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Plug-In Electric Vehicles’ Charging
Dr. Alireza Khaligh
Electrical and Computer Engineering Department Institute for Systems Research
University of Maryland College Park, MD 20742 http://khaligh.umd.edu/
April 2015
Engineering Sustainability Workshop
§ Current Statistics:
§ Transportation: § Invention of Internal Combustion Engine (ICE), 150
years ago
TRANSPORTATION
POWER ELECTRONICS, ENERGY HARVESTING and RENEWABLE ENERGIES LAB !
§ Over 900 million vehicles worldwide
§ Over 250 million registered vehicles in the U.S.
§ 50 million vehicles are being manufactured every year
§ Recent economic growth in China, India, elsewhere
POWER ELECTRONICS, ENERGY HARVESTING and RENEWABLE ENERGIES LAB !
TRANSPORTATION
§ Concerns: § Rising fuel costs
§ Economic apprehensions
§ National security dreads
§ Environmental and public health
§ Transportation: § Accounts for 40% of GHG and 70% of emissions
§ 99% Dependence on ONE source of fuel
§ Not Sustainable
POWER ELECTRONICS, ENERGY HARVESTING and RENEWABLE ENERGIES LAB !
TRANSPORTATION ELECTRIFICATION
§ ELECTRIFICATION
§ Hybrid Electric Vehicles (HEVs)
§ Plug-In Hybrid Electric Vehicles (PHEVs)
§ Electric Vehicles (EVs)
ICE Vehicle HEVs PHEVs EVs
Transportation 2.0: Electrified Paradigm
Shift
*Specification data is based on public information and is subject to change.
Vehicle PEV type Price Battery On-Board Charger E-Range Connector type Level 2
Nissan leaf EV $21,300 24kWh Li-ion 3.3 kW / 6.6 kW OBC 84 mi SAE J1772 JARI/TEPCO 8 hrs / 4 hrs
BWM i3 EV $41,350 22 kWh Li-ion 7.4 kW OBC 81 mi SAE J1772 4-5 hrs
Ford Focus EV $35,170 23 kWh Li-ion 6.6 kW OBC 76 mi SAE J1772 3-4 hrs
Mitsubishi iMiEV EV $22,995 16 kWh Li-ion 3.3 kW OBC 62 mi SAE J1772 JARI/TEPCO 7 hrs
Honda Fit EV $37,415 20 kWh Li-ion 6.6 kW OBC 82 mi SAE J1772 4 hrs
Toyota Plug-in Prius PHEV $29,900 4.4 kWh Li-ion 3.3 kW OBC 11 mi SAE J1772 1.5 hrs
Chevy Volt PHEV $37,100 16.5 kWh Li-ion 3.3 kW OBC 38 mi SAE J1772 4 hrs
Cadillac ELR PHEV $75,000 16.5kWh Li-ion 3.3 kW OBC 37 mi SAE J1772 5 hrs
Fiat 500E EV $31,800 24 kWh Li-ion 6.6 kW OBC 87 mi SAE J1772 4 hrs
Ford C-MAX Energi PHEV $32,920 7.6 kWh Li-ion 3.3 kW OBC 20 mi SAE J1772 2 hrs
Kia Soul EV $33,700 27 kWh Li-ion 6.6 kW OBC 93 mi SAE J1772 4 hrs
Mercedes B-Class EV EV $41,000 28 kWh Li-ion 10 kW OBC 87 mi SAE J1772 3.5 hrs
Smart Electric Drive EV $25,000 17.6 kWh Li-ion 3.3 kW OBC 68 mi SAE J1772 6 hrs
Tesla Model S 60kWh EV $71,000 60 kWh Li-ion 10 kW OBC 208 mi SAE J1772 10 hrs (std charger) / 4
hrs (80 A charger)
VW e-Golf EV $35,000 24.2 kWh Li-ion 7.2 kW OBC 85 mi SAE J1772 4 hrs
ONBOARD CHARGERS FOR COMMERCIALLY AVAILABLE PEVS
Source: California PEV Collaborative (CG3-3).
Charging Level Power Supply Charging Power
Miles of Range for
1 Hour of Charge
Charging Time
BEV PHEV
Level 1 120VAC Single Phase
1.4 kW @ 12 amp (on board) 3-4 miles ~17Hours ~7 Hours
Level 2
240VAC Single Phase Up to 19.2 kW
(up to 80 amps)
3.3 kW (on-board) 8-10 miles ~7 Hours ~3 Hours
6.6 kW (on-board) 17-20 miles ~3.5 Hours
~1.4 Hours
Level 3 DC fast Charge
200 – 450 VDC Up to 90 kW (~200 amps)
>50 kW (off board) 50-60 miles
(~80% per 0.5 hr charge)
30~45 Mins
~10 Minutes
CHARGING POWER LEVELS
Configuration of an On-Board EV Charger
Vol
tage
[V]
2.5
3.0
3.5
4.0
4.5
5.0
Time [hour]0 0.5 1.0 1.5 2.0
Cur
rent
[mA
]C
apac
ity[m
Ah]
0
500
1000
1500
2000
2500CurrentVoltageCapacity
Constant Current Constant Voltage
0
1
2
3
4
320
360
400
440
480
State of Charge0% 20% 40% 60% 80% 100%
Cur
rent
[A]
Vol
tage
[V]
CurrentVoltage
Begin point
Nominal point
Turning Point End Point
CC CV
Onboard Isolated Charger
Parameters Value
Input voltage 85-180 V
Maximum input AC current 16 A
Power factor @ peak power ~ 99%
AC input frequency 55-65 Hz
THD at peak power < 5%
Overall peak efficiency 94%
Output battery voltage 320 V ~ 420 V
Maximum output power 1 kW
Output voltage ripple < 2 V peak to peak
Cooling Air
Operating Temperature -40oC to 105oC ambient
H. Wang, S. Dusmez, and A. Khaligh, “Maximum Efficiency Point Tracking Technique for LLC Based PEV Chargers through Variable DC Link Control,” IEEE Transactions on Industrial Electronics, in press.
Efficiency
Loss breakdown for critical operating points; a) conventional LLC; b) proposed LLC.
Efficiency of the LLC converter versus battery SOC.
Begin point Normal point Turning point End point0
5
10
15
20
25
Los
s(W
)
Switching lossesConduction lossesCore losses
Begin point Normal point Turning point End point0
5
10
15
20
25
Los
s(W
)
Switching lossesConduction lossesCore losses
(a) (b)
0 10 20 30 40 50 60 70 80 90 10065
70
75
80
85
90
95
100
ConventionalProposed
Eff
icie
ncy
(%)
State of Charge (%)
• LLC Stage Efficiency Improvement at Full Load: 2.1%
• LLC Stage Efficiency Improvement at Light Load: 9.1%
• Overall Charger Efficiency Improvement at Full Load: 1.6%
• Overall Charger Efficiency Improvement at Light Load: 6.7%
Off-Board Fast Plug-In Chargers
Different system level architectures for fast charging stations: a) Common AC bus link, and b) Common DC bus link
Off-Board Fast Plug-In Chargers
Off-board charger using high frequency isolated transformer.
4.2V
2.5 V
1 V
VTVrechg Ichg
Vpre
Vlpt Ipre
Iend
Batte
ry V
olta
ge
Cha
rge
Vol
tage
Pre-chargeat 0.1 C
Constantcurrent charge
Constantvoltage charge
ChargeComplete
Re-charge Chargecomplete
A
B
C D
Deeply Depleted Cell
Perspectives for Next Generation of Plug-In Chargers
§ Onboard Charger Topologies § Isolated Chargers § Integrated Chargers
§ Isolated § Non-Isolated
§ Propulsion Machine/Inverter Integrated Chargers
§ Wireless Charging § Static Charging § Dynamic Charging
THANK YOU!