TY - JOUR
T1 - Design Optimization and Electro-thermal Modelling of an Off-Board Charging System for Electric Bus Applications
AU - Rasool, Haaris
AU - Verbrugge, Boud
AU - Zhaksylyk, Assel
AU - Tran, Manh Tuan
AU - El Baghdadi, Mohamed
AU - Geury, Thomas
AU - Hegazy, Omar
PY - 2021/6/4
Y1 - 2021/6/4
N2 - 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.
AB - 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.
KW - co-design, thermal modelling, AFE rectifier, wide bandgap, SiC, passive filter, electric vehicles, fast DC charger
KW - Passive filters , Optimization , Batteries , Rectifiers , Power harmonic filters , Mathematical model , Topology
UR - http://www.scopus.com/inward/record.url?scp=85107355223&partnerID=8YFLogxK
U2 - 10.1109/ACCESS.2021.3086392
DO - 10.1109/ACCESS.2021.3086392
M3 - Article
VL - 9
SP - 84501
EP - 84519
JO - IEEE Access
JF - IEEE Access
SN - 2169-3536
M1 - 9446870
ER -