Journal of Power Electronics

The Korean Institute of Power Electronics (전력전자학회)
권호 표지
DOI QR코드

DOI QR Code

High-efficiency 11 kW bi-directional on-board charger for EVs

  • Lee, Sang-Youn (Department of Electrical Engineering, Myongji University) ;
  • Lee, Woo-Seok (Department of Electrical Engineering, Myongji University) ;
  • Lee, Jun-Young (Department of Electrical Engineering, Myongji University) ;
  • Lee, Il-Oun (Department of Electrical Engineering, Myongji University)
  • Received : 2021.10.12
  • Accepted : 2021.11.10
  • Published : 2022.02.20
⟨ Previous Next ⟩

Abstract

This paper presents an 11 kW bi-directional on-board charger (OBC) for electric vehicles with 96% efficiency. The OBC consists of a three-phase two-level AC/DC converter and a CLLLC resonant DC/DC converter with bi-directional power transfer. In order to achieve high efficiency, all the devices in the OBC are implemented using SiC-MOSFETs while the DC-link voltage is designed to track the battery voltage level in both the forward and reverse power modes. The AC/DC converter adopts a DC-link voltage controller that can adapt its control gain according to the status of the DC-link voltage. By adjusting the DC-link voltage level according to the battery voltage, the CLLLC resonant converter always runs at a switching frequency near its resonant frequency. This ensures high-efficiency operation in both the forward and reverse power modes while achieving a full voltage gain. The feasibility of the proposed 11 kW OBC is demonstrated experimentally by constructing a prototype converter with a 3-phase 60 Hz 380 VAC input, an 11 kW capacity, and a battery voltage range of 214-413 VDC. The prototype OBC achieves a conversion efficiency of over 96% in both the forward and reverse power modes resulting in a power density of over 1.0 kW/liter.

Keywords

Acknowledgement

This research was supported by Korea Electric Power Corporation. (Grant Number: R21XO01-11)

References

  1. Ahmad, A., Alam, M.S., Chabaan, R.: A comprehensive review of wireless charging technologies for electric vehicles. IEEE Trans Transport Electrifc 4(1), 38-63 (2018) https://doi.org/10.1109/TTE.2017.2771619
  2. Mahone, A., et al.: On the path to Decarbonization: electrification and renewables in California and the Northeast United States. IEEE Power Energy Mag. 16(4), 58-68 (2018) https://doi.org/10.1109/mpe.2018.2822865
  3. Lee, W., Kim, J., Lee, J., Lee, I.: Design of an isolated DC/DC topology with high efficiency of over 97% for EV fast chargers. IEEE Trans Veh Technol 68(12), 11725-11737 (2019) https://doi.org/10.1109/tvt.2019.2949080
  4. Badawy, M.O., Arafat, M.N., Ahmed, A., Anwar, S., Sozer, Y., Yi, P., Abreu-Garcia, J.D.: Design and Implementation of a 75 kW mobile charging system for electric vehicles. IEEE Trans Ind Appl 52(1), 369-377 (2016) https://doi.org/10.1109/TIA.2015.2469775
  5. Lin, W., Hua, C.: Active battery balancing circuit with AC-link technique based on current-fed-push-pull converter, IEEE, 339-342 (2017)
  6. Kumar, B.V., Singh, R.K., Mahanty, R.: A modified non-isolated bidirectional DC-DC converter for EV/HEV's traction drive systems, 2016 IEEE International Conference on Power Electronics, Drives and Energy Systems (PEDES), Trivandrum, 1-6 (2016)
  7. Gonzalez, M.A., Escalante, M.F.: Traction system for an EV based on induction motor and 3-level NPC inverter multilevel converters, 12th IEEE International Power Electronics Congress, San Luis Potosi, 73-77 (2010)
  8. U.S. DRIVE Department of Energy, "Electrical and electronics technical team roadmap," Oct. 2017. [Online]. Available: https://www.energy.gov/sites/prod/files/2017/11/f39/EETT%20Roadmap%2010-27-17.pdf
  9. Jung, C.: Power Up with 800 V Systems: The benefits of upgrading voltage power for battery-electric passenger vehicles. IEEE Electrifc Mag 5(1), 53-58 (2017) https://doi.org/10.1109/MELE.2016.2644560
  10. Porsche Newsroom, "Porsche Taycan - The charging process: Quick, comfortable, intelligent and universal," Sep. 4, 2019. [Online]. Available: https://newsroom.porsche.com/en/products/taycan/charging-18558.html
  11. Li, B., Jing, L., Wang, X., Chen, N., Liu, B., Chen, M.: A Smooth Mode-Switching Strategy for Bidirectional OBC Base on V2G Technology," 2019 IEEE Applied Power Electronics Conference and Exposition (APEC), Anaheim, CA, USA, 3320-3324 (2019)
  12. Kisacikoglu, M.C., Kesler, M., Tolbert, L.M.: Single-phase onboard bidirectional PEV charger for V2G reactive power operation. IEEE Trans Smart Grid 6(2), 767-775 (2015) https://doi.org/10.1109/TSG.2014.2360685
  13. Lee, B., Kim, J., Kim, S., Lee, J.: An isolated/bidirectional PWM resonant converter for V2G(H) EV on-board charger. IEEE Trans Veh Technol 66(9), 7741-7750 (2017) https://doi.org/10.1109/TVT.2017.2678532
  14. Fahem, K., Chariag, D.E., Sbita, L: On-board bidirectional battery chargers topologies for plug-in hybrid electric vehicles," 2017 International Conference on Green Energy Conversion Systems (GECS), Hammamet, 2017, 1-6 (2017)
  15. Khaligh, A., D'Antonio, M.: Global trends in high-power on-board chargers for electric vehicles. IEEE Trans Veh Technol 68(4), 3306-3324 (2019) https://doi.org/10.1109/tvt.2019.2897050
  16. Lu, J., Tian, Q., Bai, K., Brown, A., McAmmond, M.: An indirect matrix converter based 97%-efficiency on-board level 2 battery charger using E-mode GaN HEMTs, 2015 IEEE 3rd Workshop on Wide Bandgap Power Devices and Applications (WiPDA), Blacksburg, VA, 351-358 (2015)
  17. Monteiro, V., Goncalves, H., Joao Afonso, L.: Impact of Electric Vehicles on Power Quality in a Smart Grid Context, 11 th IEEE International Conference on Electrical Power Quality and Utilisation (EPQU),Lisbon, Portugal, 17-19 (2011)
  18. Greifelt, A., Heiland, G., Gerling, D.: Modular 11kW bidirectional onboard charger with SiC-MOSFET technology for mobile applications, 2017 Brazilian Power Electronics Conference (COBEP), Juiz de Fora, 1-6 (2017)
  19. Li, B., Li, Q., Lee, F.C., Liu, Z., Yang, Y.: A high-efficiency high-density wide-bandgap device-based bidirectional on-board charger. IEEE J Emerg Sel Topics Power Electron 6(3), 1627-1636 (2018) https://doi.org/10.1109/jestpe.2018.2845846
  20. Huang, X., Liu, Z., Li, Q., Lee, F.C.: Evaluation and application of 600 V GaN HEMT in cascode structure. IEEE Trans Power Electron 29, 2453-2461 (2014) https://doi.org/10.1109/TPEL.2013.2276127
  21. Whitaker, B., Barkley, A., Cole, Z., Passmore, B., Martin, D., McNutt, T.R., et al.: A high-density, high-efficiency, isolated on-board vehicle battery charger utilizing silicon carbide power devices. IEEE Trans Power Electron 29, 2606-2617 (2014) https://doi.org/10.1109/TPEL.2013.2279950
  22. Chang, H., Liang, T., Yang, W.: Design and Implementation of Bidirectional DC-DC CLLLC Resonant Converter, 2018 IEEE Energy Conversion Congress and Exposition (ECCE), Portland, OR, USA, 2712-2719 (2018)
  23. Jung, J., Kim, H., Ryu, M., Baek, J.: Design methodology of bidirectional CLLC resonant converter for high-frequency isolation of DC distribution systems. IEEE Trans Power Electron. 28(4), 1741-1755 (2013) https://doi.org/10.1109/TPEL.2012.2213346
  24. Garinto, D., Sutikno, T.: Three-Phase AC-DC Converter with Asymmetrical Vienna Rectifier, 2019 IEEE Conference on Energy Conversion (CENCON), Yogyakarta, Indonesia, 177-181 (2019)
  25. Vazquez, S., et al.: Optimized Direct Power Control Strategy using Output Regulation Subspaces and Pulse Width Modulation, IECON 2006-32nd Annual Conference on IEEE Industrial Electronics, Paris, France, 1896-1901 (2006)
  26. Zhang, Y., Peng, Y.: Model predictive current control with optimal duty cycle for three-phase grid-connected AC/DC converters," 2014 International Power Electronics and Application Conference and Exposition, Shanghai, China, 837-842 (2014)
  27. Lim, C., Jeong, Y., Moon, G.: Phase-shifted full-bridge DC-DC converter with high efficiency and high power density using center-tapped clamp circuit for battery charging in electric vehicles. IEEE Trans Power Electron 34(11), 10945-10959 (2019) https://doi.org/10.1109/tpel.2019.2899960
  28. Qu, L., Wang, X., Zhang, D., Bai Z., Liu, Y.: A High efficiency and Low Shutdown Current Bidirectional DC-DC CLLLC Resonant Converter, 2019 22nd International Conference on Electrical Machines and Systems (ICEMS), Harbin, China, 1-6 (2019)
  29. Deng, J., Li, S., Hu, S., Mi, C.C., Ma, R.: Design methodology of LLC resonant converters for electric vehicle battery chargers. IEEE Trans Veh Technol 63(4), 1581-1592 (2014) https://doi.org/10.1109/TVT.2013.2287379