Thailand Chapter

Integrated On-board Battery

Chargers for EVs
Emil Levi
Liverpool John Moores University, Liverpool, UK

IEEE PES Distinguished Lecturer Programme

1
Liverpool, UK

2
 Instead of a preface

E&T news, 15 January 2018

3
 Electric vehicle charging options

 Charging possibilities for EVs:

Wireless battery charging (‘on the move’ and stationary)
Wired (plug-in) battery charging using
Single-phase or three-phase mains supply
Dc charging stations

 Options for wired charging:

Integrated on-board charger
Non-integrated on- or off-board charger

4
 Range anxiety and wireless charging

• This is not an option, is it?

• Inductive wireless charging

– a solution for the future

• Charging at home, office

and in the charging
stations (single-phase and
three-phase)
5
 Dc charging

• Specialised charging stations

are required.
• Expensive (and currently
very sparse!) infrastructure.
• It does enable the fastest
charging at present.

6
 Wired charging options

Off-board Non-integrated on-board Integrated on-board

7
 Non-integrated on-board charger properties

• If non-integrated: Takes space, adds weight, adds cost – when

designed as a separate unit.
• Integrated: Re-use of the propulsion components in the charging
process -no additional space required, no weight added, no cost
added

8
 Ideal integrated on-board charger properties

• Re-use of the propulsion components in the charging process, so that

only components used for the propulsion are required (ideally, not even
hardware reconfiguration needed): inverter works as a rectifier, stator
winding of the machine serves as a passive R-L filter. Hence no additional
space required, no weight added, no cost added.
• Operational with both three-phase and single-phase ac grid.
• Ability to work in bi-directional mode (battery charging and V2G
operation).
• No torque production in charging/V2G mode.
• Applicable in conjunction with induction and synchronous machines (PM
or electrically excited).
• If a three-phase machine is used:
– Single-phase charging/V2G easy to realise (minor hardware reconfiguration).
– Three-phase charging/V2G cannot be realised without rotating field
generation. 9

9
 Integrated on-board charger for ac supply
Why integrated?
1) Fewer new elements – lower cost of the vehicle
2) Lower weight – faster vehicle
3) Less space necessary – smaller vehicle

Why on-board?
1) More charging places
Basically any power
socket can replace a
charging station
2) V2G operation
10
 Using a three-phase machine, full integration

 Three-phase machine: three-phase charging with zero torque not possible without
additional components; single-phase charging with zero torque is possible (single-
phase current passed through the motor).
 Generally, passing three-phase currents through the machine during charging will not
cause rotation, since the voltage is rather low, but will create rotating field and cause
vibrations and other detrimental effects. Mechanical braking has to be used.
 The machine is put into open-end-winding (OeW) configuration during charging/V2G
operation.

11
Using a three-phase machine with a three-phase supply: why is there a
problem?

 Three-phase machine: recall that in a three-phase system there are only two
independent currents, since sum of all three has to equal zero.
 In a three-phase system there are only two possible phase sequence connections:
source A, B, C phases can be connected to either a, b, c phase sequence of the
machine or to a, c, b phase sequence.
 As a consequence the machine will always rotate (or try to rotate, if the voltage is very
small) and only the direction of rotation can be changed.
 As is obvious, the number of possible phase sequences is (3-1) = 2. However, if we have
a general case with n phases, where n > 3, than the number of phase sequences will be
(n  1). This is of paramount importance here and will be revisited later.
 Note also that the configuration shown in the previous slide requires opening of the
machine’s neutral point before connection to the supply. This means that switches
(contactors) are necessary – industry does not like it!

12
Using a three-phase machine, semi-integration or single-phase charging

 The solution with added rectifier can be used for single-phase or three-phase
mains connection and the propulsion inverter is re-used as a dc-dc converter.
This is a semi-integrated on-board solution.
 Single-phase charging is simple to realise without an additional rectifier and
there are many options, but all require some hardware reconfiguration.

13
Using a three-phase machine for single-phase charging (two-motor EV)
or three-phase charging (four-motor EV)

 Two-motor EV (right) enables a

simple single-phase charging
scheme.
 If one looks at a 4W-drive, than the
charging from 3-phase grid with zero
torque becomes simple!
idc iL

ic

va4 vb4 vc4 va3 vb3 vc3 va2 vb2 vc2 va1 vb1 vc1 C
vdc BAT

ia4 ib4 ic4 ia3 ib3 ic3 ia2 ib2 ic2 ia1 ib1 ic1

3-phase 3-phase 3-phase 3-phase

machine machine machine machine

idle during the icg ibg iag

charging/V2G mode + + +
vcg vbg vag
14
grid
A specific semi-integrated solution (3-phase machine) on the market

• Inverter used as a rectifier during charging/V2G mode, the motor is bypassed.

An inductive filter is added in between the grid and the rectifier inputs.
• This solution dates back to the late nineties:
• US patent: Patent Number: 5,642,270; Jun. 24, 1997
• Currently patented again in China (!) and used in BYD chargers.

15
 Current semi-integrated solution (3-phase motor): Renault ZOE

43 kW “Chameleon charger”
• Inverter and motor (synchronous) are integrated into
the charging process. Dc from junction box charges
battery through the neutral point of the 3-phase inverter
winding and the negative rail of the dc-link. No
reconfiguration required. el. motor
• The junction box: 1) manages the charging process; 2)
changes the alternating current to direct current; 3)
communicates with the charging station.
• The system does require additional power electronic
components. Source is single- or three-phase.

16
 Using a multiphase system instead of a three-phase one in an EV

 Advantages of multiphase machines include:

 Reduced current/power rating per-phase – this is relevant for EVs since,
although the power may not be too high, voltage level may be low requiring
high current.
 Degrees of freedom (DoF): the number of currents that can be controlled
independently (only two in a three-phase drive).
 In multiphase systems, there are additional degrees of freedom, which
enable:
 Improved fault tolerance (relevant for propulsion operation – ‘limp-home
mode’).
 Integrated on-board battery charging for EVs – as discussed further on, fully
integrated on-board battery chargers can be realised, using both three-
phase and single-phase supply, with zero torque generation during
charging/V2G mode.

17 17
 A current solution based on a multiphase system concept: Valeo

The machine operates as a three-phase

one in propulsion mode, but is in
essence a symmetrical six-phase
machine in charging and V2G modes; in
propulsion mode each phase is
supplied from an H-bridge inverter.

• Grid terminals are connected to machine

windings’ mid-points.
• Field is canceled within each winding – no
torque.
• No reconfiguration necessary.
• Machine has to be custom made (in essence
symmetrical six-phase machine).

18
Valeo operating principle

19
Valeo operating principle
Valeo operating principle
Multiphase motor based solutions: topologies and operating principles

• Valeo system uses in essence a symmetrical six-phase machine for

charging mode.
• Machines with more than three phases still require only two
independently controlled (d-q) currents for vector control; hence, there
are now additional degrees of freedom which can be used for charging
purposes in an opportune manner.
• An n-phase machine with k isolated neutral points has (n-k) degrees of
freedom.
• All machines with a minimum of five phases on stator could be used;
however, since the readily available supply is either single-phase or three-
phase, some phase numbers are more favourable than the others.

22
 Multiphase systems – principles of modelling

• Only so-called decoupling transformation is briefly discussed – to enable

easier following of the subsequent material.
• General form for an n-phase system (n = even number) - power invariant
form, a single neutral point:  = 2π/n

  1 cos cos 2 cos 3 ..... cos 3 cos 2 cos 

 sin  sin 2 sin 3  sin 3  sin 2  sin  
  0 ..... 
x1  1 cos 2 cos 4 cos 6 ..... cos 6 cos 4 cos 2 
 
y1  0 sin 2 sin 4 sin 6 .....  sin 6  sin 4  sin 2 
x2  1 cos 3 cos 6 cos 9 ..... cos 9 cos 6 cos 3 
 
2 2  0
y sin 3 sin 6 sin 9 .....  sin 9  sin 6  sin 3 
C  
n ...  ..... ..... ..... ..... ..... ..... ..... .....

n2 n2  n2  n2 n 2  n2 
xn4  1 cos  cos 2  cos 3  ..... cos 3  cos 2  cos 
  2   2   2   2   2   2  
2
 n2  n2  n  2  n2 n 2  n2 
y n 4  0 sin   sin 2  sin 3  .....  sin 3   sin 2   sin   
2   2   2   2   2   2   2  
0 1 2 1 2 1 2 1 2 ..... 1 2 1 2 1 2 
 
0  1 2 1 2 1 2 1 2 ..... 1 2 1 2 1 2 
23
Multiphase systems – transformation matrices for 3-phase and 5-phase
systems

Three-phase system Five-phase system

Power invariant form Power variant (amplitude
invariant) form

v s   1 cos( ) cos(2 ) cos(3 ) cos(4 )  v sa 

v    
 s  2  0 sin( ) sin(2 ) sin(3 ) sin(4 )   v sb 

 v sx    1 cos(2 ) cos(4 ) cos( ) cos(3 )    v sc 
  5  
v
 sy  0 sin(2 ) sin(4 ) sin( ) sin(3 )  v sd 
 
 v sz  1/2 1/2 1/2 1/2 1/2   v 
   se 

=2π/5
In multiphase systems we have additional planes, perpendicular to the  plane.
These are xy plane in a 5-phase system, x1y1 and x2y2 planes in a 7-phase
system, and so on.
24
 Multiphase systems – phase sequences

Recall the three-phase system: two phase sequences only, leading to

clockwise and counter clockwise rotation of the machine.

Five-phase system: there are now 4 phase sequences; connection of the

source with phase sequence A, B, C, D, E to machine’s phases a, b, c, d, e or to
a, e, d, c, b will lead to torque generation and machine will rotate clockwise or
counterclockwise.
But, there are two more sequences: source A, B, C, D, E can be connected to
a, c, e, b, d or to a, d, b, c, e phases. If this is done, this is the ‘wrong’ phase
sequence so that the machine does not generate torque; but it is the ‘right’
phase sequence for charging purposes!

Hence excitation gets displaced from the first to the second plane and we
have xy currents now. No torque is generated.
25
 Five-phase motor / five-phase grid solution

• Five-phase supply could be obtained using 3ph-5ph transformer, a

five-phase inverter (with 3ph diode front end) or using a 3ph-5ph
matrix converter.
• Phase sequence is changed in charging and V2G modes: hence
currents become non-flux/torque producing currents and there is no
torque developed. Hardware reconfiguration (opening of the neutral
point) is required. Single-phase charging is possible.
26
 Five-phase topology, three-phase supply

• Requires hardware reconfiguration, which however consists of only two switches as

additional components.
• Phase impedances seen by different grid phases are not all equal (impacts on control).
• Space vectors of currents during charging are in the two planes governed with
(pulsating excitation in both planes):

i   I  2 cos(t  0.659 ) i xy  I  2 cos(t  0.659 )

iag
three-phase
grid
five-phase idc iL
vag iag
+ EMI S1 machine
vbg ibg filter ibg b
+ ic
vcg icg (on- icg /2 ic
+ c vc
board )
ibg /2 ib vb
S2
icg iag ia C
a va
vdc BAT
ibg /2 ie
hardware ve
reconfig. icg /2 id vd
d
e

27
 Asymmetrical six-phase topology

• Propulsion: dual three-phase winding with two isolated neutral points, vector control
with two pairs of current controllers.
• Charging/V2G: hardware reconfiguration for fast charging; six-phase system of grid
voltages obtainable from three-winding transformer with star/delta connected
secondaries; single-phase charging by connecting two neutral points to the grid.
• No excitation in the first plane; only the second plane is excited.

three-phase tranformer with phase hardware

grid two secondary sets transposition reconfig.
i   0 i a1 g " i a1 g " i a1
i b1 g " i c1 g " S1 i b1
vag iag
+ i c1 g " i b1 g " S2 i c1
i xy  6 I exp( jt ) vbg ibg
+ i a2 g " i b2 g " i a2
vcg icg
+ i b2 g " i a2 g " S3 i b2
i c2 g " i c 2 g " S4 ic2

28
 Symmetrical six-phase topology

• Propulsion: dual three-phase winding with two isolated neutral points, vector control
with two pairs of current controllers.
• Charging/V2G: hardware reconfiguration for fast charging; six-phase system of grid
voltages obtainable from a transformer with open-end winding secondary; single-
phase charging by connecting two neutral points directly to the grid.
• Both planes excited, but only by pulsating current:

i   6 I cos(t ) i xy  j 6 I sin( t )
idc iL
three-phase isolation phase hardware six-phase
grid tranformer transposition reconfig. machine
ic
vag iag iag" iag" Lf, Rf i a1
+ v a1
vag" -iag" icg" S1 Lf, Rf i b1 v b1
vbg ibg ibg" ibg" S2 Lf, Rf i c1 vc1
+ C BAT
vbg" -ibg" -icg" Lf, Rf i a2 v a2 vdc
N
vcg icg icg" -iag" S3 Lf, Rf i b2 v b2
+
-icg" -ibg" S4 Lf, Rf ic2 v c2

isolated voltage supply (off-board)

29
 An alternative six-phase topology

• Transformer not required.

• Applicable to double three-phase machine (two three-phase windings
spatially in phase), asymmetrical six-phase and symmetrical six-phase
machine.
• The idea here is to generate with each three-phase winding a rotating
field; however, due to the used connection to the three-phase mains, the
two individual fields rotate in opposite direction and cancel each other.
optional 6-phase machine 6-phase inverter dc-dc converter 6-phase machine
idc
reconfiguration ibg /2 ib1
three-phase b1
grid S3 a1 ic
iag iag /2 ia1
vag S4
+ S5 vb1
EMI ibg c1 icg /2 ic1 va1
vc1 iL
vbg filter C
+ vb2 vdc
(on- icg /2 ib2 va2
b2 vc2
vcg board ) icg S1 S2
+ a2 iag /2 ia2 BAT
ibg /2 ic2
hardware c2
reconfig.

30
 Symmetrical or asymmetrical nine-phase topology

Applicable to any triple three-phase topology (including the one with no

spatial shift between three-phase windings)
Applicable to single-phase and three-phase grid connection.
The idea here is to pass one phase current through all three phases of a
winding so that the resultant field is zero instantaneously in each three-phase
winding.

31
 Nine-phase topology: equivalent charging topology
• In propulsion mode triple three-phase winding configuration (symmetrical or
asymmetrical) with three isolated neutral points (three pairs of current controllers).
• The equivalent configuration in charging/V2G is either a three-phase (as the case is for
nine-phase structure) or, in a general case, a multiphase rectifier.
• Filter inductance is equal to the equivalent machine leakage inductance – in the nine-
phase topology this is 1/3 of the stator leakage inductance.

32
 Nine-phase topology: operating principle
torque producing non-torque producing
• In charging mode 1 1

excitation is transferred 0.5 0.5

from torque-producing
(α-β) to non-torque
0
iαβ 0
ix1y1
producing (xk-yk) plane.
-0.5 -0.5

-1 -1

-1 -0.5 0 0.5 1 -1 -0.5 0 0.5 1

8 degrees of 1 1

freedom 0.5 0.5

0
ix2y2 0
ix3y3
[C] -0.5 -0.5

-1 -1

ii = -ia-ib -…-in -1 -0.5 0 0.5 1 -1 -0.5 0 0.5 1

 NO TORQUE
NO RECONFIGURATION

AC/DC BATTERY
 Control in charging, V2G and propulsion modes
Control in propulsion mode:
• Rotor flux oriented control with (n-k)/2 pairs of current controllers
• PI current control for the d-q plane; various current controller types can be used in other planes.

Control in charging and V2G modes:

• Grid synchronization – general PLL configuration with added PR filter
• Grid current is controlled to only have non-zero d component – assuring unity power factor. Grid
voltage oriented control (VOC) is used.
• The d current component is the output of dc-bus voltage controller.
• For V2G mode reference current has the opposite sign.
• Current control in the d-q plane is sufficient only if there are no dead-time harmonics and all grid
phases see the same impedance.

36
 Additional current controllers
• To suppress dead-time harmonics, current control in other planes is required.

∡ θg
[vg]
[vg] Current controller
∡ θg, vg vg
∡ θg
PLL
idg vd*
+_ PI ++
[ig] iqg vq* dq
+_ PI
... ... [v]*
[ig] ix( n 3)/2g vx(n3)/2g * [ton]
+_ PI PWM
[i(dq)g] iy( n 3)/2g +_ PI
vy( n 3)/2g * abc..n vdc
Voltage controller
_ idg*
vdc + PI
iqg*
0
... ...
ix( n 3)/2g *
0 i
y g*
0 ( n 3)/2

Vdc*

37
 Properties of the nine-phase topology

• No hardware reconfiguration required for charging/ V2G with either

single-phase or three-phase grid use.
• Natural zero torque operation during charging/V2G modes.
• Not a single additional hardware component required.
• Full utilisation of all components used in propulsion mode.
• Applicable to both synchronous and induction machines.
• Easy to realise using three three-phase modules for the inverter.

38
Experimental rig and results: five-phase system, three-phase grid

Battery is emulated using a voltage amplifier with added load resistors for
sinking the power in charging mode.

39
 Charging and V2G modes

Charging: grid voltage and current

and grid current spectrum (voltage V2G: Current is in anti-phase with voltage
and current in phase – unity power
factor operation)

vag
Waveform, First harmonic is 1.16 A rms vag Waveform, First harmonic is 1.166 A rms
Grid current i (A)

2
ibg

Grid current i (A)

icg 2
ag

cg
0 iag iag ibg icg
0

-2 -2

0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018 0.02 0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018 0.02
Time (s) Time (s)
FFT of waveform (THD=0.09598) FFT of waveform (THD=0.1113)
1 0.03 1 0.03
Harmonic rms (p.u.)
Harmonic rms (p.u.)

0.02 0.02

0.01 0.01
0.5 0.5
0 0
0 0.2 0.4 0.6 0.8
0 0.2 0.4 0.6 0.8

0
0 0 5 10 15 20 25
0 5 10 15 20 25
Harmonic frequency (kHz)
Harmonic frequency (kHz)

40
 Charging and V2G modes

Charging: Grid phase voltage vag, machine V2G mode: Grid phase voltage vag,
currents ib and ie, battery current iL machine currents ic and id, battery
current iL

iL

vag
ib and ie ic and id vag
Machine current component i (A) Machine current component i (A)

Machine current component i (A) Machine current component i (A)



2 4
1 i 3
0 2
iL
-1 1
-2 0
i
-3 -1
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018 0.02
Time (s)
y
x

2 4
1 3
ix
0 2
-1 1
-2 0
iy
-3 -1
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018 0.02
Time (s)

41
 Charging to V2G transient

Grid voltage, grid current and battery current for the transient from V2G
into charging mode

iL

vag

iag

42
 Nine-phase system, demonstrator with an induction or a PM machine
https://www.youtube.com/watch?v=TJEAB5QuD8s

Oscilloscope
displaying
waveforms

Laptop
Nine-phase
DSP control
induction machine
unit
7.5 kW DC/DC
converter and
Grid voltage nine-phase
sensor inverter

12V, 40Ah
LiFePO4
batteries
43
 Nine-phase system, PM machine

The results shown in this slide are https://www.youtube.com/watch?v=TJEAB5Qu

for a PM machine, three-phase grid. D8s (1,578 views as of 07 Sep 2018 )

Charging mode without and with interleaving

44
 Asymmetrical nine-phase induction machine system
• In this slide, operation with an asymmetrical induction machine is shown, to
illustrate that the machine type is irrelevant (without interleaving).
Charging V2G

and transient

45
 Single-phase charging using multiphase drive topologies
• Available in conjunction with any of the systems discussed so far (five-, six-
and nine-phase).
Nine-phase, six-phase and five-phase topologies.
single-phase 9-phase machine 9-phase inverter idc dc-dc converter
grid i+g /3 ia
i+g i+g /3 id ic
i+g /3 ig va
+ vd
vg i-g /3 ib vg
vb iL
i-g i-g /3 ie ve C
vh vdc
i-g /3 ih vc
vf
i=0 ic vi
i=0 i=0 if BAT

i=0 ii

single-phase 6-phase machine

grid i+g /3 ia single-phase 5-phase machine
grid i+g /2 ia
i+g i+g /3 ic
i+g i+g /2 ib
i+g /3 ie
+ + i-g /3 ic
vg i-g /3 ib vg i-g S1
i-g /3 id
i-g i-g /3 id
i-g /3 ie
i-g /3 if

46
Single-phase charging: charging performance without interleaving

Nine-phase and asymmetrical six-phase topology, left.

Symmetrical six-phase and five-phase topology, right.

vg
iL vg
ig iL
ig
ia
ia

vg
vg iL
iL ig
ig

ia
ia

47
 Interleaving of carriers, nine-phase system

vag va, vd, vg

400
3-phase 9-phase 400

300
300
grid machine
200

Voltage
200
Voltage

100
va 100

0 vag 0

-100
+ vd -100

-200
-200

-300 vg -300

-400
0 5 10 15 20
-400
0 5 10 15 20
Time (ms)
Time (ms)
Carrier
Carriers
300
300

250
250
Voltage

200
200

150
150

100
100

50
50

00
00 11 2 3 4 5 6 7 8 9 10

Time (us)

Carriers can be shifted by 360/n degrees. This improves harmonic

content of the grid current but worsens the ripple of the machine
currents (i.e. efficiency).
48
Single-phase charging: charging performance using interleaving

Nine-phase and asymmetrical six-phase topology, left.

Symmetrical six-phase and five-phase topology, right.

vg vg
ig iL ig iL

ia ia

vg vg
iL ig iL
ig

ia ia

49
 Efficiency testing results: single-phase grid

Efficiency results obtained with and without interleaving for charging/V2G, and with and
without the dc-dc converter:
Induction machine Permanent magnet machine

Efficiency of single-phase charging PMSM

Efficiency of single-phase charging IM 100
100
NoIntNoDc
NoIntNoDc 95
95 WIntNoDc
WIntNoDc
NoInt
NoInt 90
90 Wint
Wint
85
85
80

Efficiency (%)
80
Efficiency (%)

75
75
70
70
65
65
60
60
55
55

50
50 -1500 -1000 -500 0 500 1000 1500
-1500 -1000 -500 0 500 1000 1500
Power drawn from the grid (W)
Power drawn from the grid (W)

50
 Efficiency testing results: three-phase grid

Efficiency results obtained with and without interleaving for charging/V2G, and with and
without the dc-dc converter:
Induction machine Permanent magnet machine

Efficiency of three-phase charging IM Efficiency of three-phase charging PMSM

100 100

95 95

90 90

85 85

80
Efficiency (%)

80

Efficiency (%)
75 75

70 70

65 65

60 NoIntNoDc NoIntNoDc
60
WIntNoDc WIntNoDc
55 NoInt NoInt
55
Wint Wint
50 50
-4000 -3000 -2000 -1000 0 1000 2000 3000 4000 -4000 -3000 -2000 -1000 0 1000 2000 3000 4000
Power drawn from the grid (W) Power drawn from the grid (W)

51
 Thank you for your
Thank you for your
attention!
attention!
Contact:
Emil Levi
E.Levi@ljmu.ac.uk

Liverpool John Moores University

52