A Single-Phase On-Board Two-Stage Integrated Battery Charger for EVs Based on a Five-Phase Hybrid-Excitation Flux-Switching Machine

In this paper, to solve the existing problems in general on-board integrated chargers (IC), a novel single-phase on-board two-stage integrated charger is proposed by taking the unique advantages of the five-phase hybrid-excitation flux-switching (HEFS) motors. The general topologies and newly presented ICs are reviewed firstly, and three main problems are concluded. Then, the proposed two-stage IC is presented, and all winding selections are thoroughly investigated by theoretical analysis, finite-element analysis (FEA) and experiments. In the proposed topology, the existing problems are all solved by employing this multi-phase system, making the reasonable winding selection, and reconfiguring the field winding. After that, a control method for charge mode and two current balance control methods are developed. The simulation results verify the effectiveness of the proposed control methods. Finally, based on a 5-kW five-phase HEFS prototype machine and two sets of the 3-phase generic motor controller, an experiment platform is built. The experiment results agree well with the simulation results. Therefore, the feasibility of a two-stage integrated on-board charger that can operate at any voltage level is confirmed, where only the hybrid-exciting machine and its own driving system are used without any additional power devices.