Experimental study of a DC charging station for full electric and plug in hybrid vehicles

This paper is aimed to analyze design criteria, setting up, control strategies and experimental tests related to a power configuration of DC micro-grid for fast charging,of full electric and plug in hybrid vehicles. The proposed DC fast charging architecture is derived by an analysis comparing the main characteristics of well known architectures, mainly based on AC and DC bus, taking also into account the integration of renewable energy sources (RESs) with stationary energy storage systems and fleets of road electric/hybrid vehicles. On the base of the proposed architecture a laboratory prototype of charging station has been realized by means of a 20 kW AC/DC bidirectional grid tie converter interconnected with two different power DC/DC converters of similar rated power. In this micro-grid architecture the AC/DC converter realizes a conversion stage at 790 V DC, whereas other two converters allow either the electric vehicle battery packs to be charged or an energy storage buffer to save electric energy and support the main grid during the fast charging operations. The laboratory tests described in this paper are mainly devoted to characterize the laboratory demonstrator, in different operative conditions, such as vehicle-to-grid (V2G), charging/discharging operations of different types of storage systems and fast charging operations of road electric vehicles. Then the study of the proposed power conversion architecture is focused on the evaluation of charging/discharging power, efficiency, energy flux management and its impact on the main grid. In addition proper control strategies are evaluated and implemented, allowing the proposed architecture to follow the required operations. The obtained experimental results demonstrate real advantages in terms of charging times and power requirements from the main grid, when adopting DC buffer architecture for fast charging operations. Finally, these results support the identification of a knowledge base, useful to evaluate energy management and control strategies to be adopted for DC charging stations and each one of their power converters in a smart grid scenario with distributed generation systems. (C) 2015 Elsevier Ltd. All rights reserved.