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) |