Comprehensive Documentation for On-Board Charger Simulation for Two-Wheeler Vehicle

System Overview

What is an On-Board Charger (OBC)?

An on-board charger (OBC) is an integrated power electronic system in electric vehicles (EVs) that converts AC grid power into regulated DC power to charge the vehicle’s battery. It includes power factor correction (PFC), rectification, and DC-DC conversion stages to ensure efficient and safe battery charging.

Purpose of the Simulation

The simulation aims to:

• Analyze AC-DC conversion and power factor correction efficiency.
• Validate charging algorithms for different battery chemistries.
• Optimize power management and thermal performance.

Key Features

High-Efficiency Power Conversion

The OBC achieves high efficiency through advanced power conversion topologies, reducing energy losses during charging. ➡️ HIL/PHIL Benefit: Real-time evaluation of efficiency under different grid conditions ensures optimal charger operation.

Intelligent Battery Charging Algorithms

The simulation supports Constant Current (CC), Constant Voltage (CV), and adaptive charging techniques for lithium-ion and other battery chemistry. ➡️ HIL/PHIL Benefit: Enables real-time testing of various charging profiles and adaptive algorithms.

Power Factor Correction (PFC) Implementation

Compact Design:Helps design lightweight and compact OBCs suitable for two-wheelers.

Reliability and Safety: Ensures safe and reliable operation under various conditions.

Cost Savings: Reduces development time and cost by minimizing physical testing.

Active PFC circuits ensure compliance with grid regulations by maintaining a near-unity power factor. ➡️ HIL/PHIL Benefit: Testing under different grid disturbances ensures compliance with international power quality standards.

Simulation Objectives

This simulation helps evaluate:

• Charger efficiency and thermal performance.
• Dynamic response to varying input voltage and battery SOC (State of Charge).
• Grid compliance, including harmonic distortion and power factor correction. ➡️ HIL/PHIL Benefit: Real-time validation allows engineers to fine-tune charger control strategies before hardware deployment.

Technical Description

System Configuration

• Input: Single-phase or three-phase AC grid (110V/230V/400V).
• Power Conversion Stages: Rectifier, PFC, and isolated DC-DC converter.
• Output: Regulated DC power to charge a two-wheeler battery pack (typically 48V-72V Li-ion batteries).
• Control System: Digital control with DSP/FPGA-based algorithms for optimized charging.

Control Methodology

• Power Factor Correction (PFC): Ensures high power quality and reduces grid-side harmonics.
• DC-DC Regulation: Provides stable charging voltage and current.
• Battery Management System (BMS) Integration: Monitors battery health and adjusts charging profiles dynamically. ➡️ HIL/PHIL Benefit: Real-time emulation of grid and battery conditions ensures robust control validation.

Advantages of On-Board Chargers for Two-Wheelers

• Compact and Lightweight: Designed for integration into electric scooters and motorcycles.
• Grid-Friendly Operation: Ensures compliance with grid regulations.
• Fast and Adaptive Charging: Optimized for rapid charging while ensuring battery longevity. ➡️ HIL/PHIL Benefit: Full-cycle testing from simulation to real-world validation using Impedyme’s platforms.

Applications

• Electric Two-Wheelers: Motorcycles and scooters with integrated charging.
• Urban Mobility Solutions: Battery swapping and fast-charging infrastructure.
• Last-Mile Delivery Vehicles: Optimized charging for delivery fleets. ➡️ HIL/PHIL Benefit: Accelerates development of application-specific charging solutions.
• Power Quality and Efficiency: Harmonic Analysis: Simulations help analyze and mitigate harmonic distortion caused by the OBC, ensuring compliance with power quality standards like IEEE 519.

Power Factor Correction (PFC): Simulations are used to design and test active PFC circuits in the OBC to improve efficiency and reduce reactive power.

•  Grid Compatibility and Safety: Grid Interaction Studies: Simulations help study the interaction between the OBC and the grid, ensuring stable operation under varying grid conditions (e.g., voltage fluctuations, frequency variations).

Isolation and Safety: Simulations are used to test the OBC’s isolation and safety features, such as ground fault detection and protection.

•  Cost Reduction and Time-to-Market: Prototype Testing: Simulations reduce the need for physical prototypes, saving time and cost during the development phase.

Fault Scenario Analysis: Simulations help identify and address potential issues early in the design process, reducing the risk of costly recalls or failures.

Simulation Benefits

With this simulation, users can:

• Explore charger efficiency under real-world scenarios.
• Validate PFC and charging control strategies.
• Optimize thermal performance and EMI/EMC compliance. ➡️ HIL/PHIL Benefit: Simulation insights can be directly implemented in hardware prototypes for validation.