A Minimalist High-Power Boost Charging Solution Integrated into Electric Drives

<div class="section abstract"><div class="htmlview paragraph">The driving capability and charging performance of electric vehicles (EVs) are continuously improving, with high-performance EVs increasing the voltage platform from below 500V to 800V or even 900V. To accommodate existing low-voltage public charging stations, vehicles with high-voltage platforms typically incorporate boost chargers. However, these boost chargers incur additional costs, weight, and spatial requirements. Most mature solutions add a DC-DC boost converter, which results in lower charging power and higher costs. Some new methods leverage the power switching devices and motor inductance within the electric drive motor to form a boost circuit using a three-phase current in-phase control strategy for charging. This approach requires an external inductor to reduce charging current ripple. Another method avoids the use of an external inductor by employing a two-parallel-one-series topology to minimize current ripple; however, this reduces charging power and increases the risk of torque control during charging. This paper presents an innovative integrated boost charging solution that utilizes a three-phase phase-shift control algorithm. This method eliminates the need for additional external inductors. In addition, intelligent voltage regulation strategies, low-loss motor design, and improved cooling schemes are implemented to address thermal risks associated with motor magnets. Compared to traditional approaches, this method offers advantages in terms of minimal cost increase, reduced space occupation, maximum boost charging power, and safest zero torque output.</div></div>