required to transform the electric scooter powetrain into a PFC battery charger, suitable for current-controlled or voltage-controlled recharge. The AC current is controlled at unitary power factor with no harmonic distortion. Switching harmonics are also drastically reduced by means of phase-interleaving. The battery charge is regulated according to the requests of the Battery Monitor System (BMS) that is embedded into the battery packs. The effectiveness of the integrated battery charger is demonstrated here on an electric scooter with high voltage Li-Ion battery (260V) and DC/DC/AC power conversion scheme. The integrated PFC charger concept is also valid for electric vehicles with AC traction drives based on a direct DC/AC conversion scheme, as demonstrated throughout the paper

Integrated battery charger for electric scooter

The paper deals with a battery charger integrated into the traction hardware of an electric scooter, for recharging the scooter batteries by means of a single-phase AC source. A mechanical switch and a rectifier bridge are the only additional components required to transform the electric scooter powetrain into a PFC battery charger, suitable for current-controlled or voltage-controlled recharge. The AC current is controlled at unitary power factor with no harmonic distortion. Switching harmonics are also drastically reduced by means of phase-interleaving. The battery charge is regulated according to the requests of the Battery Monitor System (BMS) that is embedded into the battery packs. The effectiveness of the integrated battery charger is demonstrated here on an electric scooter with high voltage Li-Ion battery (260V) and DC/DC/AC power conversion scheme. The integrated PFC charger concept is also valid for electric vehicles with AC traction drives based on a direct DC/AC conversion scheme, as demonstrated throughout the paper

Single-Sensor DCM PFC Based Onboard Chargers for Low Voltage Electric Vehicles

Grid-connected plug-in electric vehicles (PEVs) are considered as one of the most sustainable solutions to substantially reduce both the oil consumption and greenhouse gas emissions. Electric vehicles (EVs) are broadly categorized into low power EVs (48/72 V battery) and high power EVs (450/650 V battery). Low power EVs comprise two-wheelers, three-wheelers (rickshaws), golf carts, intra-logistics equipment and short-range EVs whereas high power EVs consist of passenger cars, trucks and electric buses. Charger, which is a power electronic converter, is an important component of EV infrastructures. These chargers consist of power converters to convert AC voltage (grid) to constant DC voltage (battery). The existing chargers are bulky, have high components’ count, complex control system and poor input power quality. Henceforth, to overcome these drawbacks, this thesis focuses on the onboard charging solutions (two-stage isolated and single-stage non-isolated) for the low voltage battery EVs. Power factor correction (PFC) is the fundamental component in the EV charger. Considering the specific boundaries of the continuous conduction mode (CCM) operation for AC-DC power conversion and their complexity, the proposed chargers are designed to operate in discontinuous conduction mode (DCM) and benefiting from the characteristics like built-in PFC, single sensor, simple control, easy implementation, inherent zero-current turn-on of the switches, and inherent zero diode reverse recovery losses. Proposed converters can operate for the wide input voltage range and the output voltage is controlled by a single sensor-based single voltage control loop making the control simple and easy to implement, and improves the system reliability and robustness. This thesis studies and designs both single-stage non-isolated and two-stage isolated onboard battery chargers to charge a 48 V lead-acid battery pack. At first, a non-isolated single-stage single-cell buck-boost PFC AC-DC converter is studied and analyzed that offers reduced components’ count and is cost-effective, compact in size and illustrates high efficiency. While the DCM operation ensures unity power factor (UPF) operation at AC mains without the use of input voltage and current sensors. However, they employ high current rated semiconductor devices and the use of diode bridge rectifier suffers from higher conduction losses. To overcome these issues, a new front-end bridgeless AC-DC PFC topology is proposed and analyzed. With this new bridgeless front-end topology, the conduction losses are significantly reduced resulting in improved efficiency. The low voltage stress on the semiconductor devices are observed because of the voltage doubler configuration. Later, an isolated two-stage topology is proposed. The previously proposed bridgeless buck-boost derived PFC converter is employed followed by an isolated half-bridge LLC resonant converter. Loss analysis is done to determine optimal DC-link voltage for the efficient operation of the proposed conversion. The converters' steady-state operation, DCM condition, and design equations are reported in detail. The small-signal models for all the proposed topologies using the average current injected equivalent circuit approach are developed, and detailed closed-loop controller design is illustrated. The simulation results from PSIM 11.1 software and the experimental results from proof-of-concept laboratory hardware prototypes are provided in order to validate the reported analysis, design, and performance

Multimegawatt dynamic NEP PMAD study

The National Aeronautics and Space Administration Lewis Research Center (NASA LeRC) is developing a FORTRAN-based model of a complete nuclear electric propulsion (NEP) vehicle to be used for piloted or cargo missions to the Moon or Mars. The proposed vehicle will use either a Brayton or K-Rankine power conversion cycle, and either ion or magnetoplasmadynamic (MPD) thrusters. In support of this effort, Rocketdyne evaluated various power management and distribution (PMAD) approaches and selected a low-frequency design that is based on the direct use of the alternator voltage and frequency for power transmission. This approach was compared with dc and high-frequency ac designs, and selected on the basis of mass, efficiency, and qualitative assessment of power quality, reliability and development costs. This low-frequency architecture will be used as the reference in future NEP PMAD studies and for the subsequent FORTRAN model development

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

Hybrid electric vehicle power management solutions based on isolated and nonisolated configurations of multilevel modular capacitor-clamped converter

Journal ArticleAbstract-This paper presents the various configurations of a multilevel modular capacitor-clamped converter (MMCCC), and it reveals many useful and new formations of the original MMCCC for transferring power in either an isolated or nonisolated manner. The various features of the original MMCCC circuit are best suited for a multibus system in future plug-in hybrid or fuel-cell-powered vehicles' drive train. The original MMCCC is capable of bidirectional power transfer using multilevel modular structure with capacitor-clamped topology. It has a nonisolated structure, and it offers very high efficiency even at partial loads. This circuit was modified to integrate single or multiple high-frequency transformers by using the intermediate voltage nodes of the converter. On the other hand, a special formation of the MMCCC can exhibit dc outputs offering limited isolation without using any isolation transformer. This modified version can produce a high conversion ratio from a limited number of components and has several useful applications in providing power to multiple low-voltage loads in a hybrid or electric automobile. This paper will investigate the origin of generating ac outputs from the MMCCC and shows how the transformer-free version can be modified to create limited isolation from the circuit. In addition, this paper will compare various modified forms of the MMCCC topology with existing dc-dc converter circuits from compactness and component utilization perspectives

An Integral Battery Charger with Power Factor Correction for Electric Scooter

This paper presents an integral battery charger for an electric scooter with high voltage batteries and interior-permanent-magnet motor traction drive. The battery charger is derived from the power hardware of the scooter, with the ac motor drive that operates as three-phase boost rectifier with power factor correction capability. The control of the charger is also integrated into the scooter control firmware that is implemented on a fixed-point DSP controller. Current-controlled or voltage-controlled charge modes are actuated according to the requirements of the battery management system, that is embedded into the battery pack. With respect to previous integrated chargers, the ac current is absorbed at unitary power factor with no harmonic distortion. Moreover, no additional filtering is needed since the pulsewidth modulation ripple is minimized by means of phase interleaving. The feasibility of the integral charger with different ac motors (induction motor, surface-mounted phase modulation motor) is also discussed, by means of a general model purposely developed for three-phase ac machines. The effectiveness of the proposed battery charger is experimentally demonstrated on a prototype electric scooter, equipped with two Li-ion battery packs rated 260 V, 20 A