AC Direct Charging for Electric Vehicles via a Reconfigurable Cascaded Multilevel Converter

This paper presents a charging architecture for the Reconfigurable Cascaded Multilevel converter, which was specifically designed for electric vehicle (EV) powertrain applications. The RCMC topology is capable of executing power conversion and actively managing battery systems concurrently. The active battery management is achieved using the Reconfigurable Battery Module, which regulates the serial connection of cells via a switch pattern. In this paper, the RCMC is directly interfaced with an AC three-phase power system, facilitating the dynamic control over battery cells charging. Its inherent design allows for the implementation of various charging algorithms, customizable to specific requirements, without necessitating additional intermediary power stages. Firstly, an overview of the RCMC topology is given, and an analysis to define the optimal filter inductance is carried out. Subsequently, after the AC system characteristics are explained, two charging algorithms are presented and described: one prioritizes State of Charge (SOC) balancing among battery cells, while the other focuses on minimizing power losses. Moreover, a time estimation computation for the RCMC is carried out considering a two-level AC charging station. The result is compared with the time required for a conventional battery pack. The results show a reduction of 10 s in charging time for a mere 20% increase in SOC. Finally, the experimental setup is presented and used to validate the efficacy of the proposed algorithms.