Integrated On-board Power Converter for EVs Based on an Open-end Winding Motor

The power level of the on-board chargers in electric vehicles (EVs) is limited due to the limited interior space and the lightweight requirement. Since the motor-driving system and battery-charging system of EVs have similar topologies, they can be integrated into one system to reduce the number of appliances and increase power density. Considering the excellent characteristics of the open-end winding motor in terms of output power, operating range and fault tolerance, this paper proposes an integrated topology based on the open-end winding permanent magnet synchronous motor (OEW-PMSM). In motor-driving mode, the integrated topology is equivalent to a common DC bus OEW-PMSM system. To suppress the zero-sequence current (ZSC) and improve the steady performance, a dual-vector model predictive control (MPC) method is proposed. In battery-charging mode, the integrated topology is equivalent to a 3-ph PWM rectifier and a 3-ph interleaved Buck converter, which can realize high power levels and current ripple suppression. In the charging process, the three windings of the motor stator can be utilized as the inductors of a 3-ph interleaved Buck converter, and torque cancelation is achieved with the current-sharing control strategy. The experiment verifies the feasibility of the proposed integrated on-board power converter and control strategies.