Integrated on-board battery chargers (OBCs) have been recently introduced as an optimal/elegant solution to increase electric vehicle (EV) market penetration as well as minimize overall EV cost. Unlike conventional off-board and on-board battery chargers, integrated OBCs exploit the existing propulsion equipment for battery charging without extra bulky components and/or dedicated infrastructure. OBCs are broadly categorized into three-phase and single-phase types with unidirectional or bidirectional power flow. This paper starts with surveying the main topologies introduced in the recent literature employing either induction or permanent magnet motors to realize fully integrated slow (single-phase) and fast (three-phase) on-board EV battery charging systems, with emphasis on topologies that entail no or minimum hardware reconfiguration. Although, permanent magnet (PM) motors with conventional double-layer distributed winding layouts have been deployed in most commercial EV motors, the non-overlapped fractional slot concentrated winding (FSCW) has been the prevailing choice in the most recent permanent magnet motor designs due to its outstanding operational merits. Hence, a thorough investigation of the impact different FSCW stator winding designs have on machine performance under the charging process is presented in this paper. To this end, the induced magnet losses, which represent a challenging demerit of the FSCW, have been used to compare different topologies under both propulsion and charging operation modes. Based on the introduced comparative study, the optimal slot/pole combinations that correspond to the best compromise under both operational modes have been highlighted.

Multiphase winding configurations have gained significant attention in high-performance variable speed drives and wind energy conversion systems (WECS) owing to their myriad advantages. In the available literature, various multiphase winding layouts have been designed aiming at boosting the machine performance to meet the requirements of the proposed applications. Ultimately, this paper surveyed the state-of-the-art in the available multiphase winding layouts proposed for various innovative applications. Various types of windings were discussed, while investigating their advantages and limitations. This typically considers the winding layouts employed in multiphase induction motors (IMs) and permanent magnet (PM) machines with prime phase and multiple three-phase orders. This study extensively provides innovative winding arrangements that offer better machine characteristics in terms of torque density, efficiency, and fault-tolerance capability. Moreover, the construction of multiphase machines with general $n$ -phase using standard three-phase stator frames has been elaborated. This latter technique obviates the basic necessity of special stator frames with a prime number of phases. Finally, this paper sheds light on the commercial applications that include multiphase winding layouts.

This article presents the operation of onboard integrated battery chargers tied to a nine-phase EV-drive train, shedding light on the charging performance during the postfault operation, when one or more faulty inverter legs are disconnected. The objective in that case is to ensure balanced grid currents, while maintaining minimum machine losses at zero average torque production. The proposed concept requires a minimalistic change from a control structure perspective to switch between the pre- and postfault cases. Limitations and fault cases are discussed and corroborated with experimental tests on a 1.5-kW prototype.The derived concept is parameter independent and applicable to nine-phase drives, irrespective of the type of rotor used.

Integrated onboard battery charger (IOBC) is an emerging technology that charges electric car battery packs utilizing the same circuitry for electric propulsion, reducing the cost and weight of an EV. During charging, while ensuring zero-average torque to avoid rotation, permanent magnets (PMs) synchronous motors with fractional slot concentrated winding (FSCW) may be subjected to irreversible demagnetization due to sub and super space harmonics with relatively high magnitudes. This paper presents the design and optimization of six-phase surface-mounted permanent magnet (SPM) and interior permanent magnet (IPM) motors with FSCW considering the impact of PM demagnetization during IOBC. A detailed thermal and demagnetization analysis is conducted to identify the risk of PM demagnetization during propulsion and IOBC modes. The performance and demagnetization risk for SPM and IPM motors with different power ratings used in commercial EVs are compared at various operating conditions. In the integrated charging process, grid-to-vehicle and vehicle-to-grid power circulations are practically implemented. Simulations are conducted using a three-dimensional finite element analysis. Experimental results of a 15 kW IPM motor are provided for further verification.

Electric vehicles (EVs) play a major role in the evolution towards sustainable transportation. The integration of information and communication technology (ICT) into the electric vehicle (EV) charging process has witnessed rapid progress. Wireless communication between EVs has become commercially viable, supporting vehicle-to-sensor, vehicle-to-vehicle, and vehicle-to-internet regimes. However, EVs still have limited market penetration due to charging process constraints such as charging time and the availability of charging points. This paper considers an asymmetrical nine-phase smart integrated on-board charging (OBC) system with a reduced cost, size and weight. All the propulsion components are utilized in the charging process. Both zero machine average torque production and unity power factor operation at the grid side can simultaneously be obtained during the charging process. Additionally, no hardware reconfiguration is required to allow the transition between propulsion and charging modes for this system topology. Furthermore, the proposed integrated on-board charger is completely monitored, and the charging rate is controlled through a smartphone application via internet of things (IoT) technology, thus optimizing the user experience. A 1.5 kW prototype is implemented to validate the proposed system by rewinding a three-phase induction motor (IM).

Integrated On-Board Battery Chargers (IOBCs) have shown promise as an elegant charging solution for electric vehicles in recent literature. Although the three-phase charging technique of IOBCs has extensively been discussed in the literature, single-phase charging is still a challenging research topic. The Predictive Current Control (PCC) approach has shown many benefits, including a straightforward algorithm, simple implementation, comparatively quick response, and appropriate performance, when compared to conventional control techniques. This paper investigates the impact of single-phase charging of a six-phase-based IOBC system with different winding configurations using PCC, which, up to the best authors’ knowledge, has not been conceived thus far. Under single-phase charging, the zero-sequence current component is utilized to ensure zero torque production during charging mode. Since the impedance of the zero subspace is highly affected by the employed winding design, the performance of PCC with different winding layouts of either induction machine (IM) or permanent magnet synchronous machine (PMSM) is investigated and compared. The proposed method is experimentally validated using a 1.1kW six-phase IM and a 2 kW 12-slot/10-pole PMSM. Finite Element analysis is also carried out to investigate the effect of single-phase charging mode on the induced radial forces and vibration level when PM machine is employed.