A Three-Phase Non-Isolated Pseudo Six-Phase-Based Integrated Onboard Battery Charger for Electric Vehicles

— The trending modern designs of electric vehicle motors are concerned with maximizing the machine torque density while offering a fault tolerance capability. Among different available stator winding layouts, the so-called pseudo-six-phase winding has recently been proposed, which offers an improved torque density and fault tolerance over conventional six-phase distributed winding. An integrated onboard battery charger (IOBC) has also been proposed as a new leading technology that employs the propulsion components of the EV in the charging process to achieve the highest possible charging current with zero machine torque production. In this context, this paper proposes a new pseudo six-phase-based IOBC system. Two different controllers have been investigated, namely, conventional proportional resonant (PR)-based current control and predictive current control (PCC) techniques. Under charging mode, the control objectives aim at achieving a balanced three-phase grid current while nullifying machine torque production. To this end, the sequence stator currents are regulated to ensure a balanced 𝒙𝒚 current while both the 𝜶𝜷 and 𝟎 + 𝟎 − current components are controlled to zero. Furthermore, a novel postfault controller using a PR-based current controller has been proposed which ensures balanced grid line currents under one open phase fault. A comparative experimental study has been carried out under different controllers for both vehicle to grid (V2G) and grid to vehicle (G2V) modes using a 2 Hp prototype machine.