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Portable Battery Charger for Electric Vehicles

Aman Jha, Senior Member, IEEE and Bhim Singh, Fellow, IEEE

(BOM), an isolation as well good power quality. The quasi

2021 International Conference on Sustainable Energy and Future Electric Transportation (SEFET) | 978-1-7281-5681-1/20/$31.00 ©2021 IEEE | DOI: 10.1109/SeFet48154.2021.9375782

Abstract—This paper deals with design and development of a

resonant flyback converter performs dual functions of power
light electric vehicle (EV) charger. This EV charger operates in
bulk charge as well as float charge mode with the battery deep factor correction (PFC) as well as constant voltage and
discharge cutoff to enhance battery life. Its power converter is constant current mode using peak current mode controller.
of 85W rating having operating voltages from 36V to 42V with This approach is useful to reduce multiple integrating circuits
2A maximum current in bulk charge mode. Test results are (ICs) for the charger application [6]. For power quality
presented for a 36V, 10Ah-20Ah battery, which is requirement, active power factor correction (PFC) is a todays
commercially used for electric cycle or equivalent EV requirement. The current mode controller is used in this
application. The input voltage for this power converter is for converter to perform zero voltage switching (ZVS) as well as
universal input voltages (90VAC -265VAC/47Hz-63Hz). The good active power factor (PF).
AC-DC converter power switch operates in quasi-resonant The QR flyback converter in switch off condition is ensured
mode for high efficiency in wide input voltage range. The
converter size as well as thermal parameters are well within Input
the limits as observed in test results. 90-265V
Filter and
Bridge Battery
Rectifier
Keywords—AC-DC Converter, Light Electric Vehicle Charger, AC Input
Self Start
RCD
Snubber
Secondary Output
Reverse
Circuit
Protection
Power Factor Correction, Power Quality, Quasi Resonant Gate
and HV
Input N-channel
Rectification Filter

Protection Mosfet
Converter. Drive
Injection
Single Switch
Peak Current
Gate Drive
I. INTRODUCTION Mode PFC
Controller Battery
Load
VCC 36V 10-

The electric vehicle (EV) industry is now increasing day by Zero Voltage Detection
20AH

day. Higher global carbon footprint, rate of rise in fossil fuel THD Optimizer
Feedback
Voltage Feedback
Constant
price, enhancement of battery technology as well as efficient Current &
Voltage Current Feedback

motor and motor control techniques are now in favor of Optocoupler

Reference
Battery
Short

electric vehicle ecosystem. The market size and volume of Circuit

Protection

low to medium speed vehicles are large for developing Fig. 1. EV charger block diagram
country like India [1]. So, there is big push from the by primary reduced envelope tracking for every switching
government as well as regulatory agency for electrification cycle. The transformer saturation protection for every
of such vehicles [2]. The charging of such EVs could be a switching cycle is ensured by peak current control of the
challenge for present charging station as well as poor traffic primary current. In this way, switch ON and OFF condition
conditions as reported in [3]. In order to mitigate such is monitored. The passive snubber circuit is used in this
challenge, portable chargers are very much needed. It is to converter to protect switch in OFF condition. In secondary
provide extra advantage for consumers for charging purposes side, high performance operational amplifier (Op-Amp) is
and offload the traffic issues as well charging infrastructure, used to regulate voltage and current in reasonable fashion to
which can be utilized for high speed as well as heavy EVs. charge the battery as per need. An op-amp output as per need
The power quality is another challenge for such power through phototransistor enable feedback signal in primary
converter introduction for utility system. The IEC61000-3-2 side. EV charger design specification is given in Table I.
is applicable for such power converters [4]. The proposed
EV charger is working at good power factor (PF) and limited TABLE I. SPECIFICATION OF ELECTRIC CHARGER
total harmonic distortion (THD) with line and battery side Items Detail
protection. The design is taken considerations of limited Single Phase Input Source Universal (90 – 265 VAC),
temperature rise well below thermal limits of individual Source Frequency (47-63Hz)
active as well as passive components. Power factor (PF) >0.98
Total Harmonic Distortion (THD) <10%
In this paper, an EV charger design for parametric Battery voltage 36 V, 10AH-20AH
calculation, test measurements for the solution and Battery bulk charge current 2A
conclusion are given. The low voltage as well as high input No load voltage 47V
voltage cutoff is implemented in it. The implementation is Standby consumption < 0.5 W
made in the latched mode so power conversion recovers Open Battery No failure (Latched mode)
whenever the protection condition is recovered. The open-
Short Battery No failure (Latched mode)
circuit as well as short-circuit load protection is implemented
without compromising with efficiency and the cost. The III. EV CHARGER DESIRED CHARACTERISTICS
most improved THD (Total Harmonics Distortion)
enhancement circuit is implemented at low cost. In the literature, it is said that the battery is a critical
requirement in terms of cost, maintenance, safety and range
II.EV CHARGER ARCITECTURE anxiety for EVs [7]. The battery health management system
The EV charger block diagram is shown in Fig.1. The input (BHMS) is very much required for reliable application to
source is processed through protection, line filter and full integrate and inform the user the complete status of the
bridge converter. The UL690350 is followed as per safety battery [8]. The charging profile of a battery is one of the
and EMI/EMC norms [5]. The basic power converter is main requirements of BHMS, which is dependent on the
quasi-resonant (QR) flyback converter. The selection of battery chemistry as well as environment near to the battery
flyback converter is a choice for low bill of material cost like temperature, humidity etc. [9].

978-1-7281-5681-1/20/$31.00 ©2021 IEEE

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The power designer aim is to match the charging profile of

the battery as close as possible using different control
techniques [10]. Figs. 2(a)-(b) show the charging profile
needed for lead-acid as well as lithium ion battery chemistry
at ambient temperature for 36V/10Ah battery system.
A V
2.45 VPC =44.1V
0.2 C 2.35 VPC =42.3V

2.25 VPC =40.5V

1.8 VPC =32.4V

1.2 VPC =21.1V

Voltage per cell (VPC) = 18 (a) Transformer schematics

Battery Capacity (C ) =10AH
0.03C
0.02C

(a) Lead acid battery charging profile

A V
4.1 VPC =43.1V
0.5 C
3.9 VPC =41V
0.35C

Voltage per cell (VPC) = 10.5

Battery Capacity (C ) =5AH

3.1 VPC =32.55V

2.5 VPC =26.25V
0.1C

0.08C (b) Transformer design

0.05C

Time
(b) Lithium ion battery charging profile
Fig. 2 Battery charging profile

The converter needs to provide such voltage and current

based on need of power requirement as given in Fig.2. The (c) Primary side view (d) Secondary side view (e) Top view (f) Bottom view
BHMS is needed as per need depending on the battery Fig.3 High power frequency magnetics design
chemistry. Normally a lithium ion chemistry needs advanced TABLE II. TRANSFORMER SPECIFICATION AT 25 °C TEST CONDITIONS
BHMS due to its battery chemistry and it communicates with Parameter Test Conditions Value
charger as per need of columbic charge [7-10]. The converter DC Resistance (PIN 1-3) 20 °C 0.23Ω
has the capability to supply power as per need.
DC Resistance (PIN 4-6) 20 °C 0.32Ω
IV. DESIGN OF EV CHARGER DC Resistance (PIN 7-9) 20 °C 0.040Ω
Inductance (PIN 1-3) 10kHz,100mV, Ls 560µH±10%
This battery charger is developed for a lead acid as well as Leakage Inductance (PIN 1-3) Tie (PIN 4+6, 7+9) 9µH
lithium ion battery with a voltage of 36V and desired battery 100kHz,100mV, Ls maximum
capacity based on possible charge time. This switched mode Dielectric Tie (PIN1+4) 1.5kVAC 1
power converter is suitable for electric cycle battery charger. 1875VAC 1 second minute
Following section deals with the design of charger. Turns ratio PIN (1-3):PIN(4-6) 7.5:1±1%
Turns ratio PIN (1-3):PIN(9-7) 3.33:1±1%
A. High Switching Frequency Transformer Design
B. Primary Switch Stress and Primary Inductance
Fig.3 shows high frequency transformer design schematics,
picture and parameters. The transformer core PQ32/30 core The primary active switch is selected based on peak voltage
is selected for this design [11]. Fig.3(a) shows the design across it in switch OFF condition. The peak voltage at
schematics with voltage and current handling capability maximum line voltage (265V) condition is as,
with orientation. The selection of core material, bobbin size, N pri
wire type and turns are given in detail in Fig. 3(b). For better Vsw max Vin (max)  2 Vout _ Max
N sec (1)
magnetic coupling and low leakage inductance primary
winding turns are interleaved as given in Fig.3(b). Figs.3(c)- 60
265 u1.414  2 u u 57 374.71  380 754.71V
(f) show the designed transformer view. It is very compact 18
and small form factor transformer in this power range. Table Where, Vswmax and Vin(max) are peak switch voltage and peak
II shows test specifications at nominal temperature source voltage. As per calculation, any MOSFET with
condition. The loss parameter is selected in such a way that margin of 20% can be selected for this design. Other
the temperature of transformer at full load not reaches 75°C, considerations are high switching capability as well as
at nominal operating condition. It is also matching with temperature rise need to be taken care. STPS10N95K5 is
thermal camera test results at full load condition. selected for this design. Other advantages of selected
MOSFET are discussed in datasheet [12].

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The maximum reverse voltage at primary side (VREF_MAX) D. Battery Low Voltage Cut off
calculation is based on the relation given here. Table II
shows the output peak voltage (Vout_Batt) at no load voltage The controller power cut off is used to protect the battery for
of 47V. low voltage charge condition. The minimum voltage of
battery, which can be possible to charge, is as,
N pri 60
VREF _ MAX u Vout _ Batt u 47 157V (2)
N aux 8
Nsec 18 Vcc _ min Vout _ Batt _ MIN u 24 11V (7)
Where, Nsec, Npri, Vout_Batt and VREF_MAX are secondary Nsec 18
winding number of turns, primary winding number of turns,
no load output voltage (in case of battery removed) and Where, Nsec, Naux, Vout_Batt_MIN and Vcc_min are number of
maximum reverse voltage, respectively. secondary winding turns, number of auxiliary winding turns,
The primary maximum current is calculated as, output voltage and minimum voltage supply to controller
[13]. The lower than this level of the battery voltage can be
§ Vsense · 0.745 (3) considered as deep discharge condition.
I PEAK ¨ ¸ 4.96 A
R
© sense ¹ 0.15 E. Design of Constant Voltage and Constant Current
Where, IPEAK, Rsense and Vsense are maximum current in each Sensing
switching cycle, current sensing shunt resistor and sensing For constant current and constant voltage operations, a dual
voltage. Here, Vsense is given in controller datasheet [13]. operational amplifier is needed, which can work in both
The primary inductance is an important parameter, which conditions. The TSM101 is selected for this work due to dual
decides the energy storage in every switching cycle of op-amp capability in ORed function [15]. The calculation of
flyback converter. The maximum primary inductance at constant current as well as constant voltage for battery
lowest possible input voltage for this power converter for charger is as,
minimum possible switching frequency for this controller is § R38 · § 3.3 ·
as, Vref VREF ¨ ¸ 1.24 ¨ ¸ 175mV
Vdc min 1 1 © R38  R28 ¹ © 3.3  20 ¹
LP max VBatt _ sen I Batt R122 2*0.09 180mV
§ Vdc min · F MIN _ SW I PEAK
¨¨ 1  ¸¸ Vref # VBatt _ sen
V (4)
© REF _ MAX ¹
(8)
81.05 1 1
u u 425P H Here, Vref shows the maximum possible reference current and
§ 81.05 · 25 u 1000 4.96 VBat_Sen is the maximum current measured value. Here a 2A is
¨ 1  ¸
© 150 ¹ the maximum set charge current. The charging current can be
set as per battery charge requirement up to 3A.
Where, Lpmax, Vdcmin, VREF_MAX, FSW_MIN and IPEAK are primary § R31  R34 · § 100  2.7 · (9)
inductance, minimum possible DC input voltage for V V
out _ Batt REF ¨ 1.24 u
¸ ¨ 47V ¸
operation at low line, voltage reflection possible, minimum © R34 ¹ © 2.7 ¹
possible operating switching frequency of the controller and The maximum battery charge voltage, Vout_Batt is set from
maximum switching cycle current for this input voltage. The secondary side is 47V. This is to be the maximum charging
calculated value of inductance for this design is 450µH. voltage achieved by the EV charger.
C. Secondary Diode Stress Calculation F. Design of Battery Reverse and Short Circuit Protection
The secondary side diode selection is verified as, The preload resistor to control output voltage rise in case of
N sec
open load condition is a problem with flyback converter-
Vdiode max Vout _ Batt  Vin (max) based power conversion. The preload resistor is to although
N pri create fixed loss, but it is necessary. Here a R12, 6.8K
(5)
resistance is used. For the battery reverse connection
18
42  u 265 u 1.414 155V protection diode D5 is used. For the battery short circuit
60 condition, higher current is to flow through R122 sensing
Where, Vdiodemax is maximum possible reverse voltage across resistor. If not protected at current level, the sensing resistor
secondary diode in primary switch ON condition at may fail. In this design as shown in Fig.4(b), at higher
maximum input voltage. Here, STPS20200C is selected as a current around 0.6V of voltage level, D37 operates and
catch diode in secondary side. It is fundamentally schottky generates overcurrent condition so that its controller stops
which has no reverse recovery loss and very fast operating the switching activity.
capability [14]. D5 Batt +
The reverse calculation of output voltage using the primary STTH3L06

side loop is as,

6.8K
N § R · 18 § 30 · (6)
Vout _ Max VREF sec ¨1  zcs ¸ 2.54 u ¨1  ¸ 57V
R15

N aux ¨© R f ¸¹ 8 © 3.3 ¹
Where Vout_Batt, VREF (2.54V), Naux, Rzcs and Rf are output
load voltage, reference voltage of controller, number of
auxiliary winding turns, QR reduced envelope resistance (a) Battery reverse and open circuit protection
and feedback loop selected resistance, respectively. Here an
idea is to keep primary loop some margin to better control
by secondary loop.

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Batt + A. Test Results of Overall System

The power converter is tested with fully discharged battery
Batt- for a universal input voltage as shown in Fig.5(c). The
R120
overall efficiency reported for this power converter is more
R122 D37
0.09R 1N5408 1K than 85 % and the charging current regulation is less than
1%. Fig.6(a) and Fig.6(b) conform the test result
Current actual
performance.
(b) Battery short circuit protection
Fig.4 Battery open, reverse and short circuit protection circuit
V. SYSTEM LEVEL TESTING OF EV CHARGER
Fig.5 shows a prototype on-board with selected components.
Fig.5 (c) shows test development set up for design
validation.

(a) Overall efficiencyy of EV charger

g at different input
p voltage
g

(a) Top side components of EV charger

(b) Charge current regulation at different input voltage

Fig.6. Efficiency and current regulation
B. THD and PF Measurement
Figs.7 (a) and (b) show THD and PF for different line
voltages at full load condition. The measured value for THD
is lower than 10% and PF higher than 0.98 for EV charger.
(b) Bottom side components of EV charger

(a) THD value at different line voltage at full load

(c) Validation set up

Fig.5. Prototype view and test validation set up for EV charger

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(a) Input envelope plot

CH1: Input voltage, CH2: Input current
(b) PF at universal line voltage at full load
Fig. 7. PF and THD of EV Charger
C. Active Switch Operation
The active switch cycle at peak input voltage of 265VAC
and the bulk charge current, is given in Fig.8 (a). It shows
the QR mode of operation of the charger. The current and
voltage maximum values for active switch are 3.6A and
828V.

(b) Harmonic current

Fig. 9. Power quality plot

E. Power Converter Protection

The charger is protected in the battery short as well as open
condition. In both conditions, the charger is stable, which is
confirmed in Fig.11.

(a) One switching cycle at 265VAC

(a) Battery load open

(b) One switching cycle at 90VAC

Fig. 8. Power converter switching behavior
CH1: Drain to source voltage, CH2: Peak current

The peak current is 5A at low line through active switch. (b) Load connector short
The test result shown in Fig.8 matches with calculated Fig. 10. Load side protection
values. The QR converter switch operation is also matching CH1: Drain voltage, CH2: Controller VCC voltage
with Fig.8. F. Temperature Graph
D. Input Characteristics and Harmonics Spectra The thermal imaging of power converter has been done. The
Fig.9(a) shows the voltage and current matching envelope at test result is shown in Fig. 11. These results are good as per
maximum charging current. Fig. 9(b) shows the harmonics result for entire board area.
current measured value versus IEC61000-3-2 limits. The
power converter is well within the harmonic limits set by
regulatory for Class B, C and D.

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[8] J. Zhang, L. Zhang, F. Sun and Z. Wang, “An Overview on Thermal

Safety Issues of Lithium-ion Batteries for Electric Vehicle
Application”, IEEE Access, vol. 6, pp. 23848-23863, 2018.
[9] C. Zhu, Y. Shang, F. Lu, Y. Jiang, C. Cheng and C. Mi, “Core
Temperature Estimation for Self-Heating Automotive Lithium-Ion
Batteries in Cold Climates”, IEEE Trans. Ind. Infor., vol. 16, no. 5,
pp. 3366-3375, May 2020.
[10] Q. Ouyang, J. Chen and J. Zheng, “State-of-Charge Observer Design
for Batteries With Online Model Parameter Identification: A Robust
Approach”, IEEE Trans. Power Electronics, vol. 35, no. 6, pp. 5820-
5831, June 2020.
[11] R. W. Erickson and D. Maksimovic, Fundamentals of Power
Electronics, 2nd Edition, Kluwer Academic Publishers, New York,
2001.
(a) Top surface thermal image
[12] Application datasheet,“N-channel Zener-protected Power
MOSFETs”, [Online] Available : www.st.com/resource/en/datasheet/
stp10n95k5.pdf, Aug.2020.
[13] Application datasheet,“PFC controller with voltage primary-
sensing”, [Online] Available : www.st.com/en/power-
management/hvled.html, Aug. 2020.
[14] Application datasheet, “Schottky Diode”, [Online] Available:
www.st.com/resource/en/datasheet/stps20200c.pdf, Aug. 2020.
[15] Application Datasheet,“High Performance Op-Amp”,[Online]
Available:www.st.com/en/power-management/tsm101.html,Aug.
2020.

(b) Bottom surface thermal image

Fig. 11. Charger thermal stress

VI.CONCLUSION
The designed EV charger has been developed and tested
with shown with the battery. The charger operates in
different charging modes reliably. The power charger is
good to charge the battery having capacity of 10Ah to 20Ah
with 36V nominal voltage. The measured input harmonics
current of charger is under the IEC61000-3-2 limit. It is
mandatory for single phase charger with less than 16A
current drawing capability. The charging current regulation
is also less than 1% for universal input voltage. The
protection features from battery as well as well as source
side are implemented for this charger.
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