Design Optimization and Electro-thermal Modelling of an Off-Board Charging System for Electric Bus Applications

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Abstract

This paper proposes a co-design optimization procedure of a high-power off-board charger for electric vehicle (EV) applications. The primary purpose is to design a 175 kW SiC DC-charging system with high power density to achieve high efficiency at a wide operating range. For the active part of the DC off-board charger, a three-phase active front end (AFE) rectifier topology is considered in the design optimization and the modelling. The design methodology focuses on the optimal design of the passive filters, accurate electro-thermal modelling of the converter, inductor design, capacitor selection, loss and geometric modelling of the passive filters and control system design. The design optimization of the high-power charging system is performed in MATLAB Simulink using a closed-loop dynamic electro-thermal simulation of the off-board charger. The switching frequency, loss and temperature-dependent efficiency of the charger is investigated in parallel. Through this proposed technique, efficiency greater than 96% is achieved at a switching frequency of 40 kHz, along with a smaller size and lower weight of the system. Moreover, it operates with a current total harmonic distortion (THDi) below 3% and a power factor (PF) above 99% at rated power condition.
Original languageEnglish
Article number9446870
Pages (from-to)84501-84519
Number of pages19
JournalIEEE Access
Volume9
DOIs
Publication statusPublished - 4 Jun 2021

Keywords

  • co-design, thermal modelling, AFE rectifier, wide bandgap, SiC, passive filter, electric vehicles, fast DC charger
  • Passive filters , Optimization , Batteries , Rectifiers , Power harmonic filters , Mathematical model , Topology

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