Modular Battery Systems for Electric Vehicles based on Multilevel Inverter Topologies - Opportunities and Challenges

Modular battery systems based on multilevel inverter (MLI) topologies can possibly overcome some shortcomings of two-level inverters when used for vehicle propulsion. The results presented in this thesis aim to point out the advantages and disadvantages, as well as the technical challenges, of modular vehicle battery systems based on MLIs in comparison to a conventional, two-level IGBT inverter drivetrain. The considered key aspects for this comparative investigation are the drive cycle efficiency, the inverter cost, the fault tolerance capability of the drivetrain and the conducted electromagnetic emissions. Extensive experiments have been performed to support the results and conclusions.In this work, it is shown that the simulated drive cycle efficiency of different low-voltage-MOSFET-based, cascaded seven-level inverter types is improved in comparison to a similarly rated, two-level IGBT inverter drivetrain. For example, the simulated WLTP drive cycle efficiency of a cascaded double-H-bridge (CDHB) inverter drivetrain in comparison to a two-level IGBT inverter, when used in a small passenger car, is increased from 94.24% to 95.04%, considering the inverter and the ohmic battery losses. In contrast, the obtained efficiency of a similar rated seven-level cascaded H-bridge (CHB) drivetrain is almost equal to that of the two-level inverter drivetrain, but with the help of a hybrid modulation technique, utilizing fundamental selective harmonic elimination at lower speeds, it could be improved to 94.85%. In addition, the CDHB and CHB inverters’ cost, in comparison to the two-level inverter, is reduced from 342€ to 202€ and 121€, respectively. Furthermore, based on a simple three-level inverter with a dual battery pack, it is shown that MLIs inherently allow for a fault tolerant operation. It is explained how the drivetrain of a neutral point clamped (NPC) inverter can be operated under a fault condition, so that the vehicle can drive with a limited maximum power to the next service station, referred to as limp home mode. Especially, the detection and localization of open circuit faults has been investigated and verified through simulations and experiments.Moreover, it is explained how to measure the conducted emissions of an NPC inverter with a dual battery pack according to the governing standard, CISPR 25, because the additional neutral point connection forms a peculiar three-wire DC source. To separate the measured noise spectra into CM, line-DM and phase-DMquantities, two hardware separators based on HF transformers are developed and utilized. It is shown that the CM noise is dominant. Furthermore, the CM noise is reduced by 3dB to 6dB when operating the inverter with three-level instead of two-level modulation

Efficiency of Active Three-Level and Five-Level NPC Inverters Compared to a Two-Level Inverter in a Vehicle

This paper deals with a comparison of a standard two-level inverter, with a three-level and a five-level active neutral point clamped (ANPC) inverter for vehicle traction applications. The inverter efficiencies during different drive cycles are assessed and an efficiency enhancement of the multilevel inverters for partial loading and different drive cycle scenarios is found

Hybrid Output Voltage Modulation (PWM-FSHE) for a Modular Battery System Based on a Cascaded H-Bridge Inverter for Electric Vehicles Reducing Drivetrain Losses and Current Ripple

This paper shows a preliminary study about the output voltage modulation of a modular battery system based on a seven-level cascaded H-bridge inverter used for vehicle propulsion. Two generally known modulation techniques, pulse width modulation (PWM) and fundamental selective harmonic elimination (FSHE), are extensively compared for such an innovative modular battery system inverter considering EVs\u27 broad torque-speed range. The inverter and the battery losses, as well as the inverter-induced current THD, are modeled and quantified using simulations. At low speeds, if the modulation index M is below 0.3, FSHE induces a high current THD (>>5%) and, thus, cannot be used. At medium speeds, FSHE reduces the drivetrain losses (including the battery losses), while operating at higher speeds, it even reduces the current THD. Thus, an individual boundary between multilevel PWM and FSHE can be determined using weightings for efficiency and current quality. Based on this, a simple hybrid modulation technique is suggested for modular battery system inverters, improving the simulated drive cycle efficiency by a maximum of 0.29% to 0.42% for a modeled small passenger vehicle. Furthermore, FSHE\u27s high speed dominance is demonstrated using a simple experimental setup with an inductive load

Review of Technical Design and Safety Requirements for Vehicle Chargers and Their Infrastructure According to National Swedish and Harmonized European Standards

Battery electric vehicles demand a wide variety of charging networks, such as charging stations and wallboxes, to be set up in the future. The high charging power (typically in the range of a couple of kW up to a couple of hundred kW) and the possibly long duration of the charging process (up to more than 24 h) put some special requirements on the electrical infrastructure of charging stations, sockets, and plugs. This paper gives an overview of the technical design requirements and considerations for vehicle charging stations, sockets, and plugs, including their infrastructure, according to the Swedish Standard 4364000, "Low-voltage electrical installations-Rules for design and erection of electrical installations", and the corresponding harmonized European standards. In detail, the four internationally categorized charging modes are explained and the preferable charging plugs, including their two-bus communication, according to European Directives are shown. The dimensioning of the supply lines and the proper selection of the overcurrent protection device, the insulation monitor, and the residual current device are described. Furthermore, a comprehensive overview of the required safety measures, such as the application of an isolation transformer or the implementation of an overvoltage protection mechanism, and the limits for conducted electromagnetic emissions, such as low-frequency harmonics or high-frequency (150 kHz to 108 MHz) emissions, are given

Online and On-Board Battery Impedance Estimation of Battery Cells, Modules or Packs in a Reconfigurable Battery System or Multilevel Inverter

This paper shows two approaches to determine the battery impedance of battery cells or battery modules when used in a reconfigurable battery system (RBS) or in any type of modular multilevel converter (MMC) for electric drive applications. A generic battery model is used and the concepts of the recursive time and frequency-domain parameter extraction, using a current step and an electrochemical impedance spectroscopy, are explained. Thus, it is shown and demonstrated that the balancing current of neighboring cells/modules ,when in parallel operation, can be used, similar to the time-domain parameter extraction utilizing a current step, to determine the battery parameters. Furthermore, it is shown and demonstrated that a part of the inverter can be used as variable AC voltage source to control a sinusoidal current through the motor inductances of the drive train, which can be injected to the inserted battery cells/modules of an adjacent phase to perform an on-board impedance spectroscopy. Using either of the two presented approaches, the individual battery impedances can be easily determined, yielding the state of health (SOH) and the power capability of individual battery cells/modules. Nonetheless, the analyzed approaches were just considered to be applied at machine standstill, which is not suitable for grid-tied applications

Next-Generation Battery Management Systems: Dynamic Reconfiguration

Batteries are widely applied to the energy storage and power supply in portable electronics, transportation, power systems, communication networks, etc. They are particularly demanded in the emerging technologies of vehicle electrification and renewable energy integration for a green and sustainable society. To meet various voltage, power, and energy requirements in large-scale applications, multiple battery cells have to be connected in series and/or parallel. While battery technology has advanced significantly in the past decade, existing battery management systems (BMSs) mainly focus on state monitoring and control of battery systems packed in fixed configurations. In fixed configurations, though, the battery system performance is in principle limited by the weakest cells, which can leave large parts severely underutilized. Allowing dynamic reconfiguration of battery cells, on the other hand, allows individual and flexible manipulation of the battery system at cell, module, and pack levels, which may open up a new paradigm for battery management. Following this trend, this paper provides an overview of next-generation BMSs featuring dynamic reconfiguration. Motivated by numerous potential benefits of reconfigurable battery systems (RBSs), the hardware designs, management principles, and optimization algorithms for RBSs are sequentially and systematically discussed. Theoretical and practical challenges during the design and implementation of RBSs are highlighted in the end to stimulate future research and development

Analytical Conduction Loss Calculation of a MOSFET Three-Phase Inverter Accounting for the Reverse Conduction and the Blanking Time

The reverse conduction capability of MOSFETs is beneficial for the efficiency of a three-phase inverter. In this paper analytical expressions in closed form are presented which allow to quickly evaluate the conduction losses, considering the effect of the reverse conduction and blanking time for both sinusoidal PWM operation with and without third harmonic injection. The losses of a three-phase SiC MOSFET inverter suitable for traction applications are estimated with the proposed method and show good agreement of about 98.5 % with measurements, performed with a calorimetric setup

Improved efficiency with adaptive front and rear axle independently driven powertrain and disconnect functionality

Front and rear axle independently driven (FRID) powertrains are becoming a popular solution for electric vehicles (EVs) due to torque distribution capability which can enhance powertrain energy efficiency. Typically, permanent magnet synchronous machines (PMSMs) are used for FRID powertrains due to their high torque, and power density. However, the drive-cycle efficiency of FRID powertrains with PMSMs is typically reduced in comparison to single motor drives. This is due to the unwanted no-load losses of PMSMs in the field weakening region. To overcome this drawback of PMSM FRIDs, this paper proposes an adaptive front- and rear-axle independently driven (AFRID) powertrain, utilizing two dog clutches, so that the powertrain can be operated in different modes (rear, front, and all-wheel drive) by adaptively connecting and disconnecting the front and/or rear electric drive unit (EDU). A rule-based mode selection strategy is developed to utilize the flexibility of different powertrain operating modes of the powertrain for maximizing the energy efficiency of the EDU. The simulation results show that the suggested AFRID powertrain, in comparison to a common FRID powertrain, can improve the WLTC drive-cycle consumption from 22.17 kWhh to 20.50 kWhh per 100 km. Based on the route and road-load information, the energy-saving potential of the AFRID powertrain can be further improved to 20.37 kWhh per 100 km by a suggested predictive mode selection strategy, achieving an optimal mode selection

Analysis and Estimation of the Maximum Switch Current during Battery System Reconfiguration

Batteries are interconnected in series and/or parallel to meet wide-range power or energy demands in various industrial applications. To pursue the benefits of multiple connection structures in one system, reconfigurable battery systems (RBSs) have recently emerged for safe and efficient operation, extended energy storage and delivery, etc. Switches are the essential elements to enable the battery system reconfiguration, but selecting appropriate switches for RBS designs has not been systematically investigated. To bridge this gap, analytical expressions are derived in this paper to estimate the maximum switch current and its upper limit to facilitate the selection of RBS switches. An RBS prototype based on H-bridges is set up and experimental results verify the effectiveness and advantage of the proposed estimation method. These analytical expressions, relying only on resistances of batteries and switches, are readily applicable to practical RBS design and much more efficient than conducting numerous circuit experiments, simulation tests, or circuit analyses, especially for large-scale systems. Moreover, the analysis framework and estimation method proposed for series-parallel mutual conversion can be adaptively extended to other complex system reconfigurations to facilitate various RBS designs

Exponential Modular Multilevel Converter for Low Voltage Applications

This paper presents the structure and control of a single phase Exponential Modular Multilevel Converter (EMMC), which works as a bidirectional AC/DC converter. In addition to the main H-bridge converter, it uses series connected H-bridges with DC link capacitors. The nominal voltage rating of the capacitors is increased with each module by factor of two. In this manner, the number of output voltage levels exponentially increases with the number of series connected H-bridges. By using low-voltage MOSFETs it is possible to achieve a very high efficiency, especially at partial loading. The high number of voltage levels reduces the output voltage THD, while using a low switching frequency. Thus, the required grid filter size can be substantially reduced. Furthermore, the additional capacitor modules increase the nominal output voltage at the AC side, so that the flow of the active and reactive power can be dynamically adjusted. Therefore, the EMMC could be used, for instance, as a vehicle charger directly connected to the grid