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Design Space Optimization of a Three-Phase LCL Filter for Electric Vehicle Ultra-Fast Battery Charging

Author

Listed:
  • Davide Cittanti

    (Energy Department “Galileo Ferraris”, Politecnico di Torino, 10129 Torino, Italy)

  • Fabio Mandrile

    (Energy Department “Galileo Ferraris”, Politecnico di Torino, 10129 Torino, Italy)

  • Matteo Gregorio

    (Energy Department “Galileo Ferraris”, Politecnico di Torino, 10129 Torino, Italy)

  • Radu Bojoi

    (Energy Department “Galileo Ferraris”, Politecnico di Torino, 10129 Torino, Italy)

Abstract

State-of-the-art ultra-fast battery chargers for electric vehicles simultaneously require high efficiency and high power density, leading to a challenging power converter design. In particular, the grid-side filter, which ensures sinusoidal current absorption with low pulse-width modulation (PWM) harmonic content, can be a major contributor to the overall converter size and losses. Therefore, this paper proposes a complete analysis, design and optimization procedure of a three-phase LCL filter for a modular DC fast charger. First, an overview of the basic LCL filter modeling is provided and the most significant system transfer functions are identified. Then, the optimal ratio between grid-side and converter-side inductance is discussed, aiming for the maximum filtering performance. A novel design methodology, based on a graphical representation of the filter design space, is thus proposed. Specifically, several constraints on the LCL filtering elements are enforced, such that all feasible design parameter combinations are identified. Therefore, since in low-voltage high-power applications the inductive components typically dominate the overall filter volume, loss and cost, the viable LCL filter design that minimizes the total required inductance is selected. The proposed design procedure is applied to a 30 kW, 20 kHz 3-level unidirectional rectifier, employed in a modular DC fast charger. The performance of the selected optimal design, featuring equal grid-side and converter-side 175 μ μ H inductors and 15 μ μ F capacitors, is verified experimentally on an active front-end prototype, both in terms of harmonic attenuation capability and current control dynamics. A current total harmonic distortion (THD) of 1.2% is achieved at full load and all generated current harmonics comply with the applicable harmonic standard. Moreover, separate tests are performed with different values of grid inner impedance, verifying the converter control stability in various operating conditions and supporting the general validity of the proposed design methodology.

Suggested Citation

  • Davide Cittanti & Fabio Mandrile & Matteo Gregorio & Radu Bojoi, 2021. "Design Space Optimization of a Three-Phase LCL Filter for Electric Vehicle Ultra-Fast Battery Charging," Energies, MDPI, vol. 14(5), pages 1-26, February.
    • Handle: RePEc:gam:jeners:v:14:y:2021:i:5:p:1303-:d:506991
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    References listed on IDEAS

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    1. Manzetti, Sergio & Mariasiu, Florin, 2015. "Electric vehicle battery technologies: From present state to future systems," Renewable and Sustainable Energy Reviews, Elsevier, vol. 51(C), pages 1004-1012.
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    Cited by:

    1. Gianfranco Chicco & Andrea Mazza & Salvatore Musumeci & Enrico Pons & Angela Russo, 2022. "Editorial for the Special Issue “Verifying the Targets—Selected Papers from the 55th International Universities Power Engineering Conference (UPEC 2020)”," Energies, MDPI, vol. 15(15), pages 1-8, August.
    2. Juliano C. L. da Silva & Thales Ramos & Manoel F. Medeiros Júnior, 2021. "Modeling and Harmonic Impact Mitigation of Grid-Connected SCIG Driven by an Electromagnetic Frequency Regulator," Energies, MDPI, vol. 14(15), pages 1-21, July.
    3. Davide Cittanti & Matteo Gregorio & Eugenio Bossotto & Fabio Mandrile & Radu Bojoi, 2021. "Three-Level Unidirectional Rectifiers under Non-Unity Power Factor Operation and Unbalanced Split DC-Link Loading: Analytical and Experimental Assessment," Energies, MDPI, vol. 14(17), pages 1-33, August.

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