A Reconfigurable On-Board Power Converter for Electric Vehicle With Reduced Switch Count

This paper proposes a compact reconfigurable on-board power converter for low voltage electric vehicle. The proposed converter serves the purpose of a battery charger as well as a 3-phase voltage source inverter (VSI) to drive the traction motor. The 3-phase VSI is the backbone of this converter that can be either reconfigured to a propulsion unit or to a battery charger by adding few more power electronics components. During charging mode, the topology is reconfigured to form a front-end boost power factor correction rectifier which is cascaded by a DC-DC converter through a DC link. The same power stage is reconfigured to operate as a 3-phase VSI to drive the traction motor during propulsion mode. Thus, it reduces the switch count by eliminating the requirement of a separate inverter stage. Simultaneously the weight, volume, and cost of the overall system are reduced. Unified control technique is implemented which is capable to achieve near-unity power factor operation of front-end boost rectifier as well as optimal battery charging without sensing the DC link voltage. This control scheme implements a single control loop for both stages by eliminating the need of two separate control loop for each stage of the charger. A 470 W scaled-down prototype is developed and its performance is validated with Constant Current-Constant Voltage charging of a 24 V, 30Ah battery pack in charging mode and with a 400W BLDC motor in propulsion mode.