On-board Charger Research Articles

General Fault-Tolerant Operation of Electric-Drive-Reconstructed Onboard Charger Incorporating Asymmetrical Six-Phase Drive for EVs

In this paper, the fault-tolerant operation of an electric-drive-reconstructed onboard charger (EDROC) designed on the basis of an asymmetrical six-phase permanent magnet synchronous machine (ASPMSM) drive is studied and discussed for cases where an open-phase fault (OPF) occurs in any phase. The fault-tolerant operation is realized by rearranging the stator currents, aiming to eliminate the rotating field caused by the OPFs and to ensure the balance of grid currents. Each faulty case is discussed, and the rearranging scheme of stator currents is deduced. Meanwhile, a controller shared for both healthy and faulty cases is designed. Finally, some experiments are conducted to verify the theoretical analyses.

A Multi-Functional Integrated Onboard Charger for Dual-Motor Driving EVs

In this paper, to achieve versatile, cost-effective charging for dual-motor EVs, a multi-functional integrated onboard charger is constructed using a dual-motor driving system. In the driving mode, a five-phase flux-switching permanent-magnet (FSPM) motor powers the front, while a three-phase FSPM motor drives the rear. While in the charging mode, different topologies are adopted for different application scenarios, such as the single-phase AC charging mode, the three-phase AC charging mode, and the DC charging mode. The five-phase FSPM motor and its inverters serve as a boost-based AC/DC converter in both single-phase and three-phase AC charging modes, transforming grid power to DC. In the DC charging mode, they are reconfigured to function as a buck converter. During the three-phase AC charging mode, the three-phase FSPM motor and its inverters take on the role of a rear-stage buck converter. They function to regulate the rectified DC voltage, ensuring it meets battery charging needs. The performance of the integrated charger is validated through simulation and experiment results.

Unit prediction horizon [formula omitted] based model predictive control for the fuel cell based plug-in hybrid electric vehicle with rule-based energy management system

Plug-in hybrid electric vehicles (PHEVs) provide a good alternative in achieving better performance and in the reduction of harmful gas emissions. The hybrid energy storage system (HESS) and the integrated charging unit constitute the PHEV under consideration. To meet the load demands, the proposed HESS is a coupled system comprising a fuel cell, high energy density battery, and high-power density super-capacitor. On-board charging involves the utilization of a DC–DC buck converter and an uncontrolled rectifier and two buck-boost converters are utilized to facilitate a smooth transfer of energy. A rule-based supervisory controller has been implemented for different load conditions which takes into account the state of charge of energy sources and also the total power inflow of the power sources. A model predictive control (MPC) technique is implemented to ensure that PHEVs function smoothly in terms of regulation of DC bus voltage and tracking of current. Unit prediction horizon i.e. only one step ahead looking into the future is considered for the MPC to make it computationally less expensive. MPC is designed in such a way that its performance is close to our favorite linear controller which in our case is the H∞ controller. The inverse optimal control technique is used for determining the weight matrices of the cost function. The proposed controller has been simulated using MATLAB. Also, the performance comparison is made between the designed MPC and the non-linear control approach i.e. integral sliding mode control and integral backstepping-based control to show that it achieves comparable or superior performance to the non-linear controller. The real-time performance of H∞ based MPC is verified using controller hardware in the loop experimental setup.

Two-Stage Multiple-Vector Model Predictive Control for Multiple-Phase Electric-Drive-Reconstructed Power Management for Solar-Powered Vehicles

Electric-drive-reconstructed onboard chargers (EDROCs), also known as electric-drive-reconstructed power management systems, are a promising alternative to conventional onboard chargers due to their characteristics of low cost and high power density. The model predictive control offers a fast dynamic response, simple implementation, and the ability to control multiple targets simultaneously. In this paper, a two-stage multi-vector model predictive current control (MPCC) of a six-phase EDROC for solar-powered electric vehicles (EVs) is proposed. Firstly, the topology for the EDROC incorporating a six-phase symmetrical permanent magnet synchronous machine (PMSM) is introduced, and the operation principles of the DC charge mode, the drive mode, and, especially, the in-motion charge mode are analyzed in detail. After that, a two-stage multi-vector MPCC method is proposed by using the multi-vector MPC technique and designing a two-stage MPC structure to eliminate the regulation of the weighting factor of the MPC. Finally, the effectiveness of the proposed method is verified on a self-designed 2 kW EDROC platform.

ELECTRIC VEHICLE POWERTRAIN DESIGN: INNOVATIONS IN ELECTRICAL ENGINEERING

The electrification of vehicles is reshaping transportation, with electric vehicle (EV) powertrain design playing a key role in this shift. This review focuses on recent innovations in electrical engineering that have enhanced EV powertrains, particularly in areas like electric motors, power electronics, energy storage, and thermal management. Advances in motor technology, such as permanent magnet synchronous motors (PMSM), and the integration of silicon carbide (SiC) and gallium nitride (GaN) semiconductors have improved efficiency and reduced heat generation. Battery innovations, including solid-state technologies and advanced battery management systems, along with regenerative braking, have extended EV range and efficiency. Power electronics, including inverters and onboard chargers, now utilize wide-bandgap semiconductors to minimize energy losses and improve thermal performance. Additionally, novel cooling solutions are addressing thermal challenges in EV systems. Looking forward, modular powertrain architectures and AI-driven control strategies offer promising advancements for various vehicle types. This review provides an overview of how electrical engineering innovations are driving the future of EV powertrain design and sustainable transportation.

A ZCS/ZVS DC–DC Partial Power Converter With Reconfigurable H-Bridge and Variable Turns Ratio for an Integrated On-Board Charger

A ZCS/ZVS DC–DC Partial Power Converter With Reconfigurable H-Bridge and Variable Turns Ratio for an Integrated On-Board Charger

Design and Experimental Verification of Electric Vehicle Battery Charger Using Kelvin-Connected Discrete MOSFETs and IGBTs for Energy Efficiency Improvement

This research investigates the advantages of Kelvin-connected 4-pin discrete transistors, both MOSFETs and IGBTs, in onboard battery chargers for electric vehicles. The study compares the standard 3-pin and the extended 4-pin packages based on averaged data collected from leading manufacturers. The investigation shows significant potential power loss reduction, thermal operation mitigation, and reduced gate-drive oscillation for the 4-pin package. The benefits have been quantified by analysing the operation of actual switches in an automotive battery charger based on Boost-PFC and DC-DC LLC converters. The converters’ practical design demonstrates a procedure for integrating the Kelvin-connected package into the design methodology. The results have been verified experimentally.

On-Board Chargers for Electric Vehicles: A Comprehensive Performance and Efficiency Review

The transportation industry is experiencing a switch towards electrification. Availability of electric vehicle (EV) charging infrastructure is very critical for broader acceptance of EVs. The increasing use of OBCs, due to their cost-effectiveness and ease of installation, necessitates addressing key challenges. These include achieving high efficiency and power density to overcome space limitations and reduce charging times. Additionally, the growing interest in bidirectional power flow, allowing EVs to supply power back to the grid, highlights the importance of innovative OBC solutions. This review article provides a thorough analysis of the current advancements, challenges, and prospects in EV on-board charger technology. It aims to offer a comprehensive review of OBC architectures, components, technologies, and emerging trends, guiding future research and development. Addressing these challenges is essential to enhance the efficiency, reliability, and integration of OBCs within the broader EV ecosystem.

Analysis and Comparison of Integrated Planar Transformers for 22-kW On-Board Chargers

Analysis and Comparison of Integrated Planar Transformers for 22-kW On-Board Chargers

Analysis and Suppression of Static Electromagnetic Ripple Torque in Integrated On-Board Charging System With Rotor Position Error

Analysis and Suppression of Static Electromagnetic Ripple Torque in Integrated On-Board Charging System With Rotor Position Error

Modeling and prediction of conducted EMI in on-board charging system of electric vehicle

Modeling and prediction of conducted EMI in on-board charging system of electric vehicle

Making of an Indigenous and Efficient Powertrains for EV, HEV & FCEV’s

Rise in greenhouse gas emissions which is resulting into ozone layer depletion and global warming effect is alarming to control CO2 emissions by drastically reducing fossil fuel consumption from the vehicles. This need has already started trend towards extreme downsizing and down speeding of Internal Combustion Engines (ICE) for making them highly efficient. In addition to this use of after treatment devices viz. Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), Lean NOx Catalyst (LNT), Selective Catalytic Reduction (SCR) are helping to a great extent for meeting emission norms till Euro - VI for automotive sector, Tier–IV F and Stage V for Off Highway Power sector. However, to address present greenhouse effect along with exponential decay of fossil fuels, there is need to achieve CO2 emissions less than 100 g/km or to achieve practically zero carbon footprint using an alternate powertrain. Electrification is one of the promising solutions and which is three-fold in present situation. The first level of electrification comes in the form of Hybrid Electric Vehicle (HEV) technology followed by Battery Electric Vehicles and Fuel Cell Electric Vehicles as second and third level of electrification respectively. In all these technologies a common thread is running in the form of an efficient electric drive train. Several efforts have been taken to improve torque per unit ampere by use of efficient motor and motor control algorithms viz PMSM powered with FOC, by developing controls which take care of parametric variations and external force disturbances by use of back stepping techniques which are based on rotor resistance estimation by fuzzy logic, FOC techniques based on adaptive input-output feedback linearization, by shifting towards high voltage systems, by going for higher switching frequencies for inverters which uses silicon carbide based MOSFET switches, by exploring use of multilevel inverters for Total Harmonic Distortion (THD) control etc. Use of E Axle based powertrains in EV, HEV and FCEV offers additional complimentary benefits apart from technology options described above. E Axle based powertrains offers flexibility in generating three variants of vehicle using one electric drive train architecture viz. making EV, HEV & FCEV. Compactness, modularity, scalability, flexibility along with efficient cooling system management and control over active current losses due to use of bus bars are the implicit advantages of E Axle based powertrains. These advantages further get multiplies if we go for 3 in 1 (gearbox + Stator housing + Inverter) architectures which are predominantly used in independent suspension-based vehicles. Lot of efforts are going on to inherit this technology for rigid axle suspension based commercial vehicles. Research in this area is getting further extended to make 5 in 1 E Axles where there will addition of DC - DC converter and On-Board Charger (OBC) apart from components present in 3 in 1 configuration. Two major challenges need to be addressed and to be resolved while designing E Axle based powertrains by doing concurrent vehicle engineering. This is mainly due to increased unsprang weight that need to be handled by suspension system and exposed electric drive components to excitation loads coming from roads. Fig: Indigenously Developed E Axle Based Powertrain for Small Commercial VehiclesBy proper lay outing for effective vehicle mass distribution and required CG location which is essential from overall vehicle dynamics, more space can be offered by E Axle based powertrains for increasing battery energy density for getting more electric range in case of BEV’s. This add on space benefit extend help in packaging of hydrogen fuel cell integrated with power cells in case of FCEV’s. Thus, E Axle based powertrains proves to be modern and most efficient way of making EV, HEV & FCEV’s.

Enhancing Cybersecurity in Onboard Charging Systems of Electric Vehicles: A MATLAB-based Approach

This research provides a comprehensive analysis of the impacts of various data integrity attacks on the power electronic hardware of electric vehicle (EV) chargers. The study aims to offer essential recommendations for defending against cyberattacks on electric vehicles and their onboard charging (OBC) systems. Adverse scenarios resulting from such cyberattacks are meticulously examined, and the system is simulated in MATLAB/Simulink to validate fault occurrences under different data integrity attacks. The quantitative analysis of the results clearly indicates that by incorporating adequate precautionary measures, such as integrating intelligent controls into the main controller during the design of the charging architecture, it is possible to significantly mitigate electrical hazards and prevent the degradation of component health, even in the event of a malicious cyberattack.

A Novel Non-Isolated Bidirectional DC-DC Converter with Improved Current Ripples for Low-Voltage On-Board Charging

This paper presents a novel single-phase non-isolated bidirectional buck converter topology. The proposed converter uses a basic switching cell structure with a coupled inductor and an interleaving switching scheme. This article addresses a crucial challenge in bidirectional DC-DC conversion by prioritizing reducing output current ripples and minimizing filter inductor size. The employed method includes using MOSFETs with fast recovery diodes to mitigate reverse recovery and body diode losses. Furthermore, the optimization of the switching frequency of the output inductor to be twice the actual switching frequency contributes to reducing the component size of the converter. The coupled inductor also helps to reduce stress on components by distributing currents among its legs. The experimental result demonstrates the proposed converter has a very low ripple current as compared to the conventional converter. The low current ripples and smaller filter inductor size enabled by high-frequency operation have improved the efficiency and size of the converter. A common ground between input and output terminals ensures robust performance without common mode current concerns. Overall, the proposed converter represents a significant improvement in DC-DC converters, promising enhanced efficiency, reliability, and compactness in bidirectional DC-DC conversion systems. In order to verify the performance of the proposed converter, a 460 W buck converter prototype was built and tested.

Real-time hardware-in-loop system based validation of vehicle-grid interface for bidirectional power flow control

In the context of modern sustainable transportation technology, the terms Vehicle-to-Grid (V2G) and Grid-to-Vehicle (G2V) holds significant value. During V2G and G2V modes, vehicle and grid exchange power using various power converters to modulate the power for a sustainable electrical energy ecosystem. With V2G, the EVs can also perform the role of a peak power contributor, reserve power source, and an efficient system to improve power quality issues by working as power factor corrector, reactive power compensator, and active power filter, to name a few during the V2G mode. The on-board power converter in the vehicle, working as the charger for the battery, is the component required to facilitate the intended bidirectional power exchange between the vehicle and grid and also modulates the power as and when required. The modality for operating the onboard charger as a power exchange tool depends on the type of control strategy adopted as well as on the battery and grid parameters. In this paper, a bidirectional power converter (on-board converter) is introduced, which is controlled by adopting a d-q axis-based control strategy. The MATLAB/SIMULINK-based system simulation model is created, and the Hardware-in-Loop (HIL) tool Opal-RT 4510 is used to validate the simulation results on the intended hardware and real-time scenario. The control strategy, when integrated with the adopted model, contributes to enhancing the power-transferring capability of the converter, which is assessed using the simulation and subsequent HIL-based implementation. The paper also focuses on narrating the steps to implement the vehicle-grid interface using HIL and forming a generic reference model for a bidirectional power flow converter, such that it can be used for other circuits and its implementation in real-time scenarios.

The On-board Charger and its Power Circuitry

The On-board Charger and its Power Circuitry

Pre‐ and post‐fault operation of symmetrical six‐phase electric‐drive‐reconstructed onboard charger based on subspace current injection

SummaryThe proposal of the electric‐drive‐reconstructed onboard charger (EDROC) provides a new idea for the research of electric vehicles (EVs), which utilizes the existing electric‐drive components and shows broad commercial prospects. In this paper, pre‐ and post‐fault operations of the EDROC incorporating a symmetrical six‐phase permanent magnet synchronous motor (SSPMSM) are studied. Firstly, by employing the vector space decomposition (VSD) technique, the decoupled subspaces currents of the motor under healthy and fault conditions are solved. And their trajectories associated with torque generation are depicted, which reveals there are pulsating and rotating magnetic fields in the event of one open‐phase fault (One‐OPF) and two open‐phase fault (Two‐OPF), respectively. To eliminate the unwished magnetic fields, a subspace current injection method is proposed, which can solve the fault‐tolerant current online by constructing the Lagrange function under the constraint of the minimum copper loss. Finally, the feasibility and reliability of the proposed fault‐tolerant scheme is verified by experiment.

Unbalanced Half-Bridge Split Capacitor Power Decoupling With Multiorder Frequency Control for 800-V On-Board Battery Charger

Unbalanced Half-Bridge Split Capacitor Power Decoupling With Multiorder Frequency Control for 800-V On-Board Battery Charger

Sinusoidal Phase Shift Modulation for V2H Operational Mode in Current-Fed Bidirectional Onboard Charger

Sinusoidal Phase Shift Modulation for V2H Operational Mode in Current-Fed Bidirectional Onboard Charger

Efficient On-Board Charger to Improve the Life Time of Electric Vehicle Battery

Efficient On-Board Charger to Improve the Life Time of Electric Vehicle Battery