Level-2 On-board 3.3kW EV Battery Charging System


Electric vehicle (EV) battery charging systems are classified into three levels based on their power consumption and charging time. The level goes higher (1 to 3) as the charger transfers more power and charges the battery faster. Level 2 charging is the primary method for both private and public facilities for EV battery charger. Single or three phase power supply is used for Level 2. EV battery chargers are also classified as on-board and off-board with unidirectional or bidirectional power flow.

The design example is patterned after the first generation Nissan Leaf as there was ample public data available to build the model. The example uses level-2 type on-board 3.3 kW battery charger that takes 6 to 8 hours for full charging. In this design example, Li-ion 24 kWh 32.5Ah battery is charged from single phase 230 V 50Hz AC supply. The AC voltage from electric grid is passed to full bridge diode rectifier to convert AC voltage to DC. The rectified AC voltage is converted to 400V DC voltage using interleaved boost converter. Power Factor Correction (PFC) controller is used to make the power factor close to unity that further improves the input power quality. The interleaved boost converter design involves the selection of the inductors, the input and output capacitors, the power switches and the output diodes.

How to use the example:

Download the attached " EV_Battery_charging_system.zip" and unzip to a local folder. Open the Battery_Charging_System.ai_dsn in SaberRD and run the experiments listed in the Experiment Analyzer.
For more details of the design, how to run the design, etc., refer to the README.pdf file in the attachments.

Note: This design example works only in SaberRD commercial edition 2018.09 and above.

Circuit Diagram:


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