Work Package 1 – Development of the power flow controller

T1.1 Analysis of the various scenarios in EV charging stations
T1.2 Development of the algorithm for the power flow controller (PFLC)
T1.3 Design of the digital control system
T1.4 Internal and External Communication
D1.1 Complete, developed power flow algorithm capable of controlling the system in all assumed
operating modes.
D1.2 Simulation model of the EV charging system and power flow algorithm
D1.3 Full control system with the digital control system and the PFLC along with supplementary
modules for fast and reliable controller-to-converters communication adequate for every
operation mode

Work Package 2 – SiC-based power electronics submodules

T2.1 Analysis of the operating conditions
T2.2 Selection of the power semiconductor devices and passive components
T2.3 Design of the gate drivers
T2.4 Cooling system
T2.5 Layout
T2.6 Assembling & initial tests of the module
D2.1: The layout of the power electronics submodule enabling easy adaptation to the needs of
AC-DC and DC-DC converters
D2.2: Laboratory prototype of the SiC-based power electronics submodule

Work Package 3 – Reconfigurable, multiport isolated DC-DC converter

T3.1 will focus on mapping the existing multiport isolated DC/DC converters, as well as,
power electronic converter concepts with re-configurability features.
This task will also identify design and operating challenges in the existing multiport topologies
and will propose potential improvements
T3.2 will deliver the most suitable and best performing topology for isolated DC/DC
converters based on dual-active bridge converters along with their high-frequency
transformer concept for enabling multiple interconnections in the charging station.
T3.3 A proper modulation scheme enabling bidirectional power flow through the
multiport DC/DC converter and high efficiency operation under load variations will
be developed
T3.4 The electrical modelling of the multiport isolated DC/DC converter will be developed
T3.5 will deliver the thermal modelling and simulations of the DC/DC converter,
with a particular focus on the thermal performance of the SiC power MOSFET
and high-frequency transformer at rated power and beyond ratings
(i.e. short-term overloading operation).
T3.6 . The electrical and thermal models developed in Tasks 3.4 and 3.5 will be
combined and utilized for optimizing the volume and weight of the converters,
as well as, its efficiency.
T3.7 Based on the optimized design resulted from Task 3.6, a full-scale (i.e. 10 kW)
laboratory prototype of the multiport DC/DC converter will be constructed and
the initial experimental validation will be performed
D3.1: Design guidelines for the optimized, multiport and reconfigurable isolated DC/DC converter (M14)
D3.2: Electrical and thermal models of the multiport isolated DC/DC converter (M19)
D3.3: Laboratory prototype of the multiport DC/DC converter (M27)

Work Package 4 – Bidirectional multilevel AC-DC converter rated at 20 kVA

T4.1 Selection of the AC-DC topology
T4.2 Simulation-based efficiency-oriented design of the 20 kVA AC-DC converter
T4.3 Layout of the power section
T4.4 Design of the magnetic components
T4.5 Control algorithm for bidirectional operation
T4.6 DSP-based controller
T4.7 Assembling & initial tests of the AC-DC converter
T4.8 Laboratory measurements of the AC-DC converter
D4.1 will be the full design of the proposed converter. This includes the optimal
choice of circuit components for the efficiency-oriented system, as well as
the layout of the power circuit with specified placement of system parts in 3D
space and defined dimensions. Moreover, the design of the magnetic components
which will be applied in the system is also included. The said deliverable is connected
with tasks T4.2 – T4.4. The predicted month of delivery is (6).
D4.2 is the prototype of the 20 kVA AC-DC converter with the DSP-based controller
capable of bidirectional operation according to T4.7. The predicted month of delivery
is (16)

Work Package 5 – Non-isolated DC-DC converter for the energy storage

T5.1 Assessment of the fundamental design of an non-isolated DC/DC converter topology enabling
bidirectional operation and three-level voltage on the high side.
T5.2 Theoretical and simulation-based verification of various configurations of the non-isolated
DC/DC converters for supplying charging power in the range of 10-20 kW.
T5.3 Development of the DC/DC converter control algorithm including DC voltage balancing
system and operation at maximum efficiency in different operation modes
T5.4 Identification of electrical and thermal operating parameters in terms of voltage, current and
temperature.
T5.5 Design of the non-isolated DC/DC converter including main circuit layout with the necessary
auxiliary sub-circuits and high-frequency magnetic components.
T5.6 Delivery and initial tests of the non-isolated DC/DC converter in all operation modes.
D5.1: Developed converter control algorithm capable of operation in all modes and with
supplementary DC link (+/-750V) voltage balancing implemented in digital control system.
D5.2: Laboratory prototype of the non-isolated DC/DC converter.

Work Package 6 – Integration & experiments on the complete EV charging system

T6.1 Integration of the power converters in one charging system
T6.2 Investigation of the operation when system is charging two vehicles from the grid in slow
charging mode (A). The AC-DC converter and two isolated DC-DC converters will be tested
supplying power up to 2×10 kW to two loads. Waveforms of the specific voltages and currents will
be observed but most crucial will be measurements of the efficiency at THD of the input power.
T6.3 Verification of the mode B, when slow charging and recharging of the energy storage is
considered. This test will be similar to the previous one but instead one DC-DC converter, the non
isolated DC-DC converter will be charging the battery stora
T6.4 Validation of the fast charging mode, also including the energy storage (mode C). All
components of the investigated system will be tested at full power to provide 2×20 kW at the
outputs of the isolated DC-DC converters. Again, efficiency measurements and THD f the grid
current will be observed
T6.5 Testing of the grid support with the use of the storage (D). During this test two components:
the AC-DC converter and the non-isolated DC-DC converter will be experimentally verified
(efficiency measurements, THD monitoring) during the grid support mode (up to 20kW)
T6.6 Investigation of the vehicle-to-grid operation (E). This test will be close to the previous
but instead the battery storage energy will be delivered by two isolated DC-DC converters
T6.7 Verification of the stand-alone mode, a case with charging during the grid fault (F). In this
mode, ability to deliver 2x10kW from the storage to the outputs of the non-isolated DC-DC
converters will be tested
D6.1 Complete integrated EV charging system with 20 kVA multilevel AC-DC converter, two 10/20
kW isolated DC-DC converters and 20 kW non-isolated DC-DC converters under control of the
power flow controller.
D6.2 Report with complete experimental tests of the EV charging system in all operation modes
(Milestone 6)

Reports from the deliverables