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August 9, 2021.
Digital Object Identifier 10.1109/ACCESS.2021.3101942
ABSTRACT Although there is a growing interest in developing fast charging methods to enhance the
Electric Vehicles’ appeal, the main energy supply is still the single-phase outlet. While single-phase charging
may be simpler than three-phase, there are challenges in the integration of the propulsion and charging
systems without adding inductive grid filters. Such integration would bring benefits like the simplification
and reduction of components, costs, volume or weight. This can be achieved by using the windings of the
propulsion machine as grid filters, but the use of the electric motor as a grid inductive filter leads to the
generation of pulsating torque during the charging state. This translates into vibration, noise and eventually,
damage to the motor and other components of the system. In this work, the authors propose a control strategy
that considerably reduces the peaks of pulsating torque generated in any rotor position while using the
machine wingdings as filter. Simulation tests have been carried out to validate the control strategy, taking
into account the system efficiency. Finally, experiments are conducted to prove that the reduction of the
torque pulsation is achieved.
INDEX TERMS Integrated charger, electric vehicles (EV), permanent magnet synchronous motor (PMSM),
battery charger.
I. INTRODUCTION Level 3 chargers are located off-board while the other two are
The Electric Vehicle (EV) is gaining popularity due to envi- usually located on-board. Although three phase connections
ronmental concerns and motivates research related to it. Spe- to the grid allows faster charging, single phase outlets are still
cial interest is put into the charging process, since the energy the main source of energy available to EV owners [5].
stored in the EV battery can also be used for grid services [1]. Due to the fact that the propulsion and charging systems
The charger topologies also receives a fair amount of atten- share quite a few elements, there is a trend of integrating the
tion, since it is desirable to charge the EV with the higher charging system into the power electronics already present for
efficiency and as fast as possible [2]. driving the motor [6]–[8]. In this case, the onboard charger
According to the charging power level, chargers can be becomes an Integrated Onboard Charger (IOC). The propul-
roughly classified into Level 1 (up to 1.92 kW), Level 2 (up sion inverter can be easily adapted for the charging process,
to 19.2 kW) and Level 3 (from 20 kW onwards) [3], [4]. and the motor windings could be employed as inductive
The higher the charging power, the more complex the charger filters.
will be, needing more components or bigger ones. Therefore, Some authors propose to use additional rectifiers for the
AC/DC conversion from the grid, then the machine windings
The associate editor coordinating the review of this manuscript and as inductors for a DC/DC converter [9]–[11]. The main draw-
approving it for publication was Kan Liu . back is the need of additional components that will translate
This work is licensed under a Creative Commons Attribution 4.0 License. For more information, see https://creativecommons.org/licenses/by/4.0/
108266 VOLUME 9, 2021
J. Pando-Acedo et al.: Improved Three-Phase Integrated Charger Converter Connected to Single-Phase Grid
FIGURE 5. Simulation and experiment power and control setup. (a) Power topology of the system
including storage, DC/DC converter, inverter, grid connection and propulsion machine. (b) Control block
diagram for the whole system.
FIGURE 7. Simulation results comparing the parallel topology (left) with the proposed one (right), for a complete
rotor electrical revolution. From top to bottom: torque developed by the machine; power demanded by the grid;
machine losses for phase A (blue line with circle markers), phase B (orange line with cross markers) and phase C
(solid yellow line); inverter switching losses (blue line with circle markers) and conduction losses (orange solid line);
charging efficiency.
grid current with the phase voltage and achieve unity PF.
The DC/DC converter uses a Proportional-Integral and Dead
Beat controllers to ensure the DC bus voltage follows the
reference. PWM is then used to generate the switching signals
for the converter. The main parameters of the simulation and
the semiconductors used are shown in Table 2.
The first test consists in demanding the maximum current FIGURE 8. Simulation results showing the efficiency of each branch and
the maximum combined efficiency achieved. The top plot shows the
allowed in home appliances, i.e., IC = 16A, for a fixed efficiency combined when using two branches and the bottom one, when
rotor electrical angle θ = 20 deg. It will compare the torque using three branches.
Pu = Vs Is FIGURE 10. Experiments results for the parallel topology. Three different
rotor positions: (a) θ = 1.02 rad, (b) θ = 1.4 rad, (c) θ = 2.6 rad. From top
PJ = (Iabc )2 Rs to bottom: grid voltage vs (200 V/div), grid current is (20 A/div) and
torque (10 Nm/div).
Pinv = PSW + PON (15)
where PSW and PON are the switching and conduction losses the efficiency curve is shifted 2π/3 electrical radians. In this
of the three branch inverter, and are calculated according way, the points of minimum efficiency can be avoided while
to [21]. Taking (15), the efficiency is calculated as retaining the advantage of reducing the torque generated by
the machine. The efficiency could be further improved by
PJ + Pinv
µ=1− (16) allowing the connection to the single phase grid in any of
Pu the three branches, which would allow an efficiency curve
It can be observed that for the angles where the maximum almost flat and equal to the parallel topology. This situation
torque is produced, the efficiency has margin for improve- is illustrated in Figure 8, for a complete electrical revolu-
ment. As it was stated previously, it is imperative that the tion of the rotor. The efficiency ranges from [0.70, 0.91]
system has to be able to charge no matter the rotor angle, for the case that the grid is connected to the best out of
while achieving torque cancellation. However, if the volt- two phases (C or B) and needing only one commutator, and
age source is connected in any of the other two phases, from [0.88, 0.91] for the case that the grid is connected to
FIGURE 11. Experiment results using the three phase topology, with the torque cancellation strategy. Three rotor positions: (a) θ = 1.02 rad, (b) θ = 1.4
rad, (c) θ = 2.6 rad. The left column are the oscilloscope captures showing the grid voltage vs (200 V/div), grid current is (20 A/div) and torque
(10 Nm/div), from top to bottom. The middle column show the motor currents iabc as measured by the control platform (reference current as a dashed
red line, scaled reference in green with circle markers and measured current in solid blue). The right column show the motor currents in the dq0 reference
frame (d current top, q current bottom).
the most favorable phase voltage, needing two additional if rotor angle is between 0 to π/6 or between 5π/6 and π;
commutators. phase C if the rotor angle is between π/6 and π/2, and phase
Therefore, to ensure that the electric vehicle is charging at B if it is between π/2 and 5π /6. The election is similar
the highest possible efficiency, the phase of the grid to be con- for the other half cycle (from π to 2π). With this method,
nected to the charger is determined according to the known efficiency will be at least 88 %. Another method, that will
rotor position. In this way, according to Figure 8 bottom, for not need to measure or estimate the rotor position, would
the case of using three branches, phase A will be selected be to try sequentially the three phases at the moment of
TABLE 3. Experimental results comparing the parallel topology (2φ) with maximum currents allowed, and thus they are scaled down
the proposed one (3φ). The THD is computed on the current of the phase
connected to the grid, µ is the charger efficiency and the torque factor is in order to guarantee that the nominal currents are not over-
given by 1T = Tpp /Tn . comed and still generate the minimum torque possible in the
rotor shaft. Lastly, the measured currents in the dq reference
frame are depicted in the right column. Here it can be seen
that there is still some current in the q axis, again due to
the current controller performance. It is worth noting that the
strategy proposed can be implemented with any other current
connection and selecting the one that produces the highest controller, so there is no lack of generality.
efficiency. The results of the comparison are also summarized in
Table 3. The table shows the THD for the grid current, the
IV. EXPERIMENTAL RESULTS efficiency of the charger and the torque observed as a factor
In order to test the performance of the strategy proposed, given by 1T = Tpp /Tn , where Tpp is the peak to peak torque
experimental tests are conducted. The two topologies dis- and Tn is the nominal torque from Table 1. The THD for the
cussed and represented in Figure 1 are implemented on a grid current is shows better results for the proposed topology,
testbench using a surface mounted PMSM which has the same except for the scaling scenario, since the fundamental compo-
parameters used during the simulations, i.e., the ones showed nent of the current is reduced considerably. The efficiency is
in Table 1. The system uses an IGBT inverter controlled by a in good agreement with the simulation results from Figure 7.
dSPACE platform, employing hysteresis band current control It can be seen that in the two first rotor positions there is
as it was done in simulation. The software ControlDesk is almost no reduction in efficiency. For the third case, the
used for controlling the dSPACE platform and for recording scaling reduces the charging current and the efficiency drops.
some of the experimental data. The testbench is showed However, the torque factor also drops from 1.66 to 0.19 (a
in Figure 9. In both cases, the grid is connected to phase C of 88 % reduction). In any case, if the phase connected to the grid
the machine, as it has been analysed during the whole paper. is switched for the last rotor position, the heavy scaling can
The first test results, representing the parallel topology, be avoided retaining the high efficiency and torque reduction.
is depicted in Figure 10. Three different rotor positions are
represented, and for each one the grid voltage vs , current is V. CONCLUSION
and torque measured in the shaft of the machine. In the three The use of the machine windings as grid inductors in
experiments conducted, the grid current RMS value is fixed single-phase IOC of EVs give raise to torque pulsations in the
at 16 A since it is an usual value for domestic consumers. shaft. In this paper, this torque is analyzed for a EV propelled
This current is kept in phase with the grid voltage in order to by a three-phase PMSM. It is found that, by controlling not
achieve unity power factor. It can be observed that, the closer only the grid current but the three currents flowing through
one gets to angle values of maximum torque, torque peaks the machine windings, the torque can be cancelled in any
around 20 Nm can be observed. This would severely affect rotor position.
mechanical elements connected to the shaft of the machine. The proposed control strategy only needs the power elec-
Next, the same experiments are conducted using the strat- tronics already present for the propulsion system of the EV
egy proposed, and its results presented in Figure 11, where plus one or two commutators to achieve the maximum effi-
each row corresponds to a different rotor position. The current ciency. By commutating the connection to the grid between
level for is is kept at 16 A, and the reference currents i∗a , i∗b and 2 or more phases, the charging performance of the system can
i∗c are calculated according to (9), (10) and (12) respectively. be optimized.
The left column of the figure shows the oscilloscope captures When the torque cancelling currents overpass the nominal
showing the same information as Figure 10, where it can currents of the motor, they are scaled down to guarantee the
be seen that the currents are kept in phase with the grid safe operation of the machine. Simulation results prove the
voltage as before. In the third row, it can be seen that the correct operation and efficiency of the system, and exper-
current magnitude for the grid current is much smaller than iments are conducted to confirm it. Although the current
in the other two cases. This is because in this rotor position, controller’s performance is not ideal, an 88% torque reduction
the other two currents needed for torque cancellation are so is achieved in the worst case scenario.
high that require scaling, and so does the grid current. In any
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engineering from the Universidad Politécnica de
Madrid, Madrid, Spain, in 1984, and the Ph.D.
JAIME PANDO-ACEDO received the B.S. degree degree in electrical and electronic engineering
in electrical engineering from the University of from the Universidad Nacional de Educación a
Extremadura, Badajoz, Spain, in 2015, where he Distancia, Madrid, in 1995. He is currently a Pro-
is currently pursuing the Ph.D. degree. His cur- fessor of electrical engineering with the Universi-
rent research interests include sensorless control dad de Extremadura, Badajoz, Spain, where he is
of electrical drives, power electronics, and energy coordinating the Power Electrical and Electronic
storage and management. He received a grant from Systems Research Group. His research interests include power electronics
the Junta de Extremadura in the Research Training in the power systems, flexible ac transmission systems, active power filters,
Program, in 2017. and electrical machine drives.