Swathi D, et. al.

International Journal of Engineering Research and Applications

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ISSN: 2248-9622, Vol. 10, Issue 7, (Series-IV) July 2020, pp. 01-10

RESEARCH ARTICLE OPEN ACCESS

Design and Control Methods of PFC in Onboard Chargers for

Electric Vehicles.
Swathi D*, Dr Usha P**, Winnefred Poul Luke Kingkam Durai***
*(Department of Electrical and Electronic Engineering, Dayananda Sagar College of Engineering, Bangaluru-
560078
** (Professor, Department of Electrical and Electronic Engineering, Dayananda Sagar College of Engineering,
Bangaluru-560078
*** (Senior Manager, EPD,Vitesco Technologies India Pvt Ltd, Bangaluru-560100

ABSTRACT
The Electric Vehicles are making their way in Automotive Sector with the up gradation of the technology. To
power the EV a battery is needed and this Battery has to be charged frequently, hence an Onboard charger is
needed. The onboard charger should contain a PFC circuit so that the supply or the grid is not affected by the
harmonics produced by the charger. A 3-phase 4 wire Vienna rectifier is designed as a PFC circuit because of its
ability in improving the Power factor, reduction in the power consumption of switches and decrease in the total
harmonic distortion of current. Vienna rectifier has the ability to increase the power density specially, in case of
high power DC charging. To control the Vienna rectifier a 3-level SVPWM technique is implemented because
of is robustness and dynamic response. The same is simulated in the MATLAB-Simulink Environment, the
results were analyzed and it proves that the proposed converter is feasible with good dynamic performance and
static performance.
Keywords - Electric Vehicle, On-board Chargers, PFC, Vienna Rectifier, 3-level SVPWM.
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Date of Submission: 06-07-2020 Date of Acceptance: 21-07-2020
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I.INTRODUCTION voltage and current so that there is less introduction

The Electric Vehicles gaining their of harmonics into the grid.
prominence in Automotive sector as the technology
is improving and the society is moving towards
3-
more eco-friendly use of vehicles. These vehicles PHASE AC-DC
PFC DC-DC BATTER
Y
AC CONVERTER CONVERTER
use Batteries as their source of power supply. The SUPPLY
batteries used here are rechargeable batteries,
which are charged frequently. Fast charging would
be the major criteria while designing the charger Fig.1: General Block representation of onboard charger.
for the batteries. DC charging is one of the fast
charging techniques employed but for the onboard The PFC circuit is much essential since
charger the source available in general is AC, the electronic devices using switch mode power
hence a charger to be designed must be of AC supplies are increasing. It varies the Power Factor
charging with fast charging capacity, hence a of the supply while consuming the power from the
Three-phase AC source charger is to be designed source. This causes major disturbances to the grid
and it should incorporate the standards described and affects the other equipment connected to the
by the Government of India Ministry of Power. same source and may lead to a penalty over the
According to the Ministry of Power the 3-phase customer too. Hence a PFC is must for every
source should be of 3-phase 4-wire system, the application.
efficiency of the charger should be above 95% and Power Factor is defined as in equation (1)
PF to be above 0.92. [1-4].
𝑃𝑜𝑤𝑒𝑟 𝑖𝑛𝑝𝑢𝑡
The block representation of general Power Factor= (1)
𝑉𝑟𝑚𝑠 𝐼𝑟𝑚𝑠
aspects onboard charger is given in the Fig.1. This
Power Factor can also define as the cosine of the
paper majorly concentrates on the PFC circuit
angle between voltage and current. Fig.2 shows
which is to be included in the 3-phase AC onboard
that the current and the voltage are perfectly in
charger to maintain the power factor of the input
phase even though there is a severe distortion of the

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current wave. Applying the “cosine of the phase II. 3-PHASE 4 WIRE VIENNA
angle” would lead to a wrong conclusion that this RECTIFIER.
power supply has a power factor of 1.0. Hence, A Vienna rectifier is one of the popular
power factor should be analyzed in terms of the structures for PFC correction of the rectifier circuit.
power-line fundamental frequency’s harmonic Vienna Rectifier is a 3phase, 3-level, 3
series, and it is defined as, bidirectional switch rectifier where it features the
1
𝑃𝑜𝑤𝑒𝑟 𝐹𝑎𝑐𝑡𝑜𝑟 = 2
(2) split output DC rail. The Rectifier is a combination
1+𝑇𝐻𝐷
of a boost DC\DC converter with a three-phase
diode bridge rectifier. Fig.4. illustrates this rectifier
circuit. The circuit topology is shown in Fig.2.

Fig.2. 3-Phase, 4-wire Vienna rectifier

Power-factor correction (PFC) is used to

avoid input current harmonics, thereby minimizing
interference with other devices being powered from
the same source.
A considerable attention is gained by the
three-level boost type Vienna rectifier since it has Fig.3. 3-Phase, 4-wire Vienna rectifier
the advantages such as high input power factor, the
low voltage stress on each switch and less number The Vienna rectifier has three
of switches employed. The other major advantage bidirectional switches, and by choosing their
of the Vienna rectifier is, both rectification and PF (ON\OFF) state and the polarity of the phase
correction can be achieved in a single stage and current in each phase, the voltage for each phase
improves power density of the power system will be determined. If the output voltage is
Therefore Vienna rectifier is majorly used in high considered to be constant VDC the input current is
power DC charging for electric vehicles. [8-18]. drawn in 3 levels with respect to output as VDC/2,
The 3-phase source should be of 3-phase, 4-wire 0, -VDC/2.
supply, therefore a 3-phase 4-wire Vienna rectifier The operation of the Vienna rectifier is explained
is designed to achieve PFC. considering phase A and the operation of the other
Many control technique is employed to phases is similar to that of phase A.
control the Vienna rectifier [19] one of the Mode 1: When the switch Sap is OFF and the phase
effective control strategies is found to be SVPWM current is greater than zero, the current flows
technique[20], this can increase DC voltage through the freewheeling diode Dap, as shown in
utilization, and quality of the input three phase the Fig.4. and charges the capacitor C1 , and flows
current also increases. This can solve the neutral back through neutral. Since only one diode
point voltage by adjusting the effective time of the conducts power loss is less.
redundant vector.[23-26]. The voltage level at the Mode 2: When the switch is ON the current takes
switch is determined by both switch state and the low resistant path and flows through the switch
current direction hence not all the switch Sap and diode Da1 and flows back through neutral.
combination can be achieved when SVM is The Operation is shown in Fig.5. In this cycle also
applied. Also DC voltage reduction with less the resistance offered is only by the diode Da1
voltage unbalance is achieved with the application hence the power loss is less.
of SVPWM which forms the major attraction for Mode 3: When the current is less than zero and the
industrial applications. switch San is ON, the current flows in the reverse
Hence a 3 level SVPWM technique is direction that is from neutral and flows through
employed to control the switches of the Vienna switch San and diode Da2, flows back through
rectifier and voltage balance of two capacitors Cp, source completing the loop. The Operation is
Cn. shown in Fig.6. Here too the loss occurs only in the
diode, hence low loss.
Mode 4: When the current is less than zero with
switch San to be OFF, then current from the neutral
flows through freewheeling diode Dan to source.

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Hence loss is only from the diode The Operation is

shown in Fig.7.

Fig.4. Current flow when Ia > 0 and switch is OFF.

Fig.9. Dual Closed Loop PI regulator

Fig.5. Current flow when Ia > 0 and switch is ON.

Fig.10. Dual Closed Loop PI regulator

Fig.6. Current flow when Ia < 0 and switch is ON. The current id and iq corresponds to the
active and reactive power so named active power
control channel and reactive power control channel
respectively. The signal from the PI controller is
fed as the reference signal for active power control.
To maintain the reactive power to be zero, the 0
reference is fed to control the reactive power. This
generates this control signal Udref*, Uqref*.
For zero angle between voltage and
Fig.7. Current flow when Ia < 0 and switch is OFF. current, hence the Udref* compared with Vd and
Uqref* with Vq and fed to a PI regulator now the
III. DUAL LOOP PI CONTROL control signals Uref and Uref are obtained and are
Different control strategies are employed transformed back to abc-frame. This reference
for voltage PWM rectifiers. Here Voltage oriented voltage Voabc is sent to SVPWM controller in order
control scheme is used which guarantees a fast and to generate PWM pulses for the Vienna rectifier.
dynamic response. The dual close loop control
system with decoupled feed-forward control is IV. SPACE VECTOR PULSE WIDTH
shown in Fig.10. MODULATION
The three phases Voltage and current are Many control schemes have been
transformed into DQ-frame. The outer voltage presented for the Vienna rectifier with a unity
control loop is formed by feeding back the power factor. The Vienna rectifier topology is
difference between the output voltage and the sum shown in Fig.3.Where the potential of the AC
of the voltage across 2 capacitors feeding to a PI connection points (VA, VB & VC) is under control
controller of the bidirectional switches and the direction of
phase currents, and therefore the inductor current
can also be controlled by the bidirectional switches
according to the input voltage and current
direction. A simple 3-level SVPWM technique is

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ISSN: 2248-9622, Vol. 10, Issue 7, (Series-IV) July 2020, pp. 01-10

suggested here in to control the switches of the 4.2 3-level Space Vector Pulse Width
Vienna Rectifier. Modulation:
The 3-level SVPWM technique is used to
4.1 Space Vector Pulse width Modulation: control the switches of the Vienna rectifier. In 3-
Space Vector Modulation (SVM) is one of level SVPWM there are 27 vectors, as shown in
the principles, used for the generation of PWM Fig.12. since in 3-phase, all the 3-phase current will
pulses. This technique is employed for the three- be lagging or leading from each other with certain
phase inverter, but the technique can be adopted for angle, hence vector [1, 1, 1] and [-1 -1 -1] is
the rectifier too. SVPWM can be implemented for eliminated. Hence 25 vectors are the subset of 27
2 phase system, and can be extended for poly-phase vectors. These vectors frame the hexagon as
system. Some of the features of this method that shown in Fig.12.
have made it very popular three-phase PWM
generation method are,
 It is inherently suitable for the digital platform.
 The switching losses are lesser then sinusoidal
PWM, since switching frequency of the
inverter switch is half the carrier frequency.
 It provides lower harmonics.
 High efficiency.
In SVPWM approach the 3 rotating voltage vectors
are represented by a spatial co-ordinate vector
called voltage space vector
𝑉𝐴𝑆 = 𝑉𝐴 Fig.12: Space Voltage Vectors.
2𝜋
𝑗
𝑉𝐵𝑆 = 𝑉𝐵 𝑒 3 (3) The vectors in 3-level SVPWM are
4𝜋
𝑉𝐶𝑆 = 𝑉𝐶 𝑒 𝑗(
3
) segregated into large vectors, medium Vectors,
The 3- space components can be represented by small vectors and null vectors. The vectors are
single equivalent vector, called resultant space given in the Table.1.
vector VS, which is given by Equation (4).
2𝜋 4𝜋 4.2.1 Sector Selection:
𝑉𝑆 = 𝑉𝐴 + 𝑉𝐵 𝑒 𝑗 ( 3 ) + 𝑉𝐶 𝑒 𝑗 ( 3 ) (4) Based on the reference vector position the
entire operating region is divided into 6 sectors.
Taking the base on 00 if the rotating reference
space vector’s angle, the 6 sectors are classified as
shown in the Table.2.

4.2.2 Region selection:

Each sector is further divided into 4
regions. There are 6 sets of vectors that operate in
Fig.11. abc- frame and αβ-frame each sector. Each region has 3 vectors which
operate for certain time interval in order to obtain
For the implementation of SVPWM technique the 3 the reference voltage vector. There are 4 regions as
phase voltage vector is represented in the shown in Fig.13. If the reference vector lies in
orthogonal frame as shown in Fig.11. The 3-phase region 1, Vref is the resultant vector of A0, A01, A02,
voltages are transformed into αβ-frame and are similarly in region 2 Vref is the resultant vector of
given in Equation (5). A01, A1, A12, in region 3 Vref is the resultant vector
−1 −1
1 𝑉𝐴
𝑉𝛼 2 2
of A01, A02, A12 and in region 4 Vref is the resultant
= 𝑉𝐵 (5) vector of A02, A12, A2.[31].
𝑉𝛽 3 3
0
2 2
𝑉𝐶
The Rotating reference Space vector is given by Table.1: Space Vectors.
Equation (6).
Sap San Sbp Sbn Scp Scn
𝑉𝑟𝑒𝑓 = 𝑉𝛼 2 + 𝑉𝛽 2 (6) Null vector
A0 0 1 0 1 0 1
1 0 1 0 1 0

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Small Vector are the extended projections made to ease the

A01+ 1 0 0 0 0 0
calculation of the values m1 and m2.
A01- 0 0 0 1 0 1
A02+ 0 0 0 0 0 1
A02- 1 0 1 0 0 0
A03+ 0 1 0 0 0 1
A03- 0 0 1 0 0 0
Fig.14. Region Segregation
A04+ 0 1 0 0 0 0
Apply sine rule to find m1 and m2,
A04- 0 0 1 0 1 0 𝑝 𝑞
𝜋 = 𝜋 (7)
A05+ 0 1 0 1 0 0 sin sin
2 3

A05- 0 0 0 0 1 0 2
𝑝 = 𝑚2 = 𝑞 ∗ (8)
A06+ 0 0 0 1 0 0 3

A06- 1 0 0 0 1 0
From the triangle of sides q, mn, m2 + r of Fig.(b).
𝑞 = 𝑚𝑛 sin 𝜃 (10)
Large vectors
A1=A2=A3= 2
∴ 𝑚2 = 𝑚𝑛 sin 𝜃 (11)
A4=A5= A6 0 0 0 0 0 0 3

Medium 𝑚1 = 𝑚𝑛 cos 𝜃 − 𝑟 (12)

vectors
𝜋
A12 0 0 0 1 0 0 𝑟 = 𝑝 cos (13)
3
A23 1 0 0 0 0 0 𝜋
𝑚1 = 𝑚𝑛 cos 𝜃 − 𝑝 cos (14)
A34 0 0 0 0 0 1 3

A45 0 0 1 0 0 0
p = 𝑚2
A56 0 1 0 0 0 0 2 𝜋
𝑚1 = 𝑚𝑛 cos 𝜃 − 𝑚𝑛 sin 𝜃 ∗ cos (15)
A61 0 0 0 0 1 0 3 3
sin 𝜃
∴ 𝑚1 = 𝑚𝑛 (cos 𝜃 − ) (16)
3
Table.2: Sector Selection.
Angle Sector The value of m1 and m2 is taken as the
00-600 Sector-1 duty cycle of the vectors to produce the reference
600-1200 Sector-2 vector. Table.3. summarizes the region segregation
1200-1800 Sector-3 in a sector, the same procedure can be implemented
1800-2400 Sector-4 for the other sectors.
2400-3000 Sector-5
3000-3600 Sector-6 Table.3: Region Selection.
Condition Region

m1 <= 1 1
m2 <= 1
m1+ m2 <= 1
m1 > 1 2
m1 <= 1 3
m2 <= 1
Fig.13: Regions. m1+ m2 > 1
In order to find the region where the m2 > 1 4
reference vector lies in a sector, it is assumed that
the amplitude of the reference vector fits within the The sequence of selecting the voltage vector in
hexagon. The sides of the triangular regions have each region and sector is shown in the Fig.15.
lengths equal to unity as shown in Fig.14.(a) The
reference vector mn is decomposed into two vectors
m1 and m2 along with the zero and sixty degrees
axes as shown in Fig.14.(b). The sides, p, q and r

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Fig.15: Switching Sequence. Fig.17: Timing diagram of Region-2 and 4.

4.2.3 Timing Calculation: For region 1 and region 3 the timing equation is
The time duration of the reference vector given by,
in each region of a sector is calculated with the 𝑇 𝑇 𝑇 𝑇
𝑇𝑠 = 𝑎 + 𝑏 + 𝑇0 + 𝑎 + 𝑏 (18)
assistance of volt time relationship in Equation 2 2 2 2
(17). Consider the reference vector is in region 1, For region 2 and region 4 the timing equation is
the three nearest vectors are A0, A01 and A02. given by,
𝑇 𝑇
𝑉𝑟𝑒𝑓 𝑇𝑠 = 𝐴0 𝑇0 + 𝐴01 𝑇𝑎 + 𝐴02 𝑇𝑏 (17) 𝑇𝑠 = 𝑎 + 𝑇𝑏 + 𝑇0 + 𝑎 (19)
2 2
This gives the proper on-off time for the switches
Where, in the rectifier.
1
𝑇𝑆 = ; FS =Switching frequency.
𝐹𝑠
𝑉𝛽 IV. SIMULATION AND RESULTS
𝑇𝑎 = 𝑇𝑆 𝑉𝛼 − The Vienna rectifier with a 3-level
2ℎ
𝑉𝛽 SVPWM control technique model was built in
𝑇𝑏 = 𝑇𝑆
2ℎ MATLAB-Simulink environment. The behavior is
𝑇0 = 𝑇𝑆 − 𝑇𝑎 − 𝑇𝑏 considered to be continuous. Three-phase 4 wired
3
ℎ = 2
; h= height of the triangle supply is used with an input line voltage to be
415V and 50Hz. The specifications used are given
All small vectors can be implemented with in Table-4.
2 switching states as shown in the table. Therefore
in region 1 and region 3 there are 5 switching states Table.4: Parameters List.
to be executed and in region 2 and region 4 there Parameter Symbol Value
are 4 switching state to be executed. The timing Inductor La, Lb, Lc 15µH
Capacitor Cp, Cn 1000nF
diagram in region 1 and region 3 is shown in
Resistor R 20Ω
Fig.16, and region2 and region 4 in Fig.17.
Output Voltage Vo 280V
Output Power Po 4KW

Fig.18. shows the simulation model in MATLAB-

Simulink .

Fig.16: Timing diagram of Region-1 and 3.

Fig.18: Simulink Model of Vienna Rectifier with

SVPWM Control.

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The constant output voltage is set to be 280V, and

the waveform of output voltage and current is
shown in Fig.19.

Fig.22: Three-phase input voltage and current.

Fig.19: Output voltage and current.

The voltage across the capacitors are shown in

Fig.20, the voltage is balanced across two
capacitors Fig.23: Single-phase input voltage and current.

The input power is measured, the power

factor is also measured and the THD is also
measured. The measured values are showed in
Fig.24. The RMS value of each phase is given in
Fig.25.
To step down the 280V DC voltage to the
level of the battery that will be connected at the
output, a DC-DC converter is to be designed.

Fig.20: Voltage across Capacitor Cp, Cn.

The sector and region segregation obtained with the

application of 3-level SVPWM technique is given
is given in Fig.21.

Fig.24: Measured PF, input Power and THD.

Fig.21: Sector and Region Segregation

The 3-phase input voltages and current are showed

in Fig.22. They both are in-phase. And the voltage
and current of single phase in Fig.23.

Fig.25: Measured RMS Current.

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V. CONCLUSION [5]. Sam Guccione, Mahesh M. Swamy, Ana

This paper presents 3-Phase 4-wire PFC Stankovic, “Rectifiers”, 2002 by CRC Press
for EV with 3-level SVPWM control. The Vienna LLC.
Rectifier is used for achieving PF of 0.9989 with [6]. https://www.sciencedirect.com/topics/engine
SVPWM control. With the use of the Vienna ering/three-phase-rectifier.
rectifier the voltage stress on each device is less [7]. Chongming Qiao, KeyueM.Smedley,
since current flows through a single switch in each “Unified Constant-Frequency Integration
cycle. The 3-level SVPWM control technique aids Control of Three-Phase Standard Bridge
in achieving dynamic response and power factor Boost Rectifiers With Power-Factor
correction. The proposed model is simulated in Correction”, IEEE Transactions on
MATLAB-Simulink and verified. The efficiency Industrial Electronics, 2003, 50(1):100-107.
of the PFC is 99% and PF achieved is 0.9989. The [8]. Chongming Qiao, KeyueM.Smedley,
THD of each phase current is 0.25. The output “Three-Phase Unity Power Factor Star-
power is 4KW, with output voltage 280V. Connected Switch (VIENNA) Rectifier with
Unified Constant Frequency Integration
ACKNOWLEDGEMENT: Control,” IEEE Transactions on Power
I would like to express my deep gratitude Electronics, 2003, 18(4):952-957.
to Professor Dr. P Usha and Mr. Winnefred Poul [9]. JinAijuan, Li Hangtian, Li Shaolong, “An
Luke Kingkam Durai, my research supervisors, for Improved Control Strategy of The One
their patient guidance, enthusiastic encouragement Cycle Control Three-Phase PFC Rectifier
and useful critiques of this research work. I would Under Unbalanced Conditions,”
also thank Mrs. Mohana Lakshmi J for her Transactions of China Electro-technical
guidance in my research process. My grateful Society, 2006, 21(7):116-120. (in Chinese).
thanks are also extended to staffs and team [10]. Wang Linbing, Zhang Chao, “Study Of
members of EPD, Vitesco Technologies India Pvt Single-Phase Three Level Power Factor
Ltd., Bangaluru. I would also like to thank EEE Correcting Converter”, Power Electronics,
department staffs of Dayananda Sagar College of 2006,40(2):15-19.(in Chinese) .
Engineering for their guidance and support. [11]. Wang Chunjie, Ma Xiaoliang, “Simulation
On Separable Three-Phase PFC By One-
Finally, I wish to thank my family for their support Cycle Control”, Journal of System
and encouragement throughout my study. Simulation, 2006, 18(11):3259-3262.(in
Chinese).
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