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On-board power quality charger for electric vehicles with minimized switching stresses

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Abstract

This paper intends to provide a three-level CUK converter-based on-board electrical vehicle battery charger with improved power quality features. The proposed configuration includes a diode bridge rectifier followed by a DC–DC converter suitable for the universal input voltage variations (85–265 V). It offers reduced voltage stress across the switches, reduced filter size, high efficiency, and improved dynamic response. A feed-forward control scheme is implemented for the proper functioning of the proposed converter under constant current (CC) and constant voltage (CV) modes of operation. In this paper, the mathematical modeling, operational details, and components design of the PFC converter are analyzed in continuous current mode. The simulation study on a 3.2 kW, 400 V proposed converter is carried out with MATLAB Simulink toolbox, and a real-time implementation of the same specifications of the proposed system is developed to verify the simulation study. The steady-state and dynamic behavior of the converter is investigated for power quality features like total harmonics distortion and input power factor with resistive and battery loads. The onboard charger exhibits satisfactory operation in CC and CV modes to a wide range of supply voltage variations.

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Authors and Affiliations

  1. Department of Electrical Engineering, Sardar Vallabhbhai National Institute of Technology, Dumas Road, Surat, 395007, India

    Rakesh Maurya, Sabha Raj Arya, Ravindra Kumar Saini & Jyoti Gupta

Authors
  1. Rakesh Maurya
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  2. Sabha Raj Arya
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  3. Ravindra Kumar Saini
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  4. Jyoti Gupta
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Correspondence to Rakesh Maurya.

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Appendix

Appendix

S. no.

Specific parameters

Values

1

Single-phase supply voltage

230 V, 50 Hz

2

Input and output inductances (L1, L2)

5 mH

3

Intermediate capacitors (C1, C2)

10 μF

4

Output capacitor (C0)

3000 μF

5

Switching frequency (fs)

10 kHz

6

Load

400 V/8 A

7

Battery nominal voltage

345 V, 40 AH

Control parameters: Gains of output PI voltage controller kpv = 0.00005, kiv = 20 for CV mode, gains of the output PI current controller kpi = 0.1, kii = 10 for CC mode and inner PI current controller kp1 = 0.3, ki1 = 7.8 same for both CV and CC mode operation; feed forward gain is kd = 1.8.

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Maurya, R., Arya, S.R., Saini, R.K. et al. On-board power quality charger for electric vehicles with minimized switching stresses. Electr Eng 104, 1667–1680 (2022). https://doi.org/10.1007/s00202-021-01407-1

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  • DOI: https://doi.org/10.1007/s00202-021-01407-1

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