International Conference on Innovations in Power and Advanced Computing Technologies [i-PACT2017]

A Rapid Charging System with Bi-directional Power

Flow for Plug-in Hybrid Electric Vehicle
Maloth Naresh1, Student Member, IEEE, V. Sravanthi Bai2 and Ajay Kumar Pandey3
Electrical Engineering Department, MNNIT Allahabad, Uttar Pradesh-211004, India
naresh219.m@gmail.com1, sravanthivadithya90@gmail.com2 and ajaigcet@gmail.com3

Abstract— This paper presents the rapid battery charging Majority of power architecture includes an ac-dc converter
system with bidirectional power flow capability of Plug-in- with power factor correction (PFC) based boost converter [3-4]
Hybrid Electric Vehicle (PHEV) application. Rectangular Phase followed by an isolated bi-directional dc-dc converter. The
Shift with PWM (RPPWM) is used for Zero Voltage Switching high frequency operation of transformer will increase the
(ZVS) based Dual-Active-Bridge, controls the power flow power density and reduces the material cost. The applications
capability in both direction and reduces the control complexity. of this topology found in energy storage the control of dc-dc bi-
Boost converter is fed from the rectified ac mains voltage to directional converter is very flexible compared with other
regulate the constant output DC voltage at desired level and to converters. Rectangular Phase Shift with PWM (RPPWM) has
improve the power factor. The proposed boost converter
been usually used for controlling DAB and DC/DC converters
provides the bidirectional power flow, DAB is implemented. It
[5-8]. RPPWM control is simple to implement in comparison
chooses either the Constant-Current or Constant-Voltage
approach and operates using RPPWM and Proportional-Integral with other control techniques.
controllers by which system complexity is reduced. The system The proposed system mainly consists of AC-DC converter
could charge the battery from C.C to C.V smoothly which leads with Power Factor correction based Boost Converter and Bi-
to a longer life cycle and safe operation of battery. In proposed directional DAB dual active bridge. The charging system
control method, SOC reaches maximum value within 56.4 designed using the proposed topology operates both lithium-
minutes which is less compared to that of the time. The polymer and lithium-ion battery (With a high density power
charging/discharging response of the proposed system is tested and efficiency).
and verified through simulation Study is performed in
MATLAB/ SIMULINK. II. DESIGN OF AC-DC CONVERTER AND ISOLATED BI-
DIRECTIONAL DC-DC CONVERTER
Keywords— Constant Current, Constant Voltage, Rectangular
Phase Shift with PWM (RPPWM), Plug-in-Hybrid Electric
Vehicle,State of Charge, Zero Volatge Switching.
NOMENCLATURE
CC : Constant Current
CV : Constant Voltage
SOC : State of Charge
PFC : Power factor correction
ZVS : Zero Volatge Switching
IEC : International Electrotechnical Commission
PCC : point of common coupling
DAB : Dual-Active-Bridge
PWM : Pulse Width Modulation Verror Vact
PHEV : Plug-in Hybrid Electric Vehicle

I. INTRODUCTION Vref
I error I act
Now a day’s distribution grid significant of distributed
energy resources (DERs) comprising distributed generations
(DGs) and energy storage systems (ESSs)[1]. The PHEV) is an Iref
agreeable choice for to fulfill the all electric meander range of
electric vehicle a well distributed fast charger infrastructure
should be executed [2]. This system will help in fast charging Fig.1 Proposed the on-board charging system with bi-
of battery from typically 20 to 80% of nominal voltage during directional power flow
short stops. This fast charger will be established in highway Fig.1 shows an on-board battery charging system. The on-
rest areas and near to city refueling points. board battery charging system consists of an AC-DC converter
with PFC based boost converter and dual active bridge DC-DC

978-1-5090-5682-8 /17/$31.00 ©2017 IEEE

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 International Conference on Innovations in Power and Advanced Computing Technologies [i-PACT2017]
converter. The charging system is connected to single phase
AC grid to charge the battery and to convert from AC-DC
power. AC-DC converter consists of a full bridge rectifier and
a PFC circuit based boost converter as shown in Fig 1. A PFC
based boost converter helps in maintaining a unity power
factor, regulates the inductor current rectified by the full bridge
diode rectifier and maintains a constant DC output voltage. As
we can see AC-DC converter is connected to a DC-DC
converter. DC-DC converter consists of ZVS based Dual
Active Bridge converter. The control part of DAB consists of
Delay controller and PI controller.
III. CONTROL ALGORITHIM
The control algorithm of charging system is designed in order
to increase the life-cycle and for the safe operation of both
batteries, based on characteristics and limitations of the
lithium –ion battery. The charging system conducts for two
charging sequence, when the battery is at charging state, in
order to prevent over-charging and dissolving the chopper in
electrolyte. The function of this converter is to control the
charging and discharging current.
Fig 2. Flowchart of the proposed control algorithm of
battery charging operation
A. AC-DC Conversion
The circuit of AC-DC converter is shown in Fig. 3. Active
PFC Method is used by which power factor is corrected
effectively.The converter tries to hold a constant DC output
voltage and draws a current that is in phase with line voltage
at same frequency. The outer loop of the controller is a voltage
controller and the inner loop is current controller of AC-DC
converter controller. The role of AC-DC PFC is to control the
total harmonic distortion, attain unity power factor and a
constant output DC voltage.
Fig 3. Boost PFC based on peak current mode control
B. ZVS based Dual Active Bridge
Fig. 4 shows the topology of the DAB DC-DC converter,
which consists of two full bridges that are interconnected
through a high frequency transformer T/F at H.V and L.V
side. where N is the turn ratio of a transformer. The devices of
the same leg (S11-S12, S21-S22) are controlled by the same
gate signals with constant 50% duty cycle and the devices in
same position of bridges such as S11-S21, and S14-S24. Fig.3
shows a ZVS based DAB and the switching strategy used for
DAB is a RPPWM. This paper implemented two modules for
realizing the rated charging current of 34 A . The used
topology is more compact compared with the non-isolated bi-
directional dc-dc converter particularly in case of high power
applications.
V1V2 / n ⋅ φ (Π − φ )
P= (1)
2Π 2 f s L
Power transfer is controlled by using rectangular phase
shift ݊. The above equation is used to design the inductance L
of the Dual Active Bridge. These component values are used
for analysis of the DAB operated with Rectangular Phase Shift
with PWM scheme
Fig 4. ZVS based Dual Active Bridge.
Fig. 5 shows the basic charging characteristic of the battery.
Based on state of charge (SOC) condition the mode selector
will operate. Depending on the SOC the charging mode is
selected, by following the command duty cycle of dc-dc
converter evaluated. Constant Current (CC) Charging
approach is designed to charge at maximum current of 34A.
By which battery charges rapidly with in less time in order to
attain 80% state of charge.
D=Dint+step (4)
D=Dint (5)
D=Dint-step (6)
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 International Conference on Innovations in Power and Advanced Computing Technologies [i-PACT2017]

The input AC voltage and current produced using unity power

factor technique is presented in Fig 6. The complete charging
sequence is simulated using the proposed battery model based
on the charging procedure provided by a battery manufacturer.
Fig 11 shows the waveform of battery voltage and current
throughout the entire charging sequence.
Switching pulse
2

1.5

0.5

-0.5

-1
0.022 0.024 0.026 0.028 0.03 0.032 0.034 0.036 0.038 0.04
Time

Fig 5. The charging profile of the battery Fig. 7 switching pulse of a Boost Converter

IV. SIMULATION AND RESULTS 300

Input voltage and current waveform of PFC based Boost converter

Voltage(V)
data1

The proposed topology for a battery charging system is 200

Current(amp)
data2

verified through simulation. The operating parameters for the 100

proposed converters are framed in Table I. The rated power of

V&I
0
the charging system is 2.8kW. The output voltage of the
battery is designed to operate at 84V. MATLAB/SIMULINK -100

software is used for the simulation of proposed system. -200

Table 1 Simulation Parameters

-300
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2
Time(sec)

AC-DC PFC based Boost Converter

Parameters Numerical values Fig. 8 Input voltage and current of the system with PFC
V0 200V control
output voltage of PFC based boost converter

V in 220/50 Hz 250

Resistor 1000ȍ
200

Capacitor 500ȝF
voltage(V)

150

Inductor 1mH 100

DC-DC ZVS based Dual Active Bridge 50

Turns ratio 1:02
Inductor 6ȝH 0

Switching frequency 10kHz -50

0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2

V1 200V Time

100V Fig. 9 Dc-link voltage of the system

V2

1 2
1
S11 & S14 0
0.5 -1
4 5 6 7 8 9 10
2 -4
x 10
S12 & S13 1
0 0
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 -1
4 5 6 7 8 9 10
-4
2 x 10
2 1
S21 & S24 0
-1
4 5 6 7 8 9 10
1
2 -4
x 10
S22 & S23 10
-1
0 4 5 6 7 8 9 10
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2
Time Time -4
x 10

Fig. 6 Unity voltage and inductor current of PFC based Boost Fig. 10 Driving signal of DAB
Converter

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 International Conference on Innovations in Power and Advanced Computing Technologies [i-PACT2017]

Capability of switching pulse of a Boost Converter is shown in Dc-link voltage of the system is shown in fig. 9, Driving
fig.7, Input voltage and current of the system with PFC control signal of DAB is fig 10, and Simulated waveforms of battery
is shown in fig.9 at Constant Voltage approach is shown in fig. 12. Simulated
(N2/N1)*Vh1 & Vh2 waveforms of battery during C.V mode at 85% state of charge
500 is shown in fig 13, Simulated waveforms of battery during
V1(volts) 0
-500
C.V mode at 100% state of charge is shown in fig 14,
3 4 5 6 7 8 9 10 Simulation of charging voltage and current during two
200 x 10
-4
charging approach is shown in fig 15.
V2(volts) 0
-200 SOC
(N2/N1)*Vh1 & Vh2
3 4 5 6 7 8 9 10 200
-4 100
50 x 10
0
VL(volts) 0 -100
5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10
-50 -3
3 4 5 6 7 8 9 10 Current(amp) x 10
-4 50
50 x 10
IL(amp) 0 0

-50 -50
3 4 5 6 7 8 9 10 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10
-3
-4 x 10
Voltage(volt)
40 x 10 <Voltage (V)>
Io(amp)200 86
-20 84
-40
3 4 5 6 7 8 9 10 82
-4 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10
Time (sec) x 10 Time(sec) -3
x 10

Fig 11. Simulated waveforms of DC-DC converter Fig. 14 Simulated waveforms of battery during C.V mode at
100% state of charge
Current(amp)
50
0
-50
0 0.2 0.4 0.6 0.8 1
Voltage(volt) -3
86 x 10
84
82
0 0.2 0.4 0.6 0.8 1
-3
Power(kW) x 10
5000
0
-5000
0 0.2 0.4 0.6 0.8 1
Time(sec) -3
x 10

Fig. 12 Simulated waveforms of battery at Constant Voltage

approach Fig. 15 Simulation of charging voltage and current during two
SOC charging approach
85
%

85
85
0 0.2 0.4 0.6 0.8 1
<Current (A)> -3
50 x 10
0
I

-50
0 0.2 0.4 0.6 0.8 1
<Voltage (V)> -3
86 x 10

84
V

82
0 0.2 0.4 0.6 0.8 1
-3
Time(sec) x 10

Fig. 13 Simulated waveforms of battery during C.V mode at

85% state of charge Fig. 16 Nominal discharging characteristic of the battery

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 International Conference on Innovations in Power and Advanced Computing Technologies [i-PACT2017]

V. CONCLUSION
In this paper presents This paper presents a simple,
economical battery charging system which gives 2.8kW power
for electric vehicles. The proposed charging system composes
of AC-DC PFC based boost converter and isolated bi-
directional dc-dc converter (Dual Active Bridge) which is
more compact compared to the non-isolated DC-DC
converter. It has the ability to control the power in both the
direction, which also reduces the control complexity. The
designed charging system is used to operate both lithium-
polymer and lithium-ion batteries. The proposed topology is
specified to attain the fullstate of charge at minimum time for
the battery capacity of 4.4kWh by providing a charging
current of 34A. It is regulated in order to increase the life-
cycle and safe operation of the battery.

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