High Power Density EV Integrated Fast Battery Chargers Based on the General Torque Cancelation Law for Three-Phase Motors

Abstract

Integrated battery chargers are highly effective for saving costs and improving the power density of on-board chargers in electric vehicles (EVs), However, achieving torque elimination of the commonly used three-phase (3p) motors during the fast-charging process is challenging. In this paper, the general torque cancelation law applied in 3p permanent magnet synchronous motors (PMSMs) and induction motors (IMs) is derived to design high power density integrated fast battery chargers. Two novel integrated systems with fast-charging and vehicle-to-grid (V2G) capabilities are proposed based on this law. The main advantages of the proposed systems are: (1) Two filter inductors are constituted by the stator windings while charging, and only one external inductor and several contactors are supplemented to the motor-drive circuit. Therefore, the proposed integrated systems possess high power density; (2) The 3p open-winding (OW) motor is employed, with no need to modify the propulsion system or redesign the interior structure of the motor; (3) Employing an individual controller for each phase of the inner current loop control, the proposed systems realize unity power factors and low current harmonics in the fast-charging and V2G mode. Simulation and experimental results verify the feasibility of the proposed topologies and control strategies.

Keywords

• Electric vehicles (EVs)
• fast charging
• integrated battery charger
• 3p PMSM/IM
• torque cancelation