A UPF DC Fast Charger for Plug-in Electric Vehicles Based on Dual-Stage Configuration

Mohamed Seleem, Yousry Atia, Belal Abou-Zalam, Sameh Abd-Elhaleem

Abstract


Electric vehicles (EVs) herald a new era of emission-free and eco-friendly mobility while diminishing dependency on fossil fuels. However, their adoption faces hurdles like prolonged charging durations and restricted range, limiting their widespread acceptance. Therefore, fast-charging technology is essential for EV commercialization to overcome these limitations. This paper proposes a simple and cost-effective unity power factor (UPF) DC fast charger (FC) for plug-in EVs, featuring high power quality and short charging time. The proposed FC is considered a dual-stage configuration, operating at UPF without requiring separate power factor correction (PFC) circuitry. This dual-stage configuration consists of two power stages: a 3-phase pulse width-modulated (PWM) rectifier in the input stage and a buck converter in the output stage, resulting in a significantly efficient proposed FC circuit. Also, a control strategy is proposed for the considered FC, specifying two key approaches: voltage-oriented control (VOC) scheme and constant current-constant voltage (CC-CV) charging method. The VOC scheme ensures UPF operation by attaining fast and dynamically regulated DC-bus voltage during EV charging. Meanwhile, the CC-CV charging method effectively manages EV battery charging in different charging modes, minimizing charging duration and preventing overcharging. The proposed control strategy has been validated by simulation software using the MATLAB/Simulink® environment. The simulation outcomes strongly support the efficacy of the proposed control strategy for the considered FC, including achieving a UPF, regulating the DC-bus voltage level with minimal ripple, minimizing harmonic currents though lower total harmonic distortion (THD) of 1.6%, and achieving CC-CV fast-charging.


Keywords


Electric Vehicle, Fast Charger, Battery Charging, Active Front-End Rectifier, Voltage-Oriented Control, Constant Current-Constant Voltage Technique.

Full Text:

PDF

References


M. Crippa, D. Guizzardi, F. Pagani, M. Banja, M. Muntean, E. Schaaf, W. E. Becker, F. Monforti-Ferrario, R. Quadrelli, A. Risquez Martin, P. Taghavi-Moharamli, J. Köykkä, G. Grassi, S. Rossi, J. Melo, D. Oom, A. Branco, J. San-Miguel, and E. Vignati, “GHG emissions of all world countries,” Publications Office of the European Union, Luxembourg, 2023, DOI: 10.2760/953322 (online), 10.2760/235266 (print).

A. Karki, S. Phuyal, D. Tuladhar, S. Basnet, and B. P. Shrestha, “Status of pure electric vehicle power train technology and future prospects,” Applied System Innovation, vol. 3, no. 3, 2020, DOI: 10.3390/asi3030035.

IEA, “Oil market report,” Paris, Aug. 2023.

S. Abd-Elhaleem, W. Shoeib, and A. A. Sobaih, “Improved power management under uncertain driving conditions for plug-in hybrid electric vehicles via intelligent controller,” IEEE Transactions on Intelligent Transportation Systems, vol. 24, no. 12, pp. 13698–13712, 2023, DOI: 10.1109/TITS.2023.3308509.

M. Seleem, Y. Atia, B. Abou-Zalam, and S. Abd-Elhaleem, “A Technological Review on Fast Chargers for Electric Vehicles: Standards, Architectures, Power Converter Topologies, Fast Charging Techniques, Impacts and Future Research Directions,” International Journal of Robotics and Control Systems, vol. 4, no. 1, pp. 217–261, 2024, doi: 10.31763/ijrcs.v4i1.1255.

B. S. Kaloko, M. H. P. Soebagio, and M. H. Purnomo, “Design and development of small electric vehicle using MATLAB/Simulink,” International Journal of Computer Applications, vol. 24, no. 6, pp. 19–23, 2011.

S. Abd-Elhaleem, W. Shoeib, and A. A. Sobaih, “Intelligent power management based on multi-objective cost function for plug-in biogas hybrid vehicles under uncertain driving conditions,” Complex & Intelligent Systems, vol. 9, no. 3, pp. 3115–3130, 2023, DOI: 10.1007/s40747-022-00890-8.

S. Abd-Elhaleem, W. Shoeib, and A. A. Sobaih, “A new power management strategy for plug-in hybrid electric vehicles based on an intelligent controller integrated with CIGPSO algorithm,” Energy, vol. 265, p. 126153, 2023, DOI: 10.1016/j.energy.2022.126153.

A. Babalhavaeji, H. Song, M. Radmanesh, and M. Jalili, “Identifying electric vehicles from smart meter recordings,” in Proc. 2023 11th International Conference on Smart Grid (icSmartGrid), 2023, pp. 1–3, DOI: 10.1109/icSmartGrid58556.2023.10171002.

A.H.K. Babar, Y. Ali, and A. U. Khan, “Moving toward green mobility: Overview and analysis of electric vehicle selection, Pakistan a case in point,” Environment, Development and Sustainability, vol. 23, no. 7, pp. 10994–11011, 2021, DOI: 10.1007/s10668-020-01101-5.

A. Saldarini, D. Martini, M. Longo, F. Foiadelli, and W. Yaici, “Assessing electric vehicle charging patterns: A comprehensive analysis of charging stations usage,” in Proc. 2023 12th International Conference on Renewable Energy Research and Applications (ICRERA), 2023, pp. 128–133, DOI: 10.1109/ICRERA59003.2023.10269386.

H.N. Durmus Senyapar, U. Cetinkaya, S. Ayik, Z. A. Altinok, and R. Bayindir, “Importance of charging infrastructure for the public adoption of electric vehicles - recommendations for Turkey,” in Proc. 2023 11th International Conference on Smart Grid (icSmartGrid), 2023, pp. 1–5, DOI: 10.1109/icSmartGrid58556.2023.10170969.

F. Un-Noor, S. Padmanaban, L. Mihet-Popa, M. N. Mollah, and E. Hossain, “A comprehensive study of key electric vehicle (EV) components, technologies, challenges, impacts, and future direction of development,” Energies, vol. 10, no. 8, 2017, DOI: 10.3390/en10081217.

C. Botsford and A. Szczepanek, “Fast charging vs. slow charging: Pros and cons for the new age of electric vehicles,” in Proc. International Battery Hybrid Fuel Cell Electric Vehicle Symposium, 2009, pp. 1–9.

K. Morrow, D. Karner, and J. Francfort, “Plug-in hybrid electric vehicle charging infrastructure review,” Battelle, United States, Nov. 2008, DOI: 10.2172/946853.

K. Dimitriadou, N. Rigogiannis, S. Fountoukidis, F. Kotarela, A. Kyritsis, and N. Papanikolaou, “Current trends in electric vehicle charging infrastructure; opportunities and challenges in wireless charging integration,” Energies, vol. 16, no. 4, 2023, DOI: 10.3390/en16042057.

A.E.F.A. Omran, A. E.-S. A. Nafeh, and H. K. M. Yousef, “Optimal sizing of a PV-battery stand-alone fast charging station for electric vehicles using SO,” International Journal of Renewable Energy Research, vol. 12, no. 4, pp. 1769–1778, 2022.

A.M. Foley, I. J. Winning, and B. P. Ó. Ó Gallachóir, “State-of-the-art in electric vehicle charging infrastructure,” in Proc. 2010 IEEE Vehicle Power and Propulsion Conference, 2010, pp. 1–6, DOI: 10.1109/VPPC.2010.5729014.

H. S. Das, M. M. Rahman, S. Li, and C. W. Tan, “Electric vehicles standards, charging infrastructure, and impact on grid integration: A technological review,” Renewable and Sustainable Energy Reviews, vol. 120, 2020, DOI: 10.1016/j.rser.2019.109618.

H. Tu, H. Feng, S. Srdic, and S. Lukic, “Extreme fast charging of electric vehicles: A technology overview,” IEEE Transactions on Transportation Electrification, vol. 5, no. 4, pp. 861–878, 2019, DOI: 10.1109/TTE.2019.2958709.

D. McPhail, “Evaluation of ground energy storage assisted electric vehicle DC fast charger for demand charge reduction and providing demand response,” Renewable Energy, vol. 67, pp. 103–108, 2014, DOI: 10.1016/j.renene.2013.11.023.

A. Kilic, “Analysis of charging systems for electric vehicle,” International Journal of Smart Grid-ijSmartGrid, vol. 7, no. 3, pp. 168–177, 2023.

S. Rivera, S. Kouro, S. Vazquez, S. M. Goetz, R. Lizana, and E. Romero-Cadaval, “Electric vehicle charging infrastructure: From grid to battery,” IEEE Industrial Electronics Magazine, vol. 15, no. 2, pp. 37–51, 2021, DOI: 10.1109/MIE.2020.3039039.

B. Whitaker, A. Barkley, Z. Cole, B. Passmore, D. Martin, T. R. McNutt, A. B. Lostetter, J. S. Lee, and K. Shiozaki, “A high-density, high-efficiency, isolated on-board vehicle battery charger utilizing silicon carbide power devices,” IEEE Transactions on Power Electronics, vol. 29, no. 5, pp. 2606–2617, 2014, DOI: 10.1109/TPEL.2013.2279950.

J.Y. Yong, V. K. Ramachandaramurthy, K. M. Tan, and J. Selvaraj, “Experimental validation of a three-phase off-board electric vehicle charger with new power grid voltage control,” IEEE Transactions on Smart Grid, vol. 9, no. 4, pp. 2703–2713, 2018, DOI: 10.1109/TSG.2016.2617400.

K. Drobni?, G. Grandi, M. Hammami, R. Mandrioli, M. Ricco, A. Viatkin, and M. Vujacic, “An output ripple-free fast charger for electric vehicles based on grid-tied modular three-phase interleaved converters,” IEEE Transactions on Industry Applications, vol. 55, no. 6, pp. 6102–6114, 2019, DOI: 10.1109/TIA.2019.2934082.

K. Drobni?, G. Grandi, M. Hammami, R. Mandrioli, A. Viatkin, and M. Vujacic, “A ripple-free DC output current fast charger for electric vehicles based on grid-tied modular three-phase interleaved converters,” in Proc. 2018 International Symposium on Industrial Electronics (INDEL), 2018, pp. 1–7, DOI: 10.1109/INDEL.2018.8637627.

D. Ronanki, A. Kelkar, and S. S. Williamson, “Extreme fast charging technology—prospects to enhance sustainable electric transportation,” Energies, vol. 12, no. 19, 2019, DOI: 10.3390/en12193721.

Y. Tahir, I. Khan, S. Rahman, M. F. Nadeem, A. Iqbal, Y. Xu, and M. Rafi, “A state-of-the-art review on topologies and control techniques of solid-state transformers for electric vehicle extreme fast charging,” IET Power Electronics, vol. 14, no. 9, pp. 1560–1576, 2021, DOI: 10.1049/pel2.12141.

“IEEE recommended practice and requirements for harmonic control in electric power systems,” IEEE Std 519-2014 (Revision of IEEE Std 519-1992), pp. 1–29, 2014, DOI: 10.1109/IEEESTD.2014.6826459.

International Electrotechnical Commission, “International standard IEC 61851-1, part 1: General requirements,” 2010.

A.A. Berbar, A. Khandakar, A. Rizqullah, S. Rahman, D. Kraev, A. Iqbal, and M. R. Ahmad, “Step-by-step design and simulation of boost controller for L- and LCL-filters for EV fast charging systems,” in Renewable Power for Sustainable Growth, Singapore: Springer Singapore, 2021, pp. 31–46.

M. Kaveh, S. Habibi, F. B. Ajaei, and S. Farhangi, “Practical strategy for improving harmonics and power factor using a three-phase rooftop photovoltaic inverter,” in Proc. 2023 12th International Conference on Renewable Energy Research and Applications (ICRERA), 2023, pp. 421–428, DOI: 10.1109/ICRERA59003.2023.10269387.

M. Liserre, A. Dell’Aquila, and F. Blaabjerg, “An overview of three-phase voltage source active rectifiers interfacing the utility,” in Proc. 2003 IEEE Bologna Power Tech Conference Proceedings, 2003, DOI: 10.1109/PTC.2003.1304405.

M. Malinowski and M. P. Kazmierkowski, “Chapter 11 - Control of three-phase PWM rectifiers,” in Control in Power Electronics, Burlington: Academic Press, 2002, pp. 419–459, DOI: 10.1016/B978-012402772-5/50012-0.

S.S. Lechat, “Voltage oriented control of three-phase boost PWM converters,” M.Sc. Thesis, Chalmers University of Technology, Göteborg, Sweden, 2010.

S. Leng, “Coordination of multiple active front end converters for power quality improvement,” Ph.D. Thesis, Florida State University, 2012.

H. Wang and H. Qi, “Study of control strategies for voltage-source PWM rectifier,” in Proc. 2nd International Conference on Computer Science and Electronics Engineering (ICCSEE 2013), Mar. 2013, pp. 1268–1271, DOI: 10.2991/iccsee.2013.318.

W.H. Fosse, “Design of grid-tied converter using AFE,” M.Sc. Thesis, The University of Bergen, 2023.

H. Shukla, “Vector control of three-phase active front end rectifier,” IJIRST–International Journal for Innovative Research in Science & Technology, vol. 2, no. 9, pp. 261–268, 2016.

A. Bouafia, J.-P. Gaubert, and F. Krim, “Design and implementation of predictive current control of three-phase PWM rectifier using space-vector modulation (SVM),” Energy Conversion and Management, vol. 51, no. 12, pp. 2473–2481, 2010, DOI: 10.1016/j.enconman.2010.05.010.

C.H. Dharmakeerthi, N. Mithulananthan, and T. K. Saha, “Modeling and planning of EV fast charging station in power grid,” in Proc. 2012 IEEE Power and Energy Society General Meeting, 2012, pp. 1–8, DOI: 10.1109/PESGM.2012.6345008.

S. Golestan, J. M. Guerrero, and J. C. Vasquez, “Three-phase PLLs: A review of recent advances,” IEEE Transactions on Power Electronics, vol. 32, no. 3, pp. 1894–1907, 2017, DOI: 10.1109/TPEL.2016.2565642.

M. Malinowski, M. P. Kazmierkowski, and A. Trzynadlowski, “Review and comparative study of control techniques for three-phase PWM rectifiers,” Mathematics and Computers in Simulation, vol. 63, no. 3, pp. 349–361, 2003, DOI: 10.1016/S0378-4754(03)00081-8.

A. Eliwa, M. Hassanein, M. Salem, Y. Atia, and M. Zahran, “Design and implementation of embedded controller and software development for PV on grid three phase inverter,” in Applications of Remote Sensing and GIS Based on an Innovative Vision, Cham: Springer Nature Switzerland, 2023, pp. 419–428.

M.P. Akter, S. Mekhilef, N. M. L. Tan, and H. Akagi, “Stability and performance investigations of model predictive controlled active-front-end (AFE) rectifiers for energy storage systems,” Journal of Power Electronics, vol. 15, no. 1, pp. 202–215, 2015.

A. Zhaksylyk, H. Rasool, E. Abramushkina, S. Chakraborty, T. Geury, M. El Baghdadi, and O. Hegazy, “Review of active front-end rectifiers in EV DC charging applications,” Batteries, vol. 9, no. 3, 2023, DOI: 10.3390/batteries9030150.

Z. Zhang, H. Xu, L. Shi, D. Li, and Y. Han, “A unit power factor DC fast charger for electric vehicle charging station,” in Proc. The 7th International Power Electronics and Motion Control Conference, 2012, pp. 411–415, DOI: 10.1109/IPEMC.2012.6258896.

J.S. Siva Prasad, T. Bhavsar, R. Ghosh, and G. Narayanan, “Vector control of three-phase AC/DC front-end converter,” Sadhana, vol. 33, no. 5, pp. 591–613, 2008, DOI: 10.1007/s12046-008-0045-y.

M. Liserre, F. Blaabjerg, and S. Hansen, “Design and control of an LCL-filter based three-phase active rectifier,” in Proc. Conference Record of the 2001 IEEE Industry Applications Conference, 2001, pp. 299–307, DOI: 10.1109/IAS.2001.955428.

V. Selarka, P. Shah, D. J. Vaghela, and M. T. Shah, “Close loop control of three phase active front end converter using SVPWM technique,” in Proc. 2016 International Conference on Electrical Power and Energy Systems (ICEPES), 2016, pp. 339–344, DOI: 10.1109/ICEPES.2016.7915954.

K. Fahem, D. Chariag, and L. Sbita, “Control of three-phase voltage source PWM rectifier,” in Proc. 3rd International Conference on Automation, Control, Engineering and Computer Science (ACECS’16), Hammamet, Tunisia, 2016, pp. 20–22.

Divakar, P. Dwivedi, S. Bose, and S. Pandey, “Comparative analysis of PI control with anti-windup schemes for front-end rectifier,” in Proc. 2020 IEEE First International Conference on Smart Technologies for Power, Energy and Control (STPEC), 2020, pp. 1–6, DOI: 10.1109/STPEC49749.2020.9297771.

D. Castro Carmona and J. Fernández Mandiola, “Design and implementation of a three-phase boost battery charger with PFC using CompactRIO control system,” M.Sc. Thesis, Chalmers University of Technology, Göteborg, Sweden, 2012.

M. Bongiorno and A. Sanino, Lecture slides: ENM100 Power Electronic Solutions for Power Systems, Chalmers University of Technology, Sweden, 2009.

T. Andromeda, I. Haryanto, J. Setiawan, Hermawan, B. Nugroho, M. I. Romadhon, I. Setiawan, M. Facta, and Abd. R. M. Sidek, “Design of DC fast charging buck converter for LFP battery on electric car,” in Proc. 2019 6th International Conference on Electric Vehicular Technology (ICEVT), 2019, pp. 258–262, DOI: 10.1109/ICEVT48285.2019.8993974.

C.H. Dharmakeerthi, N. Mithulananthan, and T. K. Saha, “Impact of electric vehicle fast charging on power system voltage stability,” International Journal of Electrical Power & Energy Systems, vol. 57, pp. 241–249, 2014, DOI: 10.1016/j.ijepes.2013.12.005.

M.H. Rashid, Power Electronics Handbook, 4th ed., Butterworth-Heinemann, 2018.

L.R. Dung, C.-E. Chen, and H.-F. Yuan, “A robust, intelligent CC-CV fast charger for aging lithium batteries,” in Proc. 2016 IEEE 25th International Symposium on Industrial Electronics (ISIE), 2016, pp. 268–273, DOI: 10.1109/ISIE.2016.7744901.

C.H. Lin, C.-Y. Hsieh, and K.-H. Chen, “A Li-ion battery charger with smooth control circuit and built-in resistance compensator for achieving stable and fast charging,” IEEE Transactions on Circuits and Systems I: Regular Papers, vol. 57, no. 2, pp. 506–517, 2010, DOI: 10.1109/TCSI.2009.2023830.




DOI (PDF): https://doi.org/10.20508/ijrer.v16i1.15109.g9149

Refbacks



Online ISSN: 1309-0127

Publisher: Gazi University

IJRER is indexed in EI Compendex, SCOPUS, EBSCO, WEB of SCIENCE (Clarivate Analytics)and CrossRef.

IJRER has been indexed in Emerging Sources Citation Index from 2016 in web of science.

WEB of SCIENCE in 2025; 

h=35,

Average citation per item=6.59

Last three Years Impact Factor=(1947+1753+1586)/(146+201+78)=5286/425=12.43

Category Quartile:Q4