Design and simulation of an electric vehicle charging system with battery arrangement and control parameters optimization

Abstract

The development of electric vehicle (EV) charging technology requires efficient, reliable, and economical systems to address users' concerns about battery drain. This study presents a simplification of EV charger design with an isolated model and optimal battery mode setting. The research method integrates step-up Y-Δ transformers, AC-DC converters, boost DC-DC converters, integral proportional control, and battery configurations. Series (S) - parallel (P) - series (S) battery arrangement pattern to maximize system performance. The test results using a 130 mF capacitor with the S40-P2-S6 and S80-P2-S3 array patterns produced an output voltage of 946 V, while the S100-P2-S3 array pattern achieved an output voltage of 1,182 V. The system is capable of fast charging with a time of 0.2 to 2 hours for a battery capacity of 30 to 100 kWh at a charging power of 50 to 150 kW with an efficiency of up to 97%. The combination of the use of an isolated model on the charger array and the EV battery setting pattern is proven to produce stable voltage values with minimal overshoot levels, thus addressing the complex charger design challenges and battery setting needs in the 800 to 1,100 V voltage range.