Report on simulation and analysis of converters for electric vehicles

I | S c h o o l o f E n g i n e e r i n g , N i r m a U n i v e r s i t y , A h m e d a b a d
SIMULATION AND ANALYSIS OF CONVERTERS FOR
ELECTRIC VEHICLE
A
Mini Project-II Report
Submitted in Partial Fulfilment of the Requirements for the Degree
of
Bachelor of Technology
in
Electrical Engineering
Submitted By:
Aakansha Jha (16BEE001)
Mayank Acharya (16BEE005)
Under the Guidance of:
Prof. Chirag H. Raval
DEPARTMENT OF ELECTRICAL ENGINEERING
INSTITUTE OF TECHNOLOGY
NIRMA UNIVERSITY
Ahmedabad 382481
May 2019

I | S c h o o l o f E n g i n e e r i n g , N i r m a U n i v e r s i t y , A h m e d a b a d
INSTITUTE OF TECHNOLOGY
NIRMA UNIVERSITY
DEPARTMENT OF ELECTRICAL ENGINEERING
Ahmedabad 382481
CERTIFICATE
THIS IS TO CERTIFY THAT THE MINI PROJECT-II REPORT ENTITLED “SIMULATION AND ANALYSIS
OF CONVERTERS FOR ELECTRIC VEHICLES” SUBMITTED BY MR. MAYANK ACHARYA
(16BEE005) & MS. AAKANSHA JHA (16BEE001) TOWARDS THE PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR THE AWARD OF THE DEGREE IN BACHELOR OF TECHNOLOGY (ELECTRICAL
ENGINEERING) OF NIRMA UNIVERSITY IS THE RECORD OF WORK CARRIED OUT BY HIM/HER
UNDER MY/OUR SUPERVISION AND GUIDANCE. THE WORK SUBMITTED HAS IN OUR OPINION
REACHED A LEVEL REQUIRED FOR BEING ACCEPTED
FOR EXAMINATION.
DATE: 06 May, 2019
NAME AND SIGNATURE OF
GUIDE
HOD(EE)

III | S c h o o l o f E n g i n e e r i n g , N i r m a U n i v e r s i t y , A h m e d a b a d
ACKNOWLEDGEMENT
It is our pleasure to be indebted to various people, who directly or indirectly contributed in the
development of this project work and who influenced our thinking, behaviour, and knowledge
during the course of this work.
We would like to express our deep sense of gratitude to our Supervisor, Prof. Chirag H. Raval,
Asst. Prof., Electrical Engineering Department for his valuable guidance and motivation
throughout our study.
We would like to express our sincere respect and profound gratitude to Prof. (Dr.) S. C. Vora,
Professor & Head of Electrical Engineering Department for supporting and providing the
facilities for our project work.
Lastly, we would like to thank the almighty GOD and our parents for their moral support and
blessings, to them we bow in the deepest reverence and our friends with whom we shared our
day-to-day experience and received lots of suggestions that improved our quality of work.
Aakansha Jha (16BEE001)
Mayank Acharya(16BEE005)

IV | S c h o o l o f E n g i n e e r i n g , N i r m a U n i v e r s i t y , A h m e d a b a d
ABSTRACT
This report has covered the simulation and analysis of converters that are used in the movement of
electric vehicles, starting from rectifiers to DC-DC boost converter to an inverter to feed ac power
to the Induction Motor.
The report has also performed calculations for power ratings of all the auxiliaries used by taking
aid of a reference motor, and using typical values of efficiencies. All these help for the right kind
of designing of the converter part during hardware and for also analysing it to get maximum
efficiency for the electric vehicle, and making it work at its rated speed and above quite judiciously.
The platform used for simulation herewith in the report is MATLAB. Using MATLAB, the entire
speed control of the converter circuitry in a closed loop manner is done by incorporating the V/f
method of speed control, it being the most efficient one with high torque capabilities, and ability to
work at constant torque mode as well.

V | S c h o o l o f E n g i n e e r i n g , N i r m a U n i v e r s i t y , A h m e d a b a d
List of Figures
Figure No. Name of the Figure Page no.
1.1 Working of Electric Vehicle 3
2.1 General Configuration of Electric Vehicle 5
2.2 DC-DC Boost Converter for EV 6
3.1 Induction Motor Specifications 8
3.2 Voltage Source Inverter fed Induction Motor 9
3.3 Simulation Circuit of open loop speed control of 3-phase Induction Motor 10
3.4 Induction Motor output speed and torque during open loop control 11
3.5 Simulation Circuit of Closed loop speed control of 3-phase Induction Motor 12
3.6 Induction Motor output speed and torque during closed loop control 14
4.1 Total Harmonic Distortion(THD) of Inverter Output Voltage 16
4.2 Simulation circuit of closed loop control of converters for Electric Vehicles 17
4.3 Simulation circuit of closed loop DC-DC Boost Converter 17
4.4 Simulation circuit of firing circuit for closed loop DC-DC Boost Converter 18
4.5 Simulation circuit of closed loop firing circuit for Inverter 18
4.6 Rectified DC Voltage waveform 19
4.7 Inverter Output Voltage and Current waveform 19
4.8 Reference Speed Signal waveform 20
4.9 Induction Motor output speed and torque waveform 20

1 | S c h o o l o f E n g i n e e r i n g , N i r m a U n i v e r s i t y , A h m e d a b a d
CONTENTS
Acknowledgement III
Abstract IV
List of Figures V
Chapter 1: Introduction to Electric Vehicle Technology 3
1.1 Electric Vehicles 3
1.2 Working of Electric Vehicles 3
1.3 Why Converters in Electric Vehicles? 4
Chapter 2: Converters Employed in Electric Vehicles 5
2.1 General Configuration of Electric Vehicle 5
2.2 Requirements of Converter 6
2.3 Boost DC-DC converter for EVs 6
Chapter 3: Design of Inverter (DC-AC) for Electric Vehicles 8
3.1 Specifications of Reference Car (Mahindra E2O) 8
3.2 Induction Motor Specifications 8
3.3 Voltage Source Inverter (VSI) fed Induction Motor 9
3.4 MATLAB Simulation circuit of Open Loop Speed Control of 3-Phase Induction Motor 10
3.5 Analysis of Open Loop Control Circuit 11

3.6 MATLAB Simulation of Closed Loop Control of Induction Motor 12
3.7 Analysis of the Closed Loop Control of Induction Motor 14
Chapter 4: Simulation of Power Electronic Converters used in Electric Vehicle 15
4.1 Necessary Calculations for the complete circuit of converters in Electric Vehicles 15
4.2 Simulation circuit of Closed Loop Speed Control of Converters for Electric Vehicles 17
4.3 Analysis of Closed Loop Speed Control of Converters for Electric Vehicles 19
Conclusion
21
References 22

Fig. 1.1 Working of Electric Vehicle
Chapter 1: Introduction to Electric Vehicle Technology
1.1 Electric Vehicles
 An electric vehicle, also called an EV, uses one or more electric motors or traction
motors for its propulsion and such a vehicle does not contain an internal combustion
engine like the other conventional vehicles for its application. One of the most critical
issues for the environment today is pollution generated by hydrocarbon combustion,
which is one of the main sources of power for transportation.
 Electric vehicles (EV) are rapidly advancing as alternative power trains for green
transportation. An electric vehicle may be powered through a collector system by
electricity from off-vehicle sources, or may be self-contained with a battery, solar
panels or an electric generator to convert fuel to electricity.
 Electric vehicles are expected to increase from 2% of global share in 2016 to 22% in
2030. Hence, it is important to explore the complete system of an electric vehicle
system for efficient build-up of the entire system.
1.2 Working of Electric Vehicles
1.2.1 Components:
1. Electric Traction Motor - An electric motor provides the necessary power which is
required to rotate the wheels of the vehicle by converting the electrical energy obtained
from the battery and converter circuitry into mechanical energy, thereby given to the

wheels of the vehicle. Motors may be of DC/AC type. However, the AC motors are
more common and mostly Induction Motor is employed in EVs.
2. Electric Battery - The battery in an Electric Vehicle stores the electricity required to
run the vehicle and thereby supplies electric current to the motor. And thus, the vehicle
runs after conversion into mechanical energy by the motor. The higher the capacity of
the battery the higher is the range of the electric vehicle. Hence, any simulation
involves the correct designing of the capacity of the battery. Most modern electric
vehicles use Lithium-ion type batteries. These batteries have higher energy density. It
means they are capable of storing more energy.
3. Power Control Unit -The control unit performs the main task. It controls the activities
of all the components of an electric vehicle. It monitors the output of the motor,
charging of batteries, closed loop controlling of the motor-converter system.
4. Inverter - The current in the battery of an Electric Vehicle is in the form of a DC
current. But, the majority of the motors used in the electric vehicles run on Alternating
Current (AC) or are Ac motors. So, the inverter performs the function of converting
DC to AC for delivering to the motor.
5. Regenerative Braking System - The electric-vehicle has only limited energy
available. This regenerative braking system recovers the energy lost in braking the
vehicle and utilizes it to charge the batteries.
1.3 Why Converters in Electric Vehicles?
The application of power electronic converters in Electric Vehicle is an important aspect for
the designing of an EV system due to the following tasks to be performed:
 In electric vehicles (EVs), two key elements work together to manage power and
recharge the circuits, these critical components being the inverter and the converter.
 Converters are used for executing the process of regenerative braking in EVs.
 Rectifiers (AC-DC converters) convert the ac power into dc power for battery
charging.
 Choppers (DC-DC converters) boost up low voltage sources and step it up to high
voltage for heavy duty work in a high power consumption load, and they can also be
used to step down voltages for light loads.
 Inverters convert the DC power from battery to the AC power as per the motor
specifications.

Fig. 2.1 General Configuration of Electric Vehicle
Chapter 2: Converters Employed in Electric Vehicles
2.1 General Configuration of Electric Vehicle
 Upon examination of the general configuration of an EV, we observe that we have
three main kinds of converters employed for the working of an EV as follows: (a)
Rectifier (AC-DC), (b) Chopper (DC-DC), (c) Inverter (DC-AC).
 When the engine is put into ignition in a vehicle, it first charges the traction battery
pack, which gives a DC output, and to feed this to the following circuit, we employ a
rectifier which converts this DC input into the required AC output. Moving further
into the configuration comes the DC-DC (Boost) Converter which converts the
obtained DC output at the desired higher value or boosted value to be fed to the
inverter which then converts the DC output at desired value from the chopper into the
required AC input for the Induction Motor used in the electric vehicle, and this desired
value is obtained by calculations performed using the Motor specifications.
 The traction motor used here is an induction motor because upon research it is found
that the advantage of induction motors over other motors is that induction motors tend
to be more efficient at high speed and low torque, conditions that represent highway
cruising where many cars accumulate most of their miles.

Fig. 2.2 DC-DC Boost Converter for EV
2.2 Requirements of Converter
For converters to be used in Electric Vehicles, there are certain protocols and requirements
to be fulfilled by them so that can comply and work with the vehicle’s motor and battery
with good efficiency and provide the desired output without much hindrances. These are as
follows:
 Light Weight- The converter should be light in weight so that the entire vehicle weight
does not exceed much and does not become bulky as it has to involve many other
components.
 High Efficiency- Any system is expected to give the best and the highest efficiency
that it can give, and a converter of an EV is expected to give the maximum that it can
give even after having various components involved in its trail.
 Small Volume- So as to give way and space to a compact system.
 Low-Electromagnetic Interference as it can hinder with the system working.
 Low-Current ripple drawn from the battery as it deviates the output from what is
desired and needs to be fed to the motor working.
 Control of the DC-DC converter power flow subject to the wide variation on the
converter input.
2.3 Boost DC-DC converter for EVs
 In electrical engineering, a DC -DC converter is a kind of power electronic converter
and an electric circuit which converts a source of direct current (DC) from one voltage
level to another, as already discussed above, by temporarily storing the energy and
then giving it out at the desired voltage. The storage may be in either magnetic field

storage components (inductors, transformers etc.) or electric field storage components
like capacitors.
 DC-DC converters can be designed to transfer power in only one direction, from the
input to the output. However, almost all DC-DC converter topologies can be made bi-
directional. A bi-directional converter can move power in either direction, which is
useful in applications requiring regenerative braking.
 The amount of power flow between the input and the output can be controlled by
adjusting the duty cycle (ratio of on/off time of the switch). Usually, this is done to
control the output voltage, the input current, the output current, or to maintain a
constant power.
 Transformer-based converters may provide isolation between the input and the output.
The main drawbacks of switching converters include complexity, electronic noise and
high cost for some topologies.
 Each converter topology has its advantages and its drawbacks. For example, The
DC/DC boost converter does not meet the criteria of electrical isolation. Moreover,
the large variance in magnitude between the input and output imposes severe stresses
on the switch and this topology suffers from high current and voltage ripples and also
big volume and weight.
 A basic interleaved multi-channel DC/DC converter topology permits to reduce the
input and output current and voltage ripples, to reduce the volume and weight of the
inductors and to increase the efficiency.
 A full-bridge DC-DC converter is the most frequently implemented circuit
configuration for fuel-cell power conditioning when electrical isolation is required.
The switch used in this converter is mostly an IGBT.
 The full bridge DC-DC converter is suitable for high-power transmission because
switch voltage and current are not high. It has small input and output current and
voltage ripples. The full-bridge topology is a favorite for zero voltage switching (ZVS)
pulse width modulation (PWM) techniques.

Fig. 3.1 Induction Motor Specifications
Chapter 3: Design of Inverter (DC-AC) for Electric Vehicles
3.1 Specifications of Reference Car (Mahindra E2O)
 The specified Mahindra E2O has a lithium-ion battery pack that takes five hours for a
full charge, and delivers a range of 120 km (75 mi) and a top speed of 90 km/h (56
mph).
 Length = 3590mm, Width = 1575 mm, Height = 1585 mm, Ground Clearance = 170
mm, Wheel Base = 2258 mm, Kerb Weight = 932 kg, Gross Weight = 1252 kg
 Successor: Mahindra e2o Plus
 Electric motor: 3 Phase Induction Motor
 Range: 120 km (75 miles)
3.2 Induction Motor Specifications

Fig. 3.2 Voltage Source Inverter fed Induction Motor
3.3 Voltage Source Inverter (VSI) fed Induction Motor
The voltage source inverter is defined as the inverter which takes a variable frequency from
a DC supply. The input voltage of the voltage source inverter remains constant, and their
output voltage is independent of the load. The magnitude of the load current depends on the
nature of the load impedance.
Voltage source inverters are most commonly used in industrial applications like that of speed
control of induction motors. For controlling speed of the induction motor it is necessary to
vary the voltage or frequency, giving rise to the V/F control method for speed control of
Induction Motor. A three phase induction motor is basically a constant speed motor so it’s
somewhat difficult to control its speed. The speed control of induction motor is done at the
cost of decrease in efficiency and low electrical power factor. The advancement of power
electronics has made it possible to vary the speed of induction motor by varying supply
voltage, supply frequency or both as mentioned before.

Fig. 3.3 Simulation Circuit of open loop speed control of 3-phase Induction Motor
3.4 MATLAB Simulation circuit of Open Loop Speed Control of 3-
Phase Induction Motor
The Simulation below involves a 3-phase Induction motor being fed by a Voltage Source
Inverter which gets its input from a battery/super-capacitor.
In order to check the reliability of the system, and also for the hardware implementation of
the circuit, simulations are to be done as shown above. The simulation is that of an open loop
control of the speed of Induction Motor, with IGBT used as the switch for the Inverter and
speed control done using the Pulse Width Modulation technique.

Fig. 3.4 Induction Motor output speed and torque during open loop control
3.5 Analysis of Open Loop Control Circuit

Fig. 3.5 Simulation Circuit of Closed loop speed control of 3-phase Induction Motor
3.6 MATLAB Simulation of Closed Loop Control of Induction
Motor
 The above MATLAB simulation circuit is that of the Closed Loop speed control of
the Induction Motor. Here, the control is done by the V/F control method. This method
involves the speed control being done from the stator side of the motor.
 Whenever three phase supply is given to a three phase induction motor, Rotating
Magnetic Field is produced which rotates at synchronous speed given by,
 In three phase induction motor, emf is induced by induction in a similar way to that of
a transformer which is given by,

Where, K is the winding constant, T is the number of turns per phase and f is frequency.
 Now if we change the frequency, synchronous speed changes but with decrease in
frequency, flux will increase and this change in value of flux is capable of leading to
the saturation of rotor and stator cores which will further lead to an increase in no load
current of the motor.
 So, it is important to maintain flux, φ constant and it is only possible if we change
voltage, that is if we decrease frequency, flux increases but at the same time if we
decrease voltage, flux will also decrease, hereby causing no overall change in the flux
and hence it remains constant. So, here we are keeping the ratio of V/f as constant.
Hence its name is V/ f speed control method.
 For controlling the speed of three phase induction motor by V/f method we have to
supply variable voltage and frequency which is easily obtained by using converter and
inverter set as shown in the above simulation. The final output obtained at the
Induction Motor gives us speed, which in Closed Loop is required to be fed back to
the error control circuitry, and it controls the speed by the V/f method, rectifies it and
hence, desired speed control is obtained.

Fig. 3.6 Induction Motor output speed and torque during closed loop control
3.7 Analysis of the Closed Loop Control of Induction Motor
Here, in closed loop control, the reference speed is given as 800 rpm and output of the motor
is also 800 rpm which satisfies the closed loop speed control of Induction Motor.

Chapter 4: Simulation of Power Electronic Converters used
in Electric Vehicle
4.1 Necessary Calculations for the complete circuit of converters in Electric
Vehicles
For making the simulation and analysis of the converters as discussed and as shown in the
simulations in the previous chapters, we need to calculate necessary and important
parameters of the various converters used out here. We will find the Input and Output powers
of each converter, making use of assumed efficiencies of typical values.
Also, we have taken the typical values of capacitor, inductance and that of switching
frequency present on the dc-dc boost converter side, in the simulation as follows:
1. C = 5oo μF
2. L = 1 mH
3. Fs = 5000 Hz
These values can be referred from the datasheets of the IGBT being used in the Inverter.
Since, it is true that theoretically calculated values do not always comply with the practical
values, the below calculated values might differ from what is desired in practical scenarios;
Now, taking reference from the motor used above, we have;
 Output of Motor = 10hp = 7.5kW
As per the data taken for the 3-phase Induction motor to be used in the e-vehicle,
 Motor efficiency = 88%
 Input Real power to motor = (7.5/0.88) = 8.523kW = Output of the Inverter
Here we have assumed the inverter efficiency to be around 90%, which is its typical value;
 Input to the Inverter = (8.523/0.90) = 9.47kW = Output of DC-DC boost converter
Having assumed the typical value of efficiency for DC-DC boost converter as 85%;
 Input of the DC-DC converter = (9470/0.85) = 11.124kW
 Input of DC-DC converter = Output of the Rectifier = 11.124kW
Having assumed the typical value of efficiency of rectifier as 90%;
 Input to the Rectifier = (11124/0.90) = 12.360kW = Input from Supply
 Efficiency of the complete circuit = (7500/12360) = 60.6%
The obtained efficiency is a bit low because of the power losses created in all the converters.
The power electronics of EVs and HEVs must be design to handle the worst condition. An
example may be going up steep hill in hot day with an overloaded vehicle.
As a consequence, almost all EVs and HEVs are liquid cooled; it enables absorption of the
heat at the source and transfers it to a spot where it can be harmlessly released. In the case

Fig. 4.1 Total Harmonic Distortion(THD) of Inverter Output Voltage
of HEV, it is a benefit if the cooling system is shared by both, the ICE and power electronics.
High level integration is the key to the success.
Efficiency of the power electronics determine the distance which the vehicle may travel per
a given charge. The overall system design is always an engineering compromise. It is always
possible to increase the efficiency but it may price the vehicle out of the market.
 Total Harmonic Distortion (THD) factor measures the amount of waveform power
distortion caused by harmonics in a power electronic circuit. It is basically the ratio of
the power of all the harmonics present in the waveform, with the power in the
fundamental frequency. The THD measures the nonlinearity of a system, while
applying a single sinusoidal to it. The sinusoidal, when applied to a nonlinear system,
will produce an output with the same fundamental frequency as of the sinusoidal input,
but will also generate harmonics at multiples of the fundamental frequency. The same
is found here for the Inverter Output Voltage in the simulation as follows;

Fig. 4.2 Simulation circuit of closed loop control of converters for Electric Vehicles
Fig. 4.3 Simulation circuit of closed loop DC-DC Boost Converter
4.2 Simulation circuit of Closed Loop Speed Control of Converters
for Electric Vehicles
The MATLAB simulation shown below (Fig. 4.2) is the final circuit to be employed
consisting of all the major converters to be used at define values, allowing a flow of power
from the source to the load, which will be fed to the Induction Motor, and thereby having the
necessary speed control of V/f employed out here.
The simulation of MATLAB shown above has certain subsystems made, the below circuit
(Fig. 4.3) is that of the closed loop boost DC-DC converter;

Fig. 4.4 Simulation circuit of firing circuit for closed loop DC-DC Boost Converter
Fig. 4.5 Simulation circuit of closed loop firing circuit for Inverter
The firing circuit control of this closed loop boost DC-DC converter is as follows below
(Fig. 4.4).
Next, there is the Inverter connected who is getting its input from the DC-DC converter with
a boosted value of DC voltage, and since this circuit also needs a closed loop control, the
subsystem of the closed loop firing control circuit of the Inverter in the MATLAB simulation
is as follows (Fig. 4.5).

Fig. 4.6 Rectified DC Voltage waveform
Fig. 4.7 Inverter Output Voltage and Current waveform
4.3 Analysis of Closed Loop Speed Control of Converters for
Electric Vehicles
The below analysis have all the necessary waveforms which were given as inputs and
consequently obtained outputs from all connected auxiliaries,
1. Rectified DC voltage:
2. Inverter Output Voltage and Current:

Fig. 4.8 Reference Speed Signal waveform
Fig. 4.9 Induction Motor output speed and torque waveform
3. Reference Speed Signal:
The simulation will undergo a speed of 500 rpm from 0-5 seconds, followed by 1000 rpm
for the next 5 seconds, and then a speed of 1500 rpm will be achieved for the next 5 seconds.
4. Motor Output Speed and Torque
Here, we have given the reference signal for speed as per given in the fig. 1 and the obtained
speed of the Induction Motor is shown in the above simulation curve along with the
Electromagnetic torque (rated value) whose value was calculated by;
⇒ P= (2*pi*N*T)/60 = (2*pi*1440*T)/60 = 7500W
Therefore, we get the rated torque, T = 50N-m; (Here, 1440 rpm is the rated speed of motor.)

Conclusion:
Electric Vehicles have made way for the future of commuting, transportation and other
traction related activities owing to its greater advantages over the conventional fuel driven
vehicles. And in such a scenario, it becomes important to design the right kind of components
and auxiliaries to be used in its designing, be it that of the induction motor to be used, the
battery pack to be used, the power electronic converters to be used etc.
This report dealt with the designing, simulation and analysis of power electronic converters
used in the traction of electric vehicles to drive the induction motor that has been used. It
deals with the simulation of rectifier, which is followed by the DC-DC boost converter,
followed by the Inverter to give the Input AC power to the Induction motor.
It can be concluded that for the motor of the vehicle to work desirably, proper speed control
techniques in closed loop control mode has to be employed, and the simulation made here
incorporates the Variable Frequency Control method for the same due to its high torque
capabilities and constant torque mode operation, and efficient speed control. Using a
reference motor, the report has also performed necessary calculations of input and output
powers of the converters to define the power ratings of the same. The analysis part includes
the necessary waveforms obtained after performing the simulation. The simulation ran quite
successfully for the rated speed and power rating of the induction motor that had been used
in the simulation. Also, now taking reference from the simulation that has been made,
appropriate hardware implementation can be made to design the complete converter circuit
for use in electric vehicles.

References:
1. Reference book of Power Electronics by M H Rashid
2. Reference book of Fundamentals of Electric Drives by Gopal K. Dubey
3. Reference book of Modern power electronics and AC drives by Bimal K. Bose
4. Kirloskar Brothers Ltd. Motor Catalogue (For the reference motor)
5. https://www.e-education.psu.edu/eme812/node/738 (For Inverter efficiency
reference)
6. Efficiency calculation of DC-DC Converters (ResearchGate)
(For DC-DC boost converter efficiency reference)
7. Performance verification of parametric average-value model of line-commutated
rectifiers under balanced conditions (IEEE: Institute of Electrical and Electronics
Engineers | INSPEC Accession No: 15432069 | pISSN: 1093-5142)
(For Rectifier Efficiency reference value)

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