New EV Battery Charger PFC Rectifier Front-End Allowing Full Power Delivery in 3-Phase and 1-Phase Operation
A new universal front-end PFC rectifier topology of a battery charger for Electric Vehicles (EVs) is proposed, which allows fast charging at rated and/or full power level in case of 3-phase (Europe) as well as 1-phase (USA) mains supply. In this regard, a conventional 3-phase PFC rectifier would fac...
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-08-01
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| Series: | Electronics |
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| Online Access: | https://www.mdpi.com/2079-9292/10/17/2069 |
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| author | Panteleimon Papamanolis Dominik Bortis Florian Krismer David Menzi Johann Walter Kolar |
| author_facet | Panteleimon Papamanolis Dominik Bortis Florian Krismer David Menzi Johann Walter Kolar |
| author_sort | Panteleimon Papamanolis |
| collection | DOAJ |
| description | A new universal front-end PFC rectifier topology of a battery charger for Electric Vehicles (EVs) is proposed, which allows fast charging at rated and/or full power level in case of 3-phase (Europe) as well as 1-phase (USA) mains supply. In this regard, a conventional 3-phase PFC rectifier would facilitate only one-third of the rated power in case of 1-phase operation. The new topology is based on a two-level six-switch (2LB6) 3-phase boost-type PFC rectifier, which is extended with a diode bridge-leg and additional windings of the Common-Mode (CM) chokes of the EMI filter. Besides this extension of the power circuit, the general design of the new converter is explained, and the generated Differential Mode (DM) and Common Mode (CM) EMI disturbances are investigated for 3-phase and 1-phase operation, resulting in guidelines for the EMI filter design. The EMI performance (CISPR 11 class-B QP) is experimentally verified for 1-phase and 3-phase operation at an output power of 4.5 kW, using a full-scale hardware prototype that implements the proposed extensions for a 2LB6 3-phase boost-type PFC rectifier and that is designed for output power levels of 22 kW and 19 kW in case of 3-phase and 1-phase operation, respectively. Compared to a conventional 2LB6 PFC rectifier, the volume of the extended system increases from 2.7 dm<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mn>3</mn></msup></semantics></math></inline-formula> to 3.4 dm<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mn>3</mn></msup></semantics></math></inline-formula>, of which 0.5 dm<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mn>3</mn></msup></semantics></math></inline-formula> is due to the additional dc-link capacitance for buffering the power pulsation with twice the mains frequency occurring for 1-phase operation. |
| first_indexed | 2024-03-10T08:13:27Z |
| format | Article |
| id | doaj.art-331f7dccd4f847b581d68b64db5f5044 |
| institution | Directory Open Access Journal |
| issn | 2079-9292 |
| language | English |
| last_indexed | 2024-03-10T08:13:27Z |
| publishDate | 2021-08-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Electronics |
| spelling | doaj.art-331f7dccd4f847b581d68b64db5f50442023-11-22T10:29:28ZengMDPI AGElectronics2079-92922021-08-011017206910.3390/electronics10172069New EV Battery Charger PFC Rectifier Front-End Allowing Full Power Delivery in 3-Phase and 1-Phase OperationPanteleimon Papamanolis0Dominik Bortis1Florian Krismer2David Menzi3Johann Walter Kolar4Power Electronic Systems Laboratory, ETH Zürich, 8092 Zurich, SwitzerlandPower Electronic Systems Laboratory, ETH Zürich, 8092 Zurich, SwitzerlandPower Electronic Systems Laboratory, ETH Zürich, 8092 Zurich, SwitzerlandPower Electronic Systems Laboratory, ETH Zürich, 8092 Zurich, SwitzerlandPower Electronic Systems Laboratory, ETH Zürich, 8092 Zurich, SwitzerlandA new universal front-end PFC rectifier topology of a battery charger for Electric Vehicles (EVs) is proposed, which allows fast charging at rated and/or full power level in case of 3-phase (Europe) as well as 1-phase (USA) mains supply. In this regard, a conventional 3-phase PFC rectifier would facilitate only one-third of the rated power in case of 1-phase operation. The new topology is based on a two-level six-switch (2LB6) 3-phase boost-type PFC rectifier, which is extended with a diode bridge-leg and additional windings of the Common-Mode (CM) chokes of the EMI filter. Besides this extension of the power circuit, the general design of the new converter is explained, and the generated Differential Mode (DM) and Common Mode (CM) EMI disturbances are investigated for 3-phase and 1-phase operation, resulting in guidelines for the EMI filter design. The EMI performance (CISPR 11 class-B QP) is experimentally verified for 1-phase and 3-phase operation at an output power of 4.5 kW, using a full-scale hardware prototype that implements the proposed extensions for a 2LB6 3-phase boost-type PFC rectifier and that is designed for output power levels of 22 kW and 19 kW in case of 3-phase and 1-phase operation, respectively. Compared to a conventional 2LB6 PFC rectifier, the volume of the extended system increases from 2.7 dm<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mn>3</mn></msup></semantics></math></inline-formula> to 3.4 dm<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mn>3</mn></msup></semantics></math></inline-formula>, of which 0.5 dm<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mn>3</mn></msup></semantics></math></inline-formula> is due to the additional dc-link capacitance for buffering the power pulsation with twice the mains frequency occurring for 1-phase operation.https://www.mdpi.com/2079-9292/10/17/2069EMI filterelectric vehiclesbattery chargerac/dc PFC rectifieruniversal converter |
| spellingShingle | Panteleimon Papamanolis Dominik Bortis Florian Krismer David Menzi Johann Walter Kolar New EV Battery Charger PFC Rectifier Front-End Allowing Full Power Delivery in 3-Phase and 1-Phase Operation Electronics EMI filter electric vehicles battery charger ac/dc PFC rectifier universal converter |
| title | New EV Battery Charger PFC Rectifier Front-End Allowing Full Power Delivery in 3-Phase and 1-Phase Operation |
| title_full | New EV Battery Charger PFC Rectifier Front-End Allowing Full Power Delivery in 3-Phase and 1-Phase Operation |
| title_fullStr | New EV Battery Charger PFC Rectifier Front-End Allowing Full Power Delivery in 3-Phase and 1-Phase Operation |
| title_full_unstemmed | New EV Battery Charger PFC Rectifier Front-End Allowing Full Power Delivery in 3-Phase and 1-Phase Operation |
| title_short | New EV Battery Charger PFC Rectifier Front-End Allowing Full Power Delivery in 3-Phase and 1-Phase Operation |
| title_sort | new ev battery charger pfc rectifier front end allowing full power delivery in 3 phase and 1 phase operation |
| topic | EMI filter electric vehicles battery charger ac/dc PFC rectifier universal converter |
| url | https://www.mdpi.com/2079-9292/10/17/2069 |
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