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Three-Phase Modular Multilevel Current Source Rectifiers For Electric Vehicle Battery Charging Systems
Three-Phase Modular Multilevel Current Source Rectifiers For Electric Vehicle Battery Charging Systems
Three-Phase Modular Multilevel Current Source Rectifiers For Electric Vehicle Battery Charging Systems
Swiss Federal Institute of Technology ETH Zrich / Power Electronic Systems Laboratory
Physikstrasse 3 8092- Zrich, SWITZERLAND
Email: heldwein@inep.ufsc.br
I.
INTRODUCTION
Charging of Electric Vehicle (EV) batteries inherently requires
conversion of energy from the AC mains into DC-quantities.
Several charging voltage and power levels have been defined by
different standardization organizations (IEC 61851, IEC62196,
SAE J1772). Single-phase Power Factor Corrector (PFC) mains
interfaces are commonly employed for low charging power levels,
e.g. P < 5 kW, whereas for higher charging power levels, threephase PFCs are used [1]. The EV charger, typically implemented as
a two-stage system, i.e. comprising a PFC rectifier input stage
followed by a DC-DC converter, can be either integrated into the
car (on-board chargers) or accommodated in specially designed EV
charging stations (off-board chargers) [2]. Basic requirements for
such systems are controlled output voltage, high power factor, and
high efficiency. If the power electronics have to be accommodated
on-board the EV, low weight and high power density are also
desirable [1]-[4]. Finally, if isolation of the PFC output from the
DC-bus is necessary due to safety reasons, this could be provided
by an isolated DC-DC converter. Possible power electronic
configurations for charging of EVs are given in Fig. 1 [5].
With respect to public high power charging infrastructures, also
called semi- or ultra-fast chargers, the nearly empty battery should
be re-charged in the shortest time possible. These EV chargers,
supplied from three-phase AC lines at 110 / 220 V (rms) and
50 / 60 Hz, typically require a peak power ranging from 10 kW to
150 kW in order to inject direct current into the battery sets at
variable voltage levels according to the vehicle (50 V to 600 V) [6].
Buck-type three-phase PFC rectifiers, also known as Current
Source Rectifiers (CSRs), are appropriate for these high power
chargers as a direct connection to the battery could be used.
Compared to the boost-type systems, buck-type topologies provide
623
II.
a)
b)
d)
c)
Fig. 2. EV battery charger concepts with (2n+1) AC current levels constructed from the following unidirectional CSRs: a) six-switch buck-type PFC, b) hybrid-switch active
rd
3 harmonic current injection rectifier and a DC-DC buck-type converter, c) SWISS rectifier I, and d) SWISS rectifier II.
across the passive filters; i.e. for a five-level CSR, constructed with
two paralleled circuits (n = 2), the first current harmonic occurs at
double pulse frequency 2fp. Therefore, as the cut-off frequency of
the passive filters can be shifted to higher frequencies, their sizes
can be reduced. In addition, as the total DC-link current is
distributed to several fast-switched devices, better efficiency, due
to the lower conduction and switching losses, is achievable.
As the multilevel CSR can be operated with only a single circuit
of the modular arrangements, i.e. it operates as a conventional
CSR, the system can be designed to tolerate a faulty subcircuit. In
this case, the system could be re-activated without the faulty circuit
at the cost of reducing the CSR power capability and of increasing
the current and voltage ripples at the input and output terminals.
This interesting feature not only makes the CSR more reliable, but
it could also be used to enhance the power efficiency of the
systems for partial load operation. For instance, for low power
levels it could make sense to only activate a few subcircuits, since
the equivalent system would operate at a relatively higher power
level and therefore with a higher efficiency than a multiple parallel
system equally sharing the power [15].
624
uDC
3
uN ,l l ,rms
2
(1)
where, uDC is the output voltage of the CSR and uN,l-l,rms is the lineto-line rms value of the input voltage.
TABLE II: Applied duty cycle for the multilevel six-switch buck-type PFC rectifier.
(cf. Fig. 4 and Eq. (2)) [8].
eff,b
eff,c
Sector
eff,a
1, 7
a
1 c + td
c
2, 8
a
1 a + td
c
3, 9
1 b+ td
b
c
b
c
4, 10
1 c + td
b
1 a + td
5, 11
a
b
1 b + td
6, 12
a
Gi
600
400
200
-200
-400
-600
Fig. 6. Voltage applied to the DC-link inductors during the freewheeling state of (a)
structure 1, and (b) structure 2.
625
*
uDC
ui
ua2 ub2 uc2
(2)
200 V
ub
ua
uDC
uDC
200 V
uc
ua
ub
uc
ua
ub
uc
100 V
100 V
0V
0V
0V
0V
-100 V
-100 V
-100 V
-200 V
-200 V
iDC
64 A
ib
ia
64 A
ib
ia
ic
i+,1
iDC
64 A
ib
ia
ic
ic
0A
0A
0A
0A
-32 A
-32 A
-32 A
-32 A
-64 A
-64 A
-64 A
-64 A
ia
64 A
ir,a
iDC
i+,1
iy
64 A
ia
ir,a
32 A
64 A
ir,a
ia
32 A
0A
0A
0A
0A
-32 A
-32 A
-32 A
-32 A
-64 A
-64 A
-64 A
-64 A
(c)
(b)
iy
ia
ic
i+,2
ir,a
32 A
32 A
(a)
ib
uc
32 A
32 A
32 A
64 A
ia
64 A
32 A
i+,2
ub
-200 V
-200 V
iDC
ua
100 V
100 V
-100 V
uDC
200 V
(d)
(e)
(f)
(g)
(h)
Fig. 7. Simulation results for the studied multilevel CSRs: (a) Conventional and (b) five-level six-switch buck-type rectifier; (c) conventional and (d) five-level H3R + DC-DC
buck-type converter; (e) conventional and (f) five-level SWISS rectifier I; and (g) conventional and (h) five-level SWISS rectifier II.
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TABLE III. Modulation of the current injection circuit of a H3R (cf. Fig. 4).
Sector
Sy1a
Sy1b
Sy2a
Sy2b
Sy3a
Sy3b
0-60
0
0
1
1
0
0
60-120
1
1
0
0
0
0
120-180
0
0
0
0
1
1
180-240
0
0
1
1
0
0
240-300
1
1
0
0
0
0
300-360
0
0
0
0
1
1
G1
u pos 2uneg .
(5)
u pos uneg
2
3U N2
Fig. 8. Block diagrams of the phase-shifted PWM control appropriate for operation
of the five-level H3R + DC-DC buck-type converter.
+
uabc
u*DC
Eq. (7)
+
+
-
S+,2
180
+
0
i+,1
PWM1
+
-
S-,1
180
PWM1
+
-
S-,2
+k (s)
+ I
- +
uabc
PWM2
S1a/b
S2a/b
S3a/b
- +
i+,2
+ u
++
DC
kU(s)
kI(s)
+
+
-
PWM2
S+,1
kI(s)
Eq. (8)
i-,2
u*DC
uabc
(cf. Fig. 4)
uneg
min ua , ub , uc
(4)
627
G
*
2 u DC
.
min ua , ub , uc
3 U N2
(8)
IV.
HARDWARE DEMONSTRATOR
A laboratory prototype of the three-phase five-level inverting-link
CSR shown in Fig. 11(a) has been tested. This CSR hardware has a
power capability of 2.5 kW and can be seen in Fig. 11(b). As can be
noticed, this system implements inter-phase transformers, Ti1 and
Ti2, paralleling the two unidirectional six-switch CSRs. It is
important to point out that the subcircuits of the other multilevel
converters depicted in Fig. 2, 3 and 10 can also be connected in
parallel association in a similar way by using inter-phase
transformers and a single inductor as shown in Fig. 11(a). The
advantages of the use of these transformers over conventional
inductors, as shown in Fig. 2, have been studied in [18].
Fig. 11(c) and 11(d) show the main experimental results of the
multilevel CSR operating as a unidirectional three-phase five-level
six-switch buck-type PFC (with inverting-link circuit switches kept
turned off) with a ua/b/c=110 Vrms (60 Hz) mains and uDC= 200 V
628
+
+
III.
a)
b)
c)
Fig. 10. Bidirectional EV battery charger concepts with (2n+1) AC current levels
constructed from the following unidirectional CSRs: a) six-switch buck-type PFC, b)
hybrid-switch active 3rd harmonic current injection rectifier and a DC-DC buck-type
converter, c) SWISS rectifier I.
V. CONCLUSION
This paper proposes three-phase multilevel high power factor
mains interfaces based on current source converters which are
appropriate not only for high power EV battery charging systems,
but also for power supplies for telecommunication, DC distribution
systems, and variable speed AC drives. The characteristics of the
presented rectifier systems, including the principles of operation,
modulation strategy, and suitable control structures, have been
summarized. The feasibility of one multilevel converter was
demonstrated by means of a hardware prototype.
REFERENCES
J. J. Chen, F.-C. Yang, C.-C. Lai, Y.-S. Hwang and R.-G. Lee, A
High Efficiency Multimode Li-Ion Battery Charger with Variable
Current Source and Controlling Previous Stage Supply Voltage,
IEEE Trans. Ind. Elec., vol. 56(7), pp. 2469-2478, 2009.
[2] M. Chen and G. Rincon-Mora, Accurate, Compact, and PowerEfficient Li-Ion battery Charger Circuit, IEEE Trans. Circ. Sys.
II: Expr. Briefs, vol. 53(11), pp. 1180-1184, 2006.
[1]
[3]
[4]
[5]
a)
[6]
[7]
[8]
[9]
b)
[10]
[11]
[12]
[13]
c)
[14]
[15]
[16]
[17]
[18]
d)
Fig. 11. a) Implemented 2.5 kW five-level inverting-link six-switch PFC
rectifier; b) hardware prototype; c) phase a terminal current with five-level
feature and filtered line current; and d) output voltage uDC, input currents, ia,b,c ,
and phase a voltage, ua. Note that the current ic was calculated from the measured
ia and ib.
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[19]