Design and simulation of solar grid-connected charger for

electric vehicles
AKMAL, M. <http://orcid.org/0000-0002-3498-4146>, JAWAD, A. and
TARABSHEH, A.A.
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Published version
AKMAL, M., JAWAD, A. and TARABSHEH, A.A. (2018). Design and simulation of
solar grid-connected charger for electric vehicles. In: 2018 UKSim-AMSS 20th
International Conference on Computer Modelling and Simulation (UKSim). IEEE,
108-113.

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 Design and Simulation of Solar Grid-Connected Charger for Electric Vehicles

Muhammad Akmal, Amna Jawad and Anas Al Tarabsheh

Electrical and Computer Engineering Department
Abu Dhabi University
Abu Dhabi, United Arab Emirates
[email protected]

Abstract—Electric Vehicles (EV) are playing major role vehicles would be dependent on a clean renewable energy
in decreasing carbon emissions. The major problem so far source that way.
with the Electric Vehicles are overloading the EVs can be classified into different types mainly Hybrid,
Distribution Grids and availability of enough charging Plug-in Hybrid Electric and Battery Electric vehicles. Hybrid
stations. The main objective of this research is to design electric vehicles don’t need an electric charger and generate
and install a solar powered charging station for EVs in energy by the cars movements. The other two types however
the UAE environment. This project aims to focus on the need an external charger for charging [2]. There are two basic
need for the shifting from the traditional gas and petrol setups for PV Electric Vehicle charging systems. The first is
the PV-grid system, and the second is the PV standalone
vehicles to Electric vehicles in the UAE. Additionally, the
system. PV-grid systems are generally far feasible to operate
project intends to ease the problem of the additional load
than standalone systems, as standalone systems usually
that these EVs impose on the grid by powering the cannot support large scaled energy requirements [2].
charging station from solar energy. This will help evolve There are various ways to charge these EVs. Some of the
the existing transport system of the UAE into a cleaner different types are home charging, charging by EVSE
and greener system. The project is divided mainly into (Electric Vehicle Service Equipment) and then by charging
three important parts. First of all, the system components stations. Home charging involves the use of charging the car
are designed to match with the ratings of available most using the on-board charger and connecting it to a wall socket
common EVs. Then the system is modelled in at home. But this type of charging is extremely slow and
DIgSILENT Power factory for simulation and validation inefficient [3]. That is why, there is prompt research required
of design. Finally, the results from calculations and to design and install renewable energy based charging
simulations are described and compared. stations.

Keywords- Electric Vehicles; Charging stations; Green II. LITERATURE REVIEW

design; DC-DC power converters; Inverters; Simulation With the increase in population and economic growth, the
need for sources of energy is also quickly increasing. Diesel
I. INTRODUCTION and petrol availability is in serious questioning over the
coming years to meet all those needs, and many people are
Our lifestyles today are highly dependent on the fast going to shift their choice towards a car that they can run
consumption of energy that is generated mainly by fossil fuels. using a reliable and abundant supply of energy. Since the
These fossil fuels must be ignited to be used which produces energy from the sun will be available abundantly as it has
harmful toxins that causes the environmental pollution and always been, and with the advancements, changes and
pose a risk to all living organisms. In order to prevent these developments in photovoltaics, solar power will remain as a
adverse effects there is a lot of focus on renewable energy. A great renewable energy option. [1-4]. Moreover, the
large proportion of these non-renewable energy reserves are introduction of these stations would encourage commuters in
consumed by the transportation industry. The traditional the Middle East to reconsider their transportation choices and
transportation system needs to undergo a lot of changes and to switch to emission free vehicles [5].
new innovative measures are underway to modernize it. The The basic components that are present in nearly every PV-
shift towards renewable energy will require a parallel upgrade grid set up are a DC charger, DC-DC converters and DC-AC
of vehicle technology [1]. converter which can be split as a combination of an AC-DC
However, the main problem with using Electric vehicles is rectifier and inverter [2, 6, 7]. The DC-DC buck converters
that these Electric vehicles would again depend on the grid for are one directional and are used to ensure that the power
charging. This means that non-renewable energy will be used provided by the PV array is used only in one direction, and
again. This also puts up a lot of burden on the grid supply, as the current flow does not reverse back inside the grid the
charging Electric cars requires a lot of electric energy. To function of the MPPT. DC-DC Buck converter is to make the
solve the problem of the Electric Vehicle dependency on the most of the Power supplied by the PV array, and use it to
grid this project would aim to set up a charging station for contribute to the bus voltage. Charging buck converter is used
Electric Vehicle that is powered by solar energy. This would to lower the voltage to make it at a suitable level for charging
help in decreasing the burden on the grid and the electric [2, 7].
 The EV can be with or without an on-board charger. converter is then further connected to various DC-DC Buck
Electric vehicles with on board charger have the charger converters that are for charging the EV’s. The number of
inside the vehicle themselves, and these chargers are Buck converters depends on the number of parking spaces
equipped with bi-directional and one directional dc to dc that will have charging outlets [10].
converters as well as Boost converters in order to make the In [11] the author designs a parking space-based charging
voltage suitable for the battery. An EV without an on board station. This model would constitute of a PV system upon the
charger, has to have an external charger. Generally, external parking rooftop, which provides both shade and power to the
charging converters are preferred to on board systems, as it is car parked below. Energy calculations were based upon the
easier to increase their power supplied to the EV, without solar energy received by the array on the rooftop in both
being limited by the capacity of the on-board charger [10]. winter and summer seasons of New Jersey town where the
Also the electric vehicles without internal chargers cost and project is implemented. It is discovered that during summer,
weigh much lesser than their rivals with on board chargers the car can receive up to 12600 watts. This is far more than
[10]. Since the system is tied to the grid, an AC-DC rectifier the winter power amount which is up to only 3780 watts. The
is used to provide power to the EV cars, in case the energy author suggests modifications to be held to make more energy
produced by the PV array is insufficient. Excess energy and greater flexibility of conditions during the winter season.
produced from the PV array is sent back to the grid, as there In [12] the requirements for the design of a fast-Electric
will be no energy storage system in the PV-grid system [7]. vehicle charging station. The design used the Flemish
The authors in [7] have discussed an EV charging system Mobility as a criterion. The design is made such as to support
that can provide charging to different Electric vehicles, with the charging of one thousand cars. At first, the demand for
different energy needs through varying the DC voltage at two the charging is determined. In the second phase of the project
charging outlets. They use four strings of PV panels, with the findings from the first phase are used to demonstrate the
each string having 6 solar panels. The total power capacity of workings of the station that could be used to meet the required
the system is 4.8 KW. This power is then lowered by using needs. The energy in the station is managed and controlled by
four buck converters, to bring the voltage to a lower level. an algorithm. This will be responsible for the distribution of
The voltages at the 2 outputs can be further decreased, energy throughout the system. Additionally, a suitable
according to the needs of that car. Smaller vehicles are covering factor is also obtained by taking out many charging
provided with a lesser range than larger cars. The system is areas or spots. The system is designed for 2020, and the
grid tied by replacing a two directional AC/DC converter number of Electric vehicles is thought to increase
with an inverter and rectifier. Furthermore, an algorithm is considerably by then. The demand of charging is calculated
used to control the overall system [7]. by the demand by the 1000 cars regardless of their travel
According to [8] the EV charging has to be performed destinations [12].
cautiously, as any fluctuations in the level of charging could
impair the EV battery. There are three basic charging types. III. DESIGN AND IMPLEMENTATION
The first type is charging by keeping current as constant
while the other type keeps voltage constant. The third type A. Calculations for design
has these two types combined. However, the combination of The system design will depend on the output power that
these two charging methods is considered the best, as it is expected from it. Important calculations will determine the
avoids the disadvantages present in using both these methods. system capacity and the resulting output power that is
Constant voltage charging is generally preferred to be generated.
charging at Constant current because the EV battery may be The Real charging system proposed will have the
damaged when the incoming power is greater than the level charging capacity of charging at least 5 cars. The designing
it should be at, during constant current charging. It functions of the system was based on a number of designing factors.
by first gradually increasing the current instead of an abrupt
increase. This is then lowered, and the voltage made constant, 1). Calculations for charging 1 car
after the maximum constant value of current is reached and Firstly, the watt-hour/mile rating range of Electric
the EV has been almost eighty percent charged [8]. vehicles was considered. Most EV’s have a Wh/mile
In [9, 10] different charging systems are described. The consumption within the range of 250-400 Wh/mile [13]. To
charger that is internal to the EV has a charging circuit that ensure that the charging station is able to power any Electric
modifies the voltage supplied according to the cars need. The vehicle, 400 Wh/mile is assumed to be the total Energy
AC input is first converted into DC voltage by a bi-directional consumption of 1 electric vehicle. Next, the average total
rectifier. Any restoring changes to the power factor are made daily distance of an Electric vehicle will be assumed.
through using a bi-directional converter that is usually a boost The average total distance of 45 miles (70 kilometers) per
converter. This input is then given to the battery after being day was assumed for calculation purposes.
passed through another DC-DC converter, to further lower The energy required by one car in kWh per day can then
the voltage supplied for battery charging [10]. Moreover, the be calculated by multiplying the total energy consumption
authors describe three different set ups, being for integrating and the distance to be travelled.
these chargers into the PV charging system. In a centralized The energy required by one car = 400Wh/mile×45 miles
set up, the PV arrays will be connected to a MPPT DC-DC = 18000 Wh = 18 kWh
boost converter that is central to the system. This boost
 Since there will be some energy losses, in the form of is later stepped down to make it more suitable for the electric
heat, the energy requirements will be taken by taking the vehicles.
efficiency of the car into consideration, and an efficiency of Since the number of panels required is 130 panels, then
85 percent will be assumed. So, the energy needed for 1 car each string will have 13 panels connected in series with each
after taking the efficiency into consideration is: other and there will be 10 strings in parallel. The series
connection is necessary as the maximum voltage of 1 panel
The energy required by one car = 18kWh/0.85 is only around 30.7 volts and when the panels are connected
= 21.176 kWh in series the voltage from one string will amount to:
The average energy to be generated by the PV in one day
has to be at least 21.176 kWh, hence the design is based on 13 × 30.7 = 400 volts
23 kWh energy required. The energy requirement is increased The solar panels will then be connected to MPPT DC-DC
so that the system designed will be able to support the electric Buck converters, after being connected through a PV
vehicle charging by producing more energy than needed so combiner box and the charge controller. PV combiner box is
as to avoid any energy shortage in case of more consumption used as a joining point for the voltage and power output from
[7]. different strings in the PV system. The box helps create a bus
The system capacity of the PV system can then be linkage for the PV system [15]. The box also serves as a
calculated by using the following formula [14]: protection system as it has instruments that help protect
Output = Capacity x Peak Sun Hours x Effective Output against sudden changes in the voltage or current. The
Capacity = Output / (Peak Sun Hours × Effective Output) essential quality to look for while choosing a PV combiner
box is the encasing because it is what the combiner box's
Where, effective output is after subtracting all losses and utility life depends on. In areas such as UAE where the
derating factors. temperature and humidity can rise, we will use a PV
A value of 5.83 hours is the peak sun hours for UAE, and combiner box which comes with a encasing that has a vent
the effective output is of 75 %. This gives the system capacity installed. This helps the box to cool down as it minimizes the
in kilowatts [14]. pressure on the encasing. The combiner box is most suitable
for when output power is high. This box can be used to join
System capacity = 23kWh/(5.83h×0.75) = 5.32 kW the output from all the strings [15].The charge controller will
The number of panels are then calculated by dividing the regulate the current movement, and to direct the current to
total system capacity, with the power rating of 1 panel. flow in one direction. It will also prevent the back flow of
current into the PV array [16]
The total number of panels = 5.32 kW/240 = 23 panels The MPPT Buck converters will then be connected to
The number of panels is up-scaled to 26 panels for the PV charging DC-DC Buck converters. The MPPT converter will
system. The total area of PV panels that must be exposed to then be connected to charging converter from where they are
direct sunlight to get this output can be calculated by input to the Electric vehicles. The system is also grid
multiplying the total number of panels with the area of 1 connected via a bidirectional AC/DC inverter which will
panel. convert the AC voltage supply to 400 VDC. The Fig. 1 shows
the proposed System Architecture design for the solar
The total area = 1.703 m2 × 26 panels = 44.3 m2 powered charging station:
The system will be using 26 panels to produce the
required power for the changing needs of one car. A
collective number of these solar panels will be connected
with each other in series to form one string.

2). Calculations for charging 5 cars

Since the charging station is designed to charge a
minimum number of 5 cars to cover their daily energy usage.
Their total energy consumption, system capacity and total
panels will be 5 times of these for single car and will be Fig 1: System Architecture
105.88 kWh, 26.6 kW and 130 respectively. The area
required will also be 5 times, which will be 221.39 m2.
IV. RESULTS
3). Calculation of Voltage and Current ratings
The simulation results have been obtained by modelling
A number of the solar panels will be connected with each the system on the DIgSILENT Power Factory. The system
other in series with each other to form one string. These was tested to display results for three important events: the
strings are then connected in parallel to get required power. first event is “night” time (The switch event is disconnecting
The total voltage of the system should be in the range of 350- the PV at sunset), the second event is “day” time (at sunrise
490 VDC volts, to meet the power requirements. This voltage the switch event is connecting PV again to the system) and
the third event is “grid-off” (at a time when the grid supply is and represents the PV panels Voltage, whereas the voltage
off while during the day time in emergency condition or across the Busbar-5 represents the voltage that will be
islanded operation). The edges will be mentioned as sunset, supplied to the load attached to Busbar-5 from both the grid
sunrise and grid-off. The Fig. 3 shows the Power System used and the Panels. From the graph it can be seen that the two
for simulation purposes. voltages are at a fairly constant level before the onset of
sunset, with the value of the Busbar-2 being slightly higher
than that of Busbar-5. This is because the Busbar-5 receives
Power supply from the PV panels and the grid that has been
reduced due to losses in the lines.
2) The voltage at sunrise
At sunrise the voltage from the PV panels will start
increasing. Initially the increase will be very slow as the light
intensity will be too low. But as the light intensity continues
to increase the DC voltage would increase as well. The
voltage from the DC voltage source will be at its highest
when the light intensity is the maximum at noon.
B. Current
The Fig. 4 shows the results of the simulation of the
Fig. 2: System model in DIgSILENT Power Factory current levels of the PV-grid power station that is obtained at
A. The Voltage the three different simulation events : Sunset, Sunrise and
Grid-off. From the graph it can be seen that the current levels
The Fig. 3 shows the results of the simulation of the of all the different DC-DC converters that are present in the
Voltage levels of the PV- grid power station that is obtained system are displayed. The legends indicate the current in
for the three simulation events: sunset, sunrise and Grid-off. various sections of the system.
From the graph it can be seen that the Voltage levels of all
the different DC-DC converters that are present in the system
are displayed. The Voltage across the DC-DC converter
attached to Busbar-2 is represented by Light Blue. This is the
main DC-DC converter which supplies voltage from the DC
photovoltaic cells to the loads or Electric vehicles attached to
the system. The Voltage across the DC-DC converter
attached to Busbar-5 is represented by Green. Finally, the
voltage across the line is represented by Dark Blue. The
terminal is being supplied by the grid, so the graph basically
represents the line Voltage of the AC grid supply.

Fig 4: The current readings of the system for the three events.

1) The current at sunset

The sunset section shows the results of the simulation of
the current levels of the PV-grid power station that is
obtained at sunset when the solar intensity is at its lowest. At
2 seconds when the power supply from the Photovoltaic DC
system is cut off, the current then starts increasing sharply
because the system loads will entirely depend on the grid
supply. Hence as soon as the current from the DC source
Fig 3: The voltage readings of the system for the three events. becomes zero, the current from the grid supply will reach its
maximum point.
1) The voltage at sunset 2) The current at sunrise
The sunset section shows the results of the simulation of At sunrise, with the increase in light intensity, the current
the voltage levels of the PV- grid power station that is from the DC source starts increasing. The grid current starts
obtained at sunset when the solar intensity is at its lowest. The decreasing at the same time, as the DC power source will start
voltages are represented in per unit. From the graph it can be providing the system with the solar power being produced.
seen that the Busbar-2 is being supplied by the DC supply The grid current will decrease and become at the same level
that it was prior to sunset. It then becomes constant. The DC power (that is representing the grid power) continues to drop
source current, which was initially at 0 Amperes, will start steeply until it reaches a value of 0 Watts altogether.
increasing and reach to the point that it was prior to sunset.
The current will then become constant at this value. The D. Simulation results compared to manual calculations
current level from the source is at a slightly reduced level than Manual calculations were performed to validate the
that of the grid. The remaining 4 parameters show the current simulation results. From the simulation, we can see that there
that is owing across the DC-DC converters of the 4 loads are 5 main DC converters. The DC-DC converter 1 is the DC
attached. It can be observed that all 4 graphs start increasing converter that is the main DC converter that is supplying the
slightly at sunrise and become constant at the same level of loads with solar DC voltage. The first step is to find the Duty
current that they were at prior to sunset. cycle out of each DC-DC converter. This can be calculated
using the below formula:
3) Current at Grid-off 𝑉𝑜𝑢𝑡
𝐷=
In the third part of the simulation, the current is observed 𝑉𝑖𝑛
when the grid is switched off. It can be seen that the grid The Duty cycle obtained is then compared to that stated
current continues to drop steeply until it reaches a value of 0 in the simulation. The percentage difference between them is
amperes altogether. This clearly suggest that there is no ow then calculated by the formula: (Difference/measured) × 100
of current from the grid to the system. On the other hand, the The next step is to calculate the current Iin that is entering
current from the DC-DC converter increases and reaches its into the DC-Dc converter.
maximum value. This converter acts as a common converter This can be done by using the following formula:
between the PV panels, the loads and the grid. 𝑃𝑖𝑛
𝐼𝑖𝑛 =
C. Power 𝑉𝑖𝑛
The Fig. 5 shows the results of the simulation of the The next step is to calculate the output current or Iout that
Power levels of the PV- grid power station that is obtained at is leaving the DC-DC converter. Since we know that
the three different simulation events: Sunset, Sunrise and
𝑉𝑜𝑢𝑡 𝐼𝑖𝑛
Grid-off. From the graph it can be seen that the Power levels 𝐷= =
of all the different DC-DC converters that are present in the 𝑉𝑖𝑛 𝑉𝑜𝑢𝑡
system are displayed. The pattern of power flows is similar
to current flows. Also, the lines and converters are the same The output current Iout can be calculated using:
through which current and power results are taken. 𝑉𝑖𝑛 𝐼𝑖𝑛
𝐼𝑜𝑢𝑡 =
𝑉𝑜𝑢𝑡

The comparison of calculations is given in the table 1.

V. CONCLUSION
Availability of EV charging is one of major problems to
demotivate a transition towards electric vehicles. This project
will help in evolving the existing transport system into a
cleaner and greener system. Another main problem with
Electric Vehicle usage was the burden that these vehicles
impose on the grid by charging. In this research a charging
station that is dependent on solar energy has been proposed
Fig 5: The Power readings of the system for the three events. for use. The results that were achieved through simulation
analysis of the system modelling are then shown. Suitability
1) The Power at sunset of PV charger for EVs will encourage the customers to shift
Initially the power was shared between the Photovoltaic to EVs with time.
and the grid. But at sunset the power from the photovoltaic
cells is suddenly cut out. This leaves the system being entirely ACKNOWLEDGMENT
power dependent on the grid. The authors would like to thank the Office of Research
2) Power at sunrise and Sponsored Programs, Abu Dhabi University, Abu Dhabi,
At sunrise, the power is shared between the Photovoltaic UAE for sponsoring this research under grant number
and the grid again as the power from the photovoltaic cells 19300212.
starts getting generated. This decreases the burden and
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Table 1: Comparison of manual calculations and simulation results

DC Vin Vin Pin Iout (sim) Iin (sim) D (sim) D Iin Iout ΔD(%) Δ Iin Δ Iout
(manual) (manual) (manual) (%) (%)
DC-1 400 300 143700 449 359 0.8 0.75 359.25 479 6.67 0.0696 6.263

DC-2 300 200 44000 193 138 0.714 0.667 146.667 220 7.1 5.909 12.272

DC-3 300 200 60000 263 188 0.714 0.667 200 300 7.1 6 12.333

DC-4 300 200 49000 214 153 0.714 0.667 163.333 245 7.1 6.327 12.653

DC-5 300 200 18000 79 56 0.714 0.667 60 90 7.1 6.667 12.222