A Single-Phase Integrated Onboard Battery Charger Using Propulsion System for Plug-in Electric Vehicles

Plug-in electric vehicles (PEVs) are equipped with onboard level-1 or level-2 chargers for home overnight or office daytime charging. In addition, off-board chargers can provide fast charging for traveling long distances. However, off-board high-power chargers are bulky, expensive, and require comprehensive evolution of charging infrastructures. An integrated onboard charger capable of fast charging of PEVs will combine the benefits of both the conventional onboard and off-board chargers, without additional weight, volume, and cost. In this paper, an innovative single-phase integrated charger, using the PEV propulsion machine and its traction converter, is introduced. The charger topology is capable of power factor correction and battery voltage/current regulation without any bulky add-on components. Ac machine windings are utilized as mutually coupled inductors, to construct a two-channel interleaved boost converter. The circuit analyses of the proposed technology, based on a permanent magnet synchronous machine (PMSM), are discussed in details. Experimental results of a 3-kW proof-of-concept prototype are carried out using a 220-Vrms, 3-phase, 8-pole PMSM. Anearly unity power factor and 3.96% total harmonic distortion of input ac current are acquired with a maximum efficiency of 93.1%.