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This article has been accepted for publication in a future issue of this journal, but has not been

fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TPEL.2020.2981955, IEEE
Transactions on Power Electronics

< TPEL-Reg-2019-10-2258.R1>

Improved Power Quality On-Board Integrated


Charger with Reduced Switching Stress
Jyoti Gupta, Student Member, Rakesh Maurya, Member, IEEE and Sabha Raj Arya, Senior Member, IEEE

hybrid vehicles. The charging time and lifetime of the battery


Abstract- There is a consistent demand for reliable, efficient, are related to the Level 1, Level 2 and Level 3 of battery
small-sized, and light weight on-board chargers for vehicular charger characteristics [5]-[6]. In general, vehicle owners are
battery charging applications. In view of aforesaid requirements, expected to charge their vehicle battery during overnight at
these chargers are restricted to level-1 and level-2 charging.
home in a garage/parking by plugged in to a convenience
Therefore, it leads to larger charging time. The proposed charger
is integrated with propulsion machine drive system that serves to
outlet for level 1 (slow) charging. On contrary, future
utilize the high power-rated electrical machine and motor-drive developments focus on level 2 (semi-fast) charging to provide
voltage source converter to facilitate vehicular battery charging ample power. Usually house hold outlet of 230 V, 50Hz is
when the vehicle is not running. This paper presents used for both level 1 and level 2 chargers. EV battery charger
mathematical modelling under various operational modes, must ensure that the utility current is drawn with low
analysis and design considerations for the proposed system distortion and at high power factor to maximize the real power
configuration. The entire system is developed in Sim Power available from a utility outlet [7]. Installation of most of the
SystemTM toolbox of MATLAB software and tested in real time charging stations should comply with the guidelines
implementation. The performance investigations of proposed
prescribed by several standards such as IEEE-1547, SAE-
charging system are carried out for vehicle battery charging
under steady state as well as source variations. Furthermore, to
J2894, IEC1000-3-2, and the U.S.National Electric Code
ensure power quality features, total harmonic distortions of (NEC) 690 etc [4], [5].
source voltage and current and input power factor, are EV battery chargers are classified into on-board and off-
monitored. The salient features of proposed systems include no board chargers with unidirectional and bidirectional power
additional circuit, on-board charger suitable for fast charging, flow. Battery charger‟s connections are of two types within
plugged in with single-phase, 230V, 50 Hz outlet. It also offers the vehicle (on-board) and outside the vehicle (off-board) [8]-
reduction in switch stress, reduced filter size, less ripple in [10]. For charging the battery, two charging connectors are
current and voltage and also improve dynamic response. accessible i.e. standard J1772 connector for level 1, level 2
charging station and a CHADeMO for level 3 fast charging
Index terms―Three-level (TL) converter, integrated battery
charger, electric vehicles, interleaved control, state of charge
stations. Off-board is a fast charger that provides high power
(SOC), single phase charging. to dc outlets but its manufacturing cost is high. As compared
to onboard charging, fast charging reduces the battery life
I. INTRODUCTION considerably[11]. Unlike off-board, onboard chargers are
lighter in weight, smaller in size and volume. Typically, two
D ue to the more stringent regulations on emissions and fuel
economy, global warming, and constraints on energy
resources, the electric vehicles (EVs) and plug-in hybrid
conversion stage of an on-board charger is a front-end ac-dc
voltage source converter with unity power factor correction
electric vehicles (PHEVs), have attracted more and more feature followed by a dc-dc converter [12],[13]. Achieving
attention by vehicle manufactures, governments, and high power level with aforesaid chargers is very difficult
customers [1]-[3]. In order to develop low-cost and reliable because of its large passive components.
EVs and PHEVs, the research and development primarily For unidirectional power flow, the vehicle batteries could
focused on battery technology, charging infrastructure motors be charged through a unidirectional charger but the injection
and drives applications [4]. Out of above, the charging of power back to the grid is not possible. These chargers
infrastructure is one of the key factors for successful operation typically utilize diode bridge rectifier with filter components
of EVs/ PHEVs system. Discharging or charging performance and dc-dc converter [14]-[17]. Today, these types of chargers
of battery plays a crucial role in the development of electrical/ are being implemented in a single stage to limit weight, size,
volume and also losses.
Manuscript received October 21, 2019; revised Dec 26, 2019; accepted March The bidirectional charging system consists two stages of
04, 2020. operation to improve power factor using PWM voltage source
Jyoti Gupta, Rakesh Maurya and Sabha Raj Arya are with the Sardar converter and regulate the battery current/voltage using
Vallabhbhai National Institute of Technology, Electrical Engineering
Department, Gujarat, Surat-395007, India. bidirectional dc-dc converter [18-20]. PWM scheme is used in
(email:jgupta973@gmail.com, rmaurya@eed.svnit.ac.in, drive-mode operation of the system to generate torque and
sabharaj94@gmail.com ). desired motor speed. In the battery charging mode, the PWM

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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TPEL.2020.2981955, IEEE
Transactions on Power Electronics

< TPEL-Reg-2019-10-2258.R1>
scheme with current control is employed to charge the battery
with unity power factor operation.While operating in charging
and discharging modes, it should draw a sinusoidal current
with minimum phase angle to improve reactive power and
maximize active power. This circuit provides fast controlling
and high power density as compared to unidirectional charger,
which accounts more components, more cost and greater
challenge for implementation [21]-[23].
To reduce size, weight and cost, windings of electric motor,
inverter and other hardware components are utilized for
charging system, thus integrated drive system with battery
charger topology have been introduced. During charging
process, few mandatory features of integrated on-board
chargers are less harmonic content in supply current, unity
power factor operation and there is no development of
unwanted torque in motor.
This paper focuses on single-phase on-board integrated Fig. 1. Integrated on-board charger (a) schematic diagram (b) power topology.
charging system along with three-level bidirectional dc-dc
converter topology. As compared to conventional dc-dc The power circuit mainly consists of two parts namely
bidirectional converter, size requirements of filter inductor are interleaved boost converter (IBC) and three-level bidirectional
considerably less in three-level bidirectional converter. dc-dc converter. The IBC comprises of stator windings of
Additionally, switch voltage stress is also reduced to half of three-phase induction motor as three inductors (L1,L2,L3),
the input dc link voltage. Therefore, the dynamic response of three-leg voltage source converter (VSC), split dc link
integrated system is also superior to its counterpart [24-28]. capacitors (C1,C2) and bidirectional three level DC-DC
The paper starts with brief description of issues and converter with power switches (Sw1-Sw4) and passive filters
challenges associated with EVs/ PHEVs. The description of (L, C) as shown in Fig. 1(b). During charging mode, single
integrated charging system is presented in section-II. The phase ac voltage (vs) is applied to interleaved boost converter
section-III includes steady state operating details of proposed after closing SAE J1772 connector. The currents (iL1, iL2, iL3)
converter under various switching modes. The control through inductors (L1,L2,L3) are unidirectional in nature, and
algorithms scheme for interleaved boost converter and three- therefore, no electromagnetic torque is developed by the
level dc-dc converter are presented in section-IV. The design motor. Thus, rotor is at standstill condition. It is predictable to
considerations of system configuration are described in have unity power factor operation, requirement of reduced
section-V. The on-board integrated system of 8 kW, switching frequency of VSC, low source current harmonic
400V/20A is developed using Simulink and Sim-Power distortion due to interleaved control of three-leg VSC
System toolbox of MATLAB software and its testing in real- connected stator windings.
time implementation are discussed in section-VI. The section- The rectified output voltage (Vdc) of VSC is divided in two
VII presents the comparative study of three-level dc-dc equal parts using split dc link capacitors (C1, C2) and fed to
converter in buck mode over conventional buck converter to three- level bidirectional DC-DC converter. It is now be used
show its effectiveness. Finally, the conclusion is provided in for conditioning the dc voltage/ current to a constant voltage
section-VIII. (CV)/ constant current (CC) for charging the vehicle battery.
The Fig.1 (b) shows three-level bidirectional dc-dc converter
II. SYSTEM DESCRIPTION OF INTEGRATED ON-BOARD CHARGER with four switches operates as buck converter. In this mode,
Fig. 1(a) shows the schematic diagram of on-board two switches (Sw1, Sw2) operate with switching signals and
integrated drive system with battery charger topology. This switches (Sw3,Sw4) in OFF condition. Main attributes of three
system includes single-phase ac source (230V, 50Hz) as house level dc-dc converter include reduced switch voltage stress,
hold outlet, electric motor, voltage source converter (VSC), reduced filter size and improved transient response.
control system, bidirectional dc-dc converter and battery pack.
Under propulsion mode of vehicle, the J1772 connector is III. STEADY STATE OPERATION
opened and battery pack delivers power to electric motor via In this section, the steady state operation under varying duty
bidirectional dc-dc converter and three-phase voltage source ratio control is presented using switching waveforms and its
converter (VSC) as demanded by the operating conditions of equivalent circuits under various operational modes. Prior to
vehicle. In charging mode electric motor is at standstill and steady state analysis, power switching devices and all passive
J1772 connector is closed. The stator windings of motor are components are assumed to be lossless.
used as filter inductors, three-phase VSC serves as a
bidirectional ac–dc converter as depicted in Fig. 1(a).

0885-8993 (c) 2020 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
Authorized licensed use limited to: University of Canberra. Downloaded on April 30,2020 at 10:07:13 UTC from IEEE Xplore. Restrictions apply.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TPEL.2020.2981955, IEEE
Transactions on Power Electronics

< TPEL-Reg-2019-10-2258.R1>

Fig. 2. Switching waveforms of onboard charger under one switching cycle (a) IBC (b) TL Buck Fig.3. Equivalent circuit during various mode of
Converter with duty ratio D < 0.5 and D > 0.5 operation under one switching cycle.

Depending upon the desired charging voltage/current, the


A. Operation of Interleaved Boost Converter
duty ratio (D) of power switches (Sw1, Sw2) of three-level
It is further assumed that for a given sampling time(Ts), bidirectional dc-dc converter (operate as buck operation) may
supply voltage (vs) remains constant. The duty ratio (d) of varies either less than 0.5 or more than 0.5. In both values of
switches (T1 to T6) varies for each sampling time as supply D, the switches are controlled to regulate output voltage/
voltage (vs) keeps on varying sinusoidal. As shown in Fig.2 current to its desired value. The switching waveform over one
(a), in each sampling time, the switches (T1,T3,T5) are on for switching cycle with D<0.5 and D>0.5 are shown in Fig.2 (b).
dTs1 and switches (T4,T6,T2) are on for (1-d)Ts1 period, where
Case-I: Buck operation with D < 0.5
Ts1 is switching period for switches of IBC. Depending upon
the switching state of switches (T1-T6), six operating modes During buck operation, the switches (Sw3, Sw4) are always
are identified as shown in Fig.2 (a). These operating modes off and its body diodes (D3,D4) are operational as per circuit
repeat several times in one cycle of the line frequency (i.e. conditions. The equivalent circuit during all possible
50/60Hz). This interleaved boost converter works satisfactory switching state of TL dc-dc converter is shown in Fig.3.
when dc link voltage (Vdc) is more than peak of supply voltage Detailed analysis of dc-dc converter under both possible
(vs) and operation is restricted in CCM mode only. The conditions (D<0.5, and D>0.5) is presented as follow:
waveforms of voltage and current of filter inductors (L1,L2,L3) 1) Mode-I[t0, t1]
are also depicted in Fig.2 (a). The inductor currents (iL1,iL2,iL3) At instant t=t0, switch Sw1 turns ON and body diode D4
increase from their respective initial value whenever voltage conducts. Switch Sw2 and body diode D3 of switch Sw3 are in
across the concerned inductors are positive by turning on off state. The equivalent circuit showing current path is
switches (T4,T6,T2) as shown in Fig.2 (a). Therefore, this mode depicted in Fig. 3(b).The voltage across Sw2 and D3 are Vdc/2.
is call as inductor charging mode. The inductor current The inductor current (iL) increases from its initial value as
decreases linearly with turning on of switches (T1,T3,T5). It is shown in Fig.2 (b). The voltage and current equations are as
observed that individual filter current has high ripple. follows:
However, the source current (is) contains lower ripple due to
phase shifted operation of each leg of IBC.
B. Operation of Three-level DC-DC Converter

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Transactions on Power Electronics

< TPEL-Reg-2019-10-2258.R1>
Vdc V below. In this case switching waveforms of voltage and
VL  - Vo ; VSw 2  VD 3  dc ; VSw1  VD 4  0;
2 2 current are depicted in Fig.2 (b).
iL  ic  I o ; iSw 2  iD 3  0; iSw1  iD 4  iL ; (1) 1) Mode-I [t0, t1] and Mode-III [t2, t3]
Vdc In these modes, both the switches Sw1 and Sw2 are in on
- Vo
iL (t )  2 (t  t0 )  iL (t0 ) state and the body diodes D3 and D4 are in reversed biased.
L The inductor current (iL) increases from its initial value are
At the end of mode-I, maximum inductor current shown in Fig.2 (b). The operation of dc-dc converter in mode-
(iL(t1)=ILmax) is obtained by substituting iL (to )  I L min and III is same as mode-I. The voltage, current equations are as
t=DTs, in equation (1) follows:
Vdc V
- Vo VL  Vdc - Vo ; VD 3  VD 4  dc ; VSw1  VSw2  0
I L max  2 DTs  I L min (2) 2
L iL  iC  I o ; iD 3  iD 4  0; iSw1  iSw 2  iL ; (7)
2) Mode-II [t1, t2]& Mode-IV [t3, t4] V -V
At instant t1=DTs, switch Sw1 turned off and Sw2 still iL (t )  dc o (t  t0 )  iL (t0 )
L
remains off. The voltage stress across both switches is Vdc/2. At the end of mode-I, the value of inductor current can be
Inductor current freewheels through body diodes (D3, D4). The obtained by substituting to=0, t=DTs-Ts/2, in equation (7),
equivalent circuit showing current path is depicted in Fig.
V -V  T 
3(d). The operation of dc-dc converter in mode-II is same as I L max  dc o  DTs  S   I L min (8)
mode-IV. The voltage and current equations are as follows: L  2
V 2) Mode-II [t1, t2]
VL  -Vo ; VD 3  VD 4  0; VSw1  VSw 2  dc ;
2 At instant t1=DTs-Ts/2, Sw1 still remains on but Sw2 is
iD 3  iD 4  iL ; iL  ic  I o ; iSw1  iSw 2  0; (3) turned off. The equivalent circuit showing current path is
depicted in Fig.3 (b). This mode operation is same as Mode-I
-V
iL (t )  o (t  t1 )  iL (t1 ) of case D<0.5 operation.
L 3) Mode-IV [t3, t4]
Under steady state condition, at the end of mode-II the
value of inductor current is same as initial value (iL(t2)=ILmin). At instant t3=DTs, switch Sw1 turned off and Sw2 still
It can be obtained by substituting t1=DTs, t=Ts/2, in equation remains on. This mode operation analysis is same as Mode-III
(3). of D<0.5 case.
-V  T 
I L min  o  s  DTs   I L max (4) IV. CONTROL ALGORITHM SCHEME
L 2  In order to regulate dc link voltage and simultaneously
3) Mode-III [t2, t3] charge the vehicle battery as per CV and CC modes, two
At instant t2=Ts/2, switch Sw2 turned on and Sw1 still control schemes are implemented. First, an interleaved control
remains off. Diode D3 still remains on and D4 becomes turned algorithm for IBC to maintain constant dc link voltage (Vdc)
off. The voltage across Sw1 and D4 is Vdc/2. For this time along with unity power factor operation. Secondly, regulation
interval Sw2 and D3 are on as shown in Fig. 3(c). The voltage of output voltage (Vo)/output current (Io) of bidirectional three-
and current equations are as follows: level dc-dc converter to maintain a constant voltage/constant
Vdc V current value in charging mode. The details of each control
VL  - Vo ; VSw 2  VD 3  0; VSw1  VD 4  dc ; algorithm are given below:
2 2
iL  ic  I o ; iD 3  iSw 2  iL ; iSw1  iD 4  0; (5)
Vdc
- Vo
iL (t )  2 (t  t2 )  iL (t2 )
L
At the end of mode-III, the value inductor current is
obtained by Substituting t2=Ts/2, t=DTs+Ts/2, in equation (5).
Vdc
- Vo
I L max  2 DTs  I L min (6)
L
Case-II: Buck operation with D > 0.5
Depending on desired voltage for battery charging, the
value of duty ratio, D may be more than 0.5. Therefore,
Fig. 4. Schematic diagram of control system (a) interleaved control algorithm
analysis of TL dc-dc converter is also carried out as given for IBC (b) control algorithm for three-level dc-dc converter.

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Transactions on Power Electronics

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A. Control Algorithm for Interleaved Boost Converter iL1c  k  = iL1c  k - 1 + K pLc ie1  k  - ie1  k - 1+ K iLc ie1  k  ;
iL 2c  k  = iL2c  k - 1 + K pLc ie2  k  - ie2  k - 1+ K iLc ie2  k  ; (14)
In order to understand the interleaved control algorithm for
power factor corrected IBC, it is assumed that for a specified
sampling time (Ts), supply voltage (vs) remains constant Vin. iL 3c  k  = iL3c  k - 1 + K pLc ie3  k  - ie3  k - 1+ K iLc ie3  k  ;
The duty ratio (d) of power switches (T1-T6) varies for each
Where, KiLc and KpLc the integral and proportional gain are
sampling as supply voltage (vs) keeps on changing. Each leg
same values for three PI current controllers. The output signal
of IBC operates with equal phase shift of Ts/3.where Ts is
of each current controller is compared with phase shifted
switching period for power switches (T1-T6).
triangular wave of frequency 2.5 kHz to generate the PWM
Fig.4 (a) shows split DC voltage controller technique for
signals for switches (T1-T6) of IBC converter as shown in
maintaining the midpoint voltage zero. Through this technique
Fig.4 (a). The ripple content in supply current is significantly
used two identical PI controller to maintain the equality of
used due to interleaved operation of each leg.
capacitor voltage VC1 and VC2. In this scheme desired voltage
V*dc/2(k) is compared with the sensed dc-link voltage VC1(k), B. Control Algorithm for Three-level DC-DC Converter
to make a voltage error Ve(k), at any instant „k‟ as given below During charging mode, three-level bidirectional dc-dc
[27]. The voltage error Ve(k), is fed to first voltage controller converter works as buck operation in which power switches
(PI1) for generation of a controlled output Vc(1)(k), as given in (Sw1, Sw2) operate as interleaved control i.e. phase shifted
equation (10). Where, Kpv1, Kiv1 are the proportional gain and 900 to lessen filter inductor and capacitor size significantly.
integral gain of the first voltage controller. The TL-Buck converter operates under constant voltage/
V *dc constant current modes as per battery state of charge (SOC).
Ve (k )   k   VC1 (k ) (9)
2 Here, Fig. 4(b) shows schematic diagram of constant
Vc (1)(k )  Vc (1)(k  1)  K pv1{Ve (k )  Ve (k  1)}  K iv1Ve ( k ) voltage/current control algorithm applied to charge the battery.
For second PI controller (PI2), To maintain VC2 equations When SOC of battery is low (below 30%), the constant
same as (9) are developed. Where, Kpv2, Kiv2 are the current charging is applied by mode selector block of Fig.
proportional gain and integral gain of the second voltage 4(b). In this control scheme, output current (Io) is compared
controller. with desired current Io* at any instant „k‟ to generate error in
V *dc current Ie(k)=I*o(k)-Io(k). This error signal is fed to
Ve (k )   k   VC 2 (k ) (10) proportional-integral (PI) controller for generation of
2
Vc (2)(k )  Vc (2)(k  1)  K pv 2 {Ve (k )  Ve (k  1)}  K iv 2Ve ( k ) controlling the current Ic(k) as given in (15).
Fig. 4(a) used zero crossing detector and sample and hold I c  k   I c  k  1  K pcc I e  k   I e  k  1  Kicc I e  k  (15)
circuit to get the d-component of input supply voltage from Where, Kicc and Kpcc are the integral and proportional gain
sine template of input sinusoidal voltage. The total output of PI current controller.
generates after adding three outputs of 2 PIs and d-component When SOC of battery reaches to 73 %, the constant voltage
of supply voltage. The peak value (Vm) of single-phase ac charging mode is selected by mode selector block. Similar to
source can be computed as follows [26] constant current charging mode, this mode is accomplished by
Vm  vd 2  vq 2 (11) comparing output voltage (Vo) with desired voltage and
voltage error signal, Ve(k)=V*o(k)-Vo(k) is generated at any
Where vd=Vmsinωt and vq =Vmsin(ωt-90) are the
instant k. This error signal is fed to voltage controller to obtain
components in-phase and quadrature of ac supply voltage. The
controlled voltage Vc(k) as given in (16).
components (vd, vq) of supply voltage (vs) can be generated
from phase shifting block which is inbuilt in estimation of sine Vc  k   Vc  k  1  K pcv Ve  k   Ve  k  1  KicvVe  k  (16)
template block of Fig.4 (a). Where, Kicv, Kpcv are the integral and proportional gain of PI
The unit template of supply voltage us(k) is derived as voltage controller. Amplified signals, Vc(k), Ic(k) are compared
follows: with phase shifted saw-tooth carrier signals of 10 kHz for
v generating the switching signals for switches. These switching
us (k) = d ; (12)
Vm signals are connected to driver circuits of power switches
The reference current i*L(k) is obtained by multiplying the (Sw1, Sw2).
total output of split dc bus controller technique Vctotal(k) [27],
with the unit template of us (k ) as follows: V. DESIGN CONSIDERATIONS
The design of system for integrated battery charger includes
iL* (k )  us (k )Vctotal (k ); (13)
* mainly selection of circuit parameters of interleaved boost
This reference current i L(k) is compared with the sensed
converter (IBC) such as selection of filters (L1,L2,L3) and dc
inductor currents (iL1, iL2, iL3) and passed through individual
link capacitors (C1,C2) and that of three-level dc-dc converter
current controller (PI1,PI2, PI3). The output signal of individual
such as inductor (L), and capacitor (C).
current controller is represented by (14):

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Authorized licensed use limited to: University of Canberra. Downloaded on April 30,2020 at 10:07:13 UTC from IEEE Xplore. Restrictions apply.
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Transactions on Power Electronics

< TPEL-Reg-2019-10-2258.R1>
A. Selection of Circuit Parameters of IBC Average value of output inductor current (IL) is same for
It is designed to provide regulated dc link voltage (Vdc) D<0.5 and D>0.5 as shown in equation (21). Thus, For
along with power factor correction at the ac supply mains. The D<0.5 the maximum and minimum value of output inductor
values of filter inductors (L1,L2,L3) are selected such that IBC currents are determined by using (8), (20) and (21) which are
operates in CCM in all operating conditions. The design given as follows:
equations of filters (L1,L2,L3) and dc link capacitors (C1,C2) are Vo Vo (1  2 D)
I L max  
given in equations (17)[28]: Ro 4 fL (22)
2 Pin V V (1  2 D)
I pk  ;Vdc 
1
V I L min  o  o ; D  0.5
(17)
Vin 1  Dmin  in Ro 4 fL
For (D>0.5) max and min value output inductor currents are
Where, Vin  2Vs ; Vs= RMS Value of supply voltage (vs) determined by using (14), (20) and (21) which given below:
2Vin Dmin V V 1  D  (2 D  1)
Li min  ; i  1, 2,3. I L max  o  o
f Sw I Ro 4 fLD
(23)
D (18) Vo Vo 1  D  (2 D  1)
C1  C2  I L min   ; D  0.5
V Ro 4 fLD
R dc f s
Vdc For the converter to operate in CCM mode, the min value of
The calculated minimum value of filters (L1=L2=L3) and dc output inductor current has to be positive. Therefore, the
link capacitor (C1,C2) are 5.6 mH and 8852μF at switching boundary condition between continuous and discontinuous
frequency (fs) 2.5 kHz, 30% ripple in input current and 1% mode of inductor current is determined from the equations
ripple in dc link voltage. The consider design values of (22) and (23) within ILmin =0. Thus, min value of output
aforesaid components are given in part-A1 of Appendix-A. inductor Lcrit for continuous mode of current in the converter is
calculated by using (24),
B. Selection of Circuit Parameters of three-level dc-dc (1  2 D) Ro
converter Lcrit  ; D  0.5
4f
It is designed to provide regulated dc output voltage/ (24)
(2 D  1)(1  D) Ro
current as required by battery charging applications. The Lcrit  ; D  0.5
values of inductor (L), and output capacitor (C) are selected 4 Df
such that three-level dc-dc converter operates in CCM mode 3) Design of Output Capacitor (C)
during battery charging. To keep the constant output voltage, capacitor value should
to be very large. But in practice, the capacitor output voltage
1) Voltage Conversion Ratio
cannot be kept completely constant with a finite value of
For periodic operation of dc-dc converter, the average of capacitance. The variation in capacitor output voltage and
inductor voltage should be zero. Express the average of ripple in output voltage are computed from the voltage and
inductor voltage over one switching cycle as follows: current relation of capacitor. The capacitor current during
 Vdc   TS  switching is ic=iL-Io. At the time of capacitor charging, the
 2  Vo  DTs  Vo  2  DTs   0; D  0.5
    (19) output capacitor current must be positive.
 TS   Vdc  The change in charge Q is determined by the area of the
Vdc  Vo   DTs      Vo  TS  DTs   0 ; D  0.5
 2   2  triangle shown in the Fig. 3(b).
Solving equation (19) for both the case of duty ratio, yields 1  i  T  i T
Q  C VO   L     L s (25)
Vo 2  2  4  16
D (20)
Vdc Expression of output capacitor (C) can be obtained by
The voltage conversion ratio of three-level buck mode solving (22), (26) and (23), (26) as given in (27).
converter is the same as that in the conventional buck i T
converter. C L s (26)
16Vo
2) Design of Output Inductor (L) An estimated expression for the essential value of
Assuming that the average power supplied by the dc link capacitance as a function of ripple voltage constraint ΔVo, duty
and absorbed by the load must be same that will determine the ratio D, and switching frequency f and output voltage Vo is
average output inductor current. Therefore output inductor specified as
current average value is evaluated as,
V DVdc
iL  I O  0  (21)
Ro Ro

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(1  2 D)
C ; D  0.5
 V0 
32 f 2 L  
 Vo  (27)
(1  D)(2 D  1)
C ; D  0.5
 V0 
32 Df 2 L  
 Vo 
Considering the ESR for the accurate design of output value
of capacitor can be carried out in the ripple of output voltage
ΔVo. Normally, ESR value is designed by manufacturer.
However, the effective value of series inductance (ESL) below
100 kHz can be neglected. The output voltage ripple with ESR
be given as,
i T
Vo  L s  I c rco (28)
16C
Based on aforementioned designed equations (20)-(28),
8kW, 400V/20A, on-board integrated system for charging
vehicle battery is developed. Selected parameters for
experimental study are given in appendix-A.

VI. RESULTS AND DISCUSSIONS


The on-board integrated charging system of 8 kW,
400V/20A is developed using Simulink and Sim- Power
System toolbox of MATLAB software and its performances
are investigated. To validate the system performance, a
prototype of same specification is built in the laboratory
environment as depicted in Fig.5.
Fig.6. Experimental performance of steady state voltage and current
The three-level bidirectional dc-dc converter in charging waveforms of bidirectional integrated system in charging mode feeding 8kW
mode with integrated system and its control algorithm is power to battery load in CC mode at source voltage of 230V.
programmed in FPGA based XC3S5000 series processor using
OP-5142 real time simulator with real time sampling Source voltage (vs), source current (is), filter inductor currents
frequency of 50μS. A Fluke make power quality analyzer in (iL1, iL2, iL3), dc link voltage (Vdc), dc link current (Idc) are
single phase (43B) and agilent make four channel DSO-X- measured at input supply and dc link side of integrated system.
2004A digital oscilloscope are used to measure test It is presented in Fig. 6. In order to investigate the
waveforms under steady state and dynamic conditions performance of three-level bidirectional dc-dc converter of
respectively. The performance of integrated system with integrated system, switch voltage (VSw), and switch current
battery charging applications is observed for constant voltage (iSw), output inductor voltage (VL), output inductor current (iL)
and constant current mode. in charging mode are also observed in Fig. 6. The battery
voltage and current (VB, IB) are also depicted in Fig.6. Fig. 6
and Fig.7 show the steady state results at supply voltage of
230 V in CC and CV charging modes.
It is observed that Fig.6 (a) shows source voltage and
current are in same phase, battery voltage of 362V, and battery
current of 20A. With wide range of variation in supply
voltage, battery current is maintained constant in constant
current mode with 30% of initial SOC.
In constant current mode battery is charging with 20A
constant current and the battery output voltage is unregulated.
Fig. 6(b) presents individual inductor current at input side,
Fig. 6(c) shows interleaved control at input side of inductor
current. Fig. 6(d) shows 700V dc link voltage and voltage
Fig.5. Photograph of a prototype integrated EV battery charger. across each input capacitor C1, C2 i.e. 350 V. Fig. 6(e) shows
1) Steady state performance of integrated charging system output inductor voltage and current, battery voltage of 362V.
at 230V in CV and CC mode Fig. 6(f) shows switch stress 350V i.e. half of input voltage of

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2) Dynamic performance of integrated system in CV and
CC mode

Fig 7. Experimental performance of steady state voltage and current


waveforms of bidirectional integrated system in charging mode feeding 2kW
power to battery load in CV mode at source voltage of 230V
Fig. 8. Experimental Dynamic performance with battery load under source
voltage disturbance from 230 to 180 V in (i-iii) CC mode (iv-vi) CV mode.
bidirectional three level converter of integrated system. Fig.
7(a)-(f) show voltage and current waveforms in same steady
Fig.8 shows dynamic performance of integrated system
state condition for charging the battery in constant voltage
against the variation in supply voltage (vs), 20% reduction in
mode with 230V supply voltage. As per practice, when battery
supply voltage from its nominal voltage (230V). During
charged reaches to 70 to 80% of SOC, at this SOC value three
changes in supply voltage from 230V to 180V, no variation
level bidirectional dc-dc converter fed power for charging
occurred across dc link of VSC, across output voltage of TL
battery shifted to constant voltage (CV) mode.
converter and battery output voltage of integrated system in
In constant voltage mode, minimum power of 2kW is
both CC and CV modes. Fig. 8 also shows that input inductor
provided to charge battery with 5A current. The battery
currents are disturbed due to disturbance in supply variation.
Charging with constant output voltage of 400V and battery
The results of Fig. 9 related with power quality indices of on-
voltage 374V when SOC is above 73%. Fig. 6(d-f) and Fig.
board integrated system at rated load condition.
7(d-f) shows DC link voltage, voltage across each input
when converter of ac input voltage 85V with THD of source
capacitor (C1, C2), switching voltage values are same in both
current obtained are 0.6% and 2.1% and when 230V of THD
the modes (CV and CC). When battery SOC shifted to 73%
source current THD obtained are 3% and 9.7% in both the
input current is reduced from 20A to 5A and input inductor
modes respectively as shown in Fig.9 (a) and (b).
current value also reduced from 56 A to 18 A. In CV mode,
These all THD values are within the limits of IEEE-519-
Fig. 7(b) shows distortion in supply current is more as
2014 standard in CC mode and CC mode at supply voltage of
compare to CC mode. Fig. 7(e) shows discontinuous current
85V and 230V respectively. It also provides experimental
flowing through inductor in CV mode but it is continuous in
analysis pertaining to power quality features of on-board
nature shown in Fig. 6(e) for CC mode. For worst case
integrated charging system feeding power to charge the
situation supply voltage of 85V, system performance is
battery for different supply voltages in Table-I.
evaluated and shown in Table-I. With the variation in supply
voltage from 85-265V, system operates with almost unity
power factor operation.

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Fig.10. Performance Comparison of conventional buck and three level buck


converter. (a) Normalized input inductor current ripple (D) (b) Normalized
output voltage ripple.
TABLE II
COMPARATIVE STUDY OF THREE-LEVEL BUCK CONVERTER
Conventional buck Three-level Buck converter
Parameters
converter (D>0.5) (D<0.5)
Vo
Vo D  0.57 V
Duty Cycle D  0.57 Vdc D  o  0.57
Vdc Vdc

Switch Vin V
VSw   350V VSw  in  350V
Voltage VSw  Vin  700V 2 2
Stress
Switch rating 700V, 20A 350V, 20A 350V, 20A
(1  D)(2D  1) Ro (1  2 D) Ro
Inductance (1  D) Ro Lcrit  Lcrit 
Lcrit  D *4 f 4* f
value 2* f

(1  D)(2 D  1)
Output (1  D) C ; (1  2 D)
C V C
capacitor V 32 f 2 L o V
Fig. 9. Performance of converter (a) under 85V (i) Ps and Qs (ii) Vs and is (iii) 8 f 2L o Vo 32 f 2 L o
value Vo Vo
Harmonic spectra of iS in CC mode and same for (iv)- (vi) in CV mode,(b)
under 230V (i)-(iii) in CC and(iv)-(vi) in CV mode.
Normalized I Lf _ Buck 1/4 times of 1/4 times of
I *Lf _ Buck 
TABLE I
Ripple I Lf _ Buck _ max conventional conventional
POWER QUALITY INDICES OF BATTERY CHARGING WITH DIFFERENT Current buck converter buck converter
SUPPLY VOLTAGES
Normalized VCf _ Buck 1/8 times of 1/8 times of
Battery Charging Modes V *Cf _ Buck 
ripple output VCf _ Buck _ max conventional conventional
Supply Voltage Constant Voltage Mode Constant Current Mode voltage buck converter buck converter
Vs (V) vsTHD isTHD vsTHD isTHD
PF PF No. of One switch and one
(%) (%) (%) (%) Two switches and two diodes.
Sim. 0 3.62 0.97 0 1.62 0.98 devices diode.
85
V I  V I 
PSwloss   in o  tr  t f  f sw  PSwloss   in o  tr  t f f
Exp. 0.8 2.1 1 0.6 0.6 1
Sim. 0 3.87 0.97 0 1.24 0.98  2  sw 
120  4 
Exp. 0.5 3.2 0.99 0.5 1.2 0.99 Switching Pcloss  I SwRMS 2 Rdson
150
Sim. 0 7.83 0.97 0 1.73 0.99 and Pcloss  I SwRMS 2 Rdson
Exp. 0.5 5.4 0.99 0.5 2.1 0.99  IO 2 DRdson  212Rdson
Sim. 0 8.48 0.95 0 3.17 0.99
conduction  I O 2 DRdson  212Rdson
180 losses across MOSFET datasheet
Exp. 0.3 7.4 0.98 0.4 2.8 1 switch MOSFET datasheet of 500V, 20A
Sim. 0 9.59 0.96 0 4.31 0.99 of 1200V, 20A
(across one switch)
200 PSwit= 2.275W
Exp. 0.3 8.2 0.98 0.4 3.4 1 PSwit= 0.6125W
Sim. 0 9.24 0.96 0 3.99 0.99 Pcond= 159W Pcond= 53W
230
Exp. 0.3 9.7 0.98 0.3 3.0 1 Pclossdiode  VF Io (1  D) Pclossdiode  VF I o (1  D)
Sim. 0 56.6 0.95 0 14.6 0.97
265 V  I t  f  V  I t  f 
Exp. 0.3 47.4 0.95 0.3 13.3 0.99 PSwloss   in RR RR sw  PSwloss   in RR RR sw 
Switching  2   4 
and
conduction Diode datasheet of Diode datasheet of 400V, 20A
VII. COMPARATIVE STUDY OF THREE LEVEL DC-DC BUCK losses across
CONVERTER diode 1200V, 20A (across one Diode)
A comparative study of the proposed three-level dc-dc Pc=11.18W Pc=12.04W
converter in integrated system is carried out under buck PSw= 4.27W PSw= 0.24W
operation. The intend of this study is to evaluate the
Fig. 10 shows, if the ripple inductor current and ripple
performance of aforesaid converter in view of voltage stress,
output voltage of three-level are same as conventional, then
ripple in output voltage and inductor current and filter size.
size of filter inductor reduces by one-fourth and that of filter

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Vandevelde, "Dc-bus voltage balancing controllers for split dc-link four- from Indian Institute of Technology (I.I.T) Delhi, New Delhi,
wire inverters and their impact on the quality of the injected currents," in
India, in 2014. He is joined as Assistant Professor, Department
CIRED - Open Access Proceedings Journal, vol. 2017, no. 1, pp. 564-
568, 10 2017. of Electrical Engineering, Sardar Vallabhbhai National
[28] M. Farhadi, M. T. Fard, M. Abapour and M. T. Hagh, "DC–AC Institute of Technology, Surat. January 2019, he is promoted
Converter-Fed Induction Motor Drive With Fault-Tolerant Capability as Associate Professor in same institute. His fields of interest
Under Open- and Short-Circuit Switch Failures," in IEEE Transactions
include Power electronics, power quality, design of power
on Power Electronics, vol. 33, no. 2, pp. 1609-1621, Feb. 2018.
filters and distributed power generation. He received Two
National Awards namely INAE Young Engineer Award from
Jyoti Gupta (S’20) received the Indian National Academy of Engineering, POSOCO Power
B.Tech. in Electrical Engineering from System Award from Power Grid Corporation of India in the
Swami Keshvanand Institue of year of 2014 for his research work. He is also received Amit
Technology, Management & Garg Memorial Research Award-2014 from I.I.T Delhi from
Gramothan, Jaipur, in 2013 and M.Tech the high impact publication in a quality journal during the
in Power Systems from Rajasthan session 2013-2014. At present, he has published more than
Technical University, Kota, Rajasthan, Hundred research paper in internal national Journals and
India in 2017. She is pursuing her Ph.D conferences in field of electrical power quality. He also serves
in the Department of Electrical Engineering of Sardar as an Associate Editor for the IET (U.K.) Renewable Power
Vallabhbhai National Institute of Technology, Surat, Gujarat, Generation.
India from 2018 onwards. She also worked as a Lecturer in
Electrical Department of Apex Institute of Engineering &
Technology, Jaipur, Rajasthan, India, from 2014 to 2015. Her
research activities are related to DC-DC Converters, Power
Quality and Battery Charging for EV Applications.

Rakesh Maurya (M’15) received B.


Tech. degree in electrical engineering
from the Kamla Nehru Institute of
Technology, Sultanpur, India, in 1998,
and M. Tech. degree in power electronics
and electric drive and Ph. D. degree in
electrical engineering from the Indian
Institute of Technology Roorkee,
Roorkee, India, in 2002 and 2014, respectively. He is currently
an Associate Professor in the Department of Electrical
Engineering, Sardar Vallabhbhai National Institute of
Technology, Surat, India. In last five years, he has published
more than 35 SCI/SCIE research papers in journals of
international repute particularly IEEE Transactions, IETs-UK
and Elsevier, Taylor& Francis and many conference papers.
His current research areas include design of switching power
converters, high power factor ac/dc converters, hybrid output
converters, improved power quality converters for battery
charging applications, power quality problems, advanced
electric drives and applications of real-time simulator for the
control of power converters. He is member of IEEE and Life
Member of System Society of India.

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