Development of Electric Vehicle Charger

Submitted by:
2021-FYP-10
MUHAMMAD SOHAIL TAHIR 2021-EE-027
NAZEER HUSSAIN 2021-EE-045
MUHAMMAD UMER GONDAL 2021-EE-078
IJLAL BAJWA 2021-EE-183

Supervised by: Prof. Umer Shami

Department of Electrical Engineering

University of Engineering and Technology Lahore
Contents

List of Figures iii

List of Tables iv

Abbreviations v

Abstract vi

1 Introduction 1
1.1 Challenges in the Problem Area . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Refining the Challenge into a Concise Statement . . . . . . . . . . . . . . 2

2 Problem Statement 3
2.1 Unmet Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Significance of the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Quantifying the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Target Customers and Market Size . . . . . . . . . . . . . . . . . . . . . . 4
2.4.1 Individual EV Owners . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4.2 Commercial Fleet Operators . . . . . . . . . . . . . . . . . . . . . 4
2.4.3 EV Charging Station Operators . . . . . . . . . . . . . . . . . . . . 4
2.4.4 Automotive Manufacturers . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Scope of the Research Problem . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Literature Review 6
3.1 Existing Solutions in the Market . . . . . . . . . . . . . . . . . . . . . . . 6
3.1.1 Level 1 and Level 2 Chargers . . . . . . . . . . . . . . . . . . . . . 6
3.1.2 DC Fast Chargers (Level 3) . . . . . . . . . . . . . . . . . . . . . . 6
3.1.3 Wireless Inductive Chargers . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Disadvantages of Existing Solutions . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Literature Review of the State-of-the-Art Solutions . . . . . . . . . . . . . 7

4 Project Overview and Objectives 9

4.1 Proposed Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Value Proposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2.1 Enhanced Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2.2 Improved Battery Lifespan . . . . . . . . . . . . . . . . . . . . . . 10
4.2.3 Universal Compatibility . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2.4 Cost-Effective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

i
Contents ii

4.2.5 Grid Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.3 Final Project Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Proposed Research is Better Than the State-of-the- . . . . . . . . . . . . 11
4.5 Project Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5 Project Development Methodology/Architecture 12

5.1 Photovoltaic (PV) Module Integration . . . . . . . . . . . . . . . . . . . . 12
5.2 Design and Implementation of the DC-DC Converter . . . . . . . . . . . . 12
5.3 Development of Bidirectional DC Converter . . . . . . . . . . . . . . . . . 12
5.4 Rectifier Design for Grid Power Conversion . . . . . . . . . . . . . . . . . 13
5.5 Pulse Width Modulation (PWM) Control . . . . . . . . . . . . . . . . . . 13
5.6 Microcontroller Unit (MCU) Integration and Control Algorithm . . . . . . 14
5.7 Testing and Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.8 Grid Integration and Final Assembly . . . . . . . . . . . . . . . . . . . . . 15

6 Project Milestones and Deliverables 16

7 Block Diagram 18

8 Flow Chart 20

9 Work Division 21

10 Costing 22

References 23
List of Figures

5.1 Bi-directional dc-dc converter . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.2 Electromagnatic Interference . . . . . . . . . . . . . . . . . . . . . . . . . 14

6.1 Project gantt chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6.2 Project gantt chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7.1 Project Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.2 Ev charger circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8.1 Project Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

iii
List of Tables

9.1 Work Division . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

10.1 Costing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

iv
Abbreviations

SOC State Of Charge

AAL Automotive Approach Layer
ICE Internal Combustion Engine
IEA International Energy Agency
SIC SIlicon Carbide
SCA Smart Control Algorithms
MCP Multi-stage Charging Process
APM Advanced Protection Mechanisms
EMI Electromagnatic Interface
PWM Pulse Width Modulation
MCU Micro Controller Unit

v
 Abstract
With the world trying to push more EVs out into the market, both from new and old
brands making a shift in fundamental direction with their vehicles, efficient charging
systems are now vital for widespread adoption of EV transport. What is one of the
biggest challenges for EVs – rapid, efficient and safe power to charge them safely across
different battery chemistries and electrical grid systems around the world? Here is an
advancement of charger circuit design and development to fulfill all needs for electric
vehicle(Specificaly focus on energy efficiency, low cost, more safty features. . . .) The
hardware of the charger circuit will involve a smart control system to manage the charg-
ing with proper power transfer and with minimum energy wastage. Utilizing the latest
power electronics components, such as MOSFETs and IGBTs in combination with this
architecture is designed for improved asymmetrical three-level InverterDynamics which
leads to better power conversion efficiency and overall performance. Additionally, the
charger will feature comprehensive protection functions including overvoltage, overcur-
rent, short-circuit and thermal overload protections that will extend both device lifetime
and vehicle safety. It has a multiple charger algorithm, one of the key innovations in
this project. With the help of this advanced algorithm, The charging current will adapt
dynamically as per SOC Etch using data from temperature and humidity sensors etc.
This does not only quicken the charging duration, but also lessens battery degradation
leading a longer lifespan of the battery. The charger circuit will also have communication
capabilities built in, meaning that the whole thing can be integrated into an automotive-
approach layer (AAL), for seamless interfacing with both grid and energy management
systems. It allows for load balancing, connection to renewable energy sources (such as
solar power) and optimization of off-peak charging to decrease the price of electricity.
The charger circuit undergoes simulation and then prototype testing to achieve real per-
formance in terms of power efficiency, thermal management, charging time as well as
safety during operation. This charging solution is intended to constructively intervene in
the emerging EV infrastructure and provide a sustainable, scalable & feasible alternative
for future-generation Electric transportation requirements.
Chapter 1

Introduction

The global transition towards electric vehicles (EVs) is accelerating rapidly due to in-
creasing concerns about environmental sustainability, rising fuel costs, and the depletion
of fossil fuels. Governments and industries worldwide are pushing for greener solutions,
with electric vehicles emerging as a promising alternative to traditional internal combus-
tion engine (ICE) vehicles. While EVs offer several advantages, such as zero emissions
and reduced dependency on fossil fuels, one of the major challenges slowing down their
widespread adoption is the availability of efficient and reliable charging infrastructure.
At the heart of this infrastructure is the charger circuit, a critical component that en-
sures the safe and efficient delivery of energy to the vehicle’s battery. As the EV market
grows, so does the demand for charger circuits that can handle high power loads, operate
efficiently across different environments, and ensure the safety and longevity of both the
charger and the vehicle’s battery.

1.1 Challenges in the Problem Area

Despite the advancements in EV technolog y, the development of an optimal charger
circuit presents several technical and operational challenges. A key issue lies in bal-
ancing the need for fast charging with the requirement to protect the vehicle’s battery
from overheating, overcharging, or degrading too quickly. Currently, many traditional
charging circuits struggle to meet the demands for efficiency, safety, and compatibility
with different types of EV batteries, which vary by vehicle manufacturers. Moreover,
the process of converting alternating current (AC) from the power grid to direct current
(DC) required by the vehicle’s battery involves energy losses, which reduce the overall
efficiency of the charging system. As EV batteries grow in size and capacity, manag-
ing these losses becomes even more critical to ensure fast, efficient charging without
excessive heat generation. Additionally, different EVs have varying battery capacities
and charging protocols, meaning a universal charging circuit must be adaptable to these
differences while maintaining high performance. Safety concerns also arise during the
charging process. Faulty circuits or substandard designs can lead to overvoltage, short

1
Abbreviations 2

circuits, or thermal issues, all of which can compromise the safety of the user, the vehi-
cle, and the charging infrastructure. Hence, designing a robust protection system that
safeguards the entire charging process is essential.

1.2 Refining the Challenge into a Concise Statement

Given the complexities surrounding EV charging infrastructure, the primary challenge
can be refined into the following concise statement: The development of a highly effi-
cient, adaptable, and safe charger circuit for electric vehicles, capable of delivering fast
charging without compromising battery life, system efficiency, or safety, remains a criti-
cal bottleneck in the widespread adoption of electric vehicles[1]. This challenge revolves
around the need to design a charger circuit that not only optimizes the charging process
in terms of speed and energy efficiency but also incorporates smart control systems and
protection mechanisms to ensure long-term reliability and compatibility with evolving
EV technologies. Addressing these issues will contribute significantly to the overall fea-
sibility and scalability of the EV industry, supporting its growth and addressing global
environmental goals.
Chapter 2

Problem Statement

The widespread adoption of electric vehicles (EVs) is a critical step towards reducing
global carbon emissions, improving air quality, and lessening dependency on fossil fuels.
However, a significant barrier to this adoption lies in the current limitations of EV
charging infrastructure, particularly in the efficiency and reliability of charger circuits.
Existing EV charger designs struggle to balance the demands for fast charging, battery
safety, and energy efficiency. These challenges are compounded by the fact that EV
batteries vary in size, chemistry, and charging protocols, making it difficult to develop
a universal charging solution that meets the diverse needs of different EV models.

2.1 Unmet Need

The primary unmet need addressed by this project is the development of a highly efficient
and adaptable charger circuit capable of delivering fast, reliable, and safe charging for
electric vehicles without sacrificing the longevity of the battery. The current market faces
critical gaps in charging technology, with many chargers experiencing energy losses, slow
charging speeds, and safety risks such as overcharging and thermal issues. This unmet
need is especially pressing as EV ownership increases globally, creating a demand for
charging infrastructure that can scale up to meet this growth.

2.2 Significance of the Problem

The significance of the problem becomes clear when considering the exponential growth
of the EV market. According to the International Energy Agency (IEA), the global
stock of EVs surpassed 10 million units in 2022 and is projected to reach 145 million
units by 2030[8]. Despite this growth, one of the key reasons for range anxiety (the fear
that a vehicle will run out of power before reaching a charging station) is the inefficient
and limited charging infrastructure. Charger circuits that can deliver high-efficiency
power, reduce charging times, and ensure battery safety are essential to overcoming
these concerns.

3
Abbreviations 4

2.3 Quantifying the Problem

In terms of market impact, slow or inefficient charging systems result in extended down-
time for EVs, which is a major inconvenience for users and fleet operators alike. For
example, fast chargers can currently recharge an EV to 80% in approximately 30 min-
utes, but inefficient circuits extend this time, potentially limiting the widespread use
of EVs. Moreover, energy losses during the AC-to-DC conversion process can lead to
wasted power, which, when scaled up to millions of charging sessions globally, repre-
sents a significant energy inefficiency challenge. If these inefficiencies are not addressed,
EV adoption may stagnate, impacting global efforts to reduce emissions and achieve
sustainable transportation goals.

2.4 Target Customers and Market Size

The potential market for an improved charger circuit includes several key customer
groups:

2.4.1 Individual EV Owners

As of 2022, over 10 million EVs were on the road globally, and this number is growing
rapidly. EV owners represent a large and expanding market for fast, efficient, and safe
charging solutions. Their need is driven by convenience (faster charging times) and
long-term cost savings (reduced energy losses and battery degradation).

2.4.2 Commercial Fleet Operators

Companies using EVs for logistics, delivery services, and ride-sharing (e.g., Amazon,
UPS, and Uber) rely on fast-charging infrastructure to keep their vehicles operational.
The potential market for fleet operators is significant, with projections suggesting the
electric fleet market will be valued at $14 billion by 2030. These operators need reliable
chargers that minimize downtime and operational costs.

2.4.3 EV Charging Station Operators

The demand for public charging stations is rising, with the number of stations expected
to grow from 1.3 million in 2021 to 12.7 million by 2030[8]. Charging station operators
need adaptable charger circuits to accommodate various vehicle models, ensuring uni-
versal compatibility, fast charging, and low energy wastage. This market is crucial for
expanding the public charging network, which is essential to EV adoption.

2.4.4 Automotive Manufacturers

As EV production increases, automakers such as Tesla, Nissan, and Volkswagen seek to
integrate advanced charging technologies directly into their vehicle ecosystems. Partner-
ing with automakers provides opportunities to integrate the charger circuit into next-
generation EVs, helping to ensure faster, more efficient charging for their customers.
Abbreviations 5

2.5 Scope of the Research Problem

From a research perspective, the development of an efficient charger circuit involves ad-
dressing several technical challenges, including optimizing power conversion efficiency,
managing thermal output, and incorporating adaptive charging protocols that can re-
spond dynamically to different battery states and environmental conditions[5]. The
scope of this research extends to the integration of smart control systems and advanced
protection mechanisms, ensuring that the circuit can operate safely under diverse con-
ditions while minimizing energy losses.
Chapter 3

Literature Review

As electric vehicles (EVs) become more prevalent, the demand for efficient and reliable
charging solutions has grown substantially. The transition to EVs is heavily reliant on
the development of charging systems that can meet the diverse needs of users, from
fast-charging capabilities to energy-efficient solutions. Numerous attempts have been
made to address these challenges, with various charger designs and technologies already
available on the market. However, each of these solutions comes with its own set of
limitations, which motivates ongoing research and development in this area.

3.1 Existing Solutions in the Market

Here are some following existing solutions in market:

3.1.1 Level 1 and Level 2 Chargers

Most residential and commercial EV chargers on the market fall into the Level 1 and
Level 2 categories. Level 1 chargers use standard household outlets, providing 120V
AC charging, which is extremely slow, typically taking 8-12 hours to fully charge a
vehicle. Level 2 chargers operate on 240V AC and are faster, but still require 4-6 hours
to charge an EV battery. While these chargers are simple and widely used, their major
disadvantage is the long charging time, which is not ideal for daily users who need a
quick turnaround[3].

3.1.2 DC Fast Chargers (Level 3)

DC fast chargers are more advanced than Level 1 and 2 chargers, delivering high-power
direct current (DC) directly to the EV battery. These chargers can reduce charging times
significantly, often to 30 minutes or less for an 80% charge. While DC fast chargers are
used in public stations and are vital for long-distance travel, they come with significant
disadvantages. The high cost of installation, increased energy losses during the AC-to-
DC conversion process, and the potential for battery degradation due to rapid charging
are major concerns. Moreover, the limited availability of DC fast chargers and the need
for grid upgrades to support high power draw are further drawbacks.

6
Abbreviations 7

3.1.3 Wireless Inductive Chargers

Another solution that has gained attention is wireless inductive charging, which elim-
inates the need for cables by using electromagnetic fields to transfer energy. While
convenient, this technology is still in its early stages and suffers from low energy effi-
ciency and high costs. Inductive chargers can only transfer about 85% [5]of the energy
compared to traditional wired systems, leading to higher power consumption and slower
charging times. Additionally, this method requires precise alignment between the vehicle
and the charger, which can be inconvenient.

3.2 Disadvantages of Existing Solutions

While the above solutions have made strides in improving the EV charging experience,
they still face several challenges:

• Efficiency Losses: Many current charger systems experience significant energy

losses, especially during AC-to-DC conversion, which reduces overall charging ef-
ficiency and increases electricity costs for users.

• High Installation Costs: Advanced systems like DC fast chargers require expen-
sive infrastructure and grid enhancements, making them impractical for widespread
use, especially in residential areas.

• Battery Degradation: Fast charging, while convenient, can lead to battery

degradation over time due to the high power and heat generated during the process.
This shortens the overall lifespan of EV batteries, leading to increased maintenance
and replacement costs.

• Limited Compatibility: Existing chargers often lack adaptability to different

types of EV batteries, which vary by manufacturer. The need for standardized
charging protocols is still a critical issue.

• Safety Risks: Many chargers lack sufficient protection mechanisms such as over-
current, overvoltage, and thermal protection, which poses risks to both the EV
and the charging system.

3.3 Literature Review of the State-of-the-Art Solutions

To address these limitations, ongoing research has explored new designs and technologies
to improve charger circuits for electric vehicles. Recent studies have focused on enhanc-
ing charging efficiency, safety, and compatibility while reducing costs and environmental
impact[7]. Below is a review of some of the latest research papers in this field:

• Zhang et al. (2023) explored the development of a bidirectional charger using SiC
MOSFETs to increase efficiency. The system demonstrated an improvement in
Abbreviations 8

energy conversion efficiency by 5-7% compared to traditional silicon-based designs,

though cost remains a barrier to widespread adoption.

• Khan and Gupta (2023) focused on the use of adaptive control algorithms in
fast chargers. Their research showed that dynamically adjusting the charging
current based on the state of charge (SOC) can reduce battery degradation by
15%, extending battery life while maintaining fast charging speeds.

• Liu et al. (2022) studied wireless inductive charging systems and proposed a
method to increase efficiency by using resonant inductive coupling. While their
system improved energy transfer efficiency to 90%, installation and operational
costs remain high, limiting practical application.

• Park et al. (2022) analyzed the integration of renewable energy sources like solar
power into EV charging stations. Their hybrid charging station design reduced grid
dependency by 25% and showcased the potential of combining renewable energy
with smart grid systems for sustainable EV charging.

• Gao et al. (2022) developed a modular charger design that can adapt to different
battery types and power levels. Their research highlights how modularity can
increase compatibility across various EV models and reduce the need for multiple
charging standards.

• Chen and Wang (2023) investigated thermal management systems integrated into
fast chargers. Their system reduced heat buildup by 30%, significantly improving
the safety and efficiency of high-power charging systems.
Chapter 4

Project Overview and Objectives

The expansion of EVs usage has raised awareness about the specific and highly impor-
tant issues of charging system infrastructure reliability, efficiency, and safety. Though
there are numerous charging solutions available in the current market, they all come
with certain restrictions like charging current, efficiency, or battery safety, etc. Such
problems lead to the increased charging time, energy conversion losses and reduced
battery lifespan, which has been a key factor inhibiting the uptake of EVs. The pur-
pose of this project is to design an enhanced charger circuit for electric vehicles which
overcomes these constraints but is compatible with various battery types in EVs and
increases system reliability. To achieve these objectives, this project shall endeavor to
develop and integrate a high-power charger circuit that can effectively minimize energy
losses and charging time, and prevent overcharging, over-heating and other related risks
facing the EV battery. With the implementation of smart control algorithms, protection
techniques, and power conversion features, the proposed solution attempts to provide a
next generation charger circuit solution that meets and even surpasses the current state
of the art.

4.1 Proposed Solution

The solution that I propose is an intelligent and self-morphing charger circuit with state
of the art power electronics and control techniques for the charging of EVs and which
offers optimum efficiency and safety. The charger circuit will feature:

• Smart Control Algorithms: Dynamically adjust charging current and voltage

based on the real-time state of charge (SOC) of the battery, ensuring fast and
efficient power delivery without risking battery degradation[4].

• Multi-Stage Charging Process: This means that charging should be done in

stages; high levels of power should be charged during the initial charging process,
then lower levels should be charged as the battery gets to full charge to prevent
straining of the battery.

9
Abbreviations 10

• Advanced Protection Mechanisms: Use overcurrent, over-voltage, thermal

over- load, short circuit protection methods to that the charger is protected to
work safely in all situations.

• High-Efficiency Power Conversion: Implement the MOSFETs or SiC-based

power converters for minimising the energy loss encounter during the AC to DC
conversion and therefore enhancing the normal charging efficiency[12].

4.2 Value Proposition

The proposed charger circuit offers several advantages over existing charging solutions:

4.2.1 Enhanced Efficiency

The efficiencies achieved by the use of power Electronics and improved conversion process
in the proposed solution decreased the energy losses by 10 to 15% this enable rapid
charging and lower charges to the end user.

4.2.2 Improved Battery Lifespan

The utilization of multi-stage charging algorithms guarantees the battery receives ap-
propriate charging without overcharging or subjecting the battery to thermal stresses.
It also assists in cutting battery down time by 3/4 and hence increase the battery life
by 15-20% to cover for most of the maintenance and replacement bills.

4.2.3 Universal Compatibility

In addition, the charger circuit is made to be flexible and compatible with other forms
of EV batteries and charging standards to support many vehicles’ brands including
passenger and commercial vehicles.

4.2.4 Cost-Effective
The concept of smart control and protection thus reduces tremendously the Improve ‘s
costs for grid modifications which enhances the profitability of the solution in residential
and commercial charging station implementations.

4.2.5 Grid Integration

The charger shall include communication interface to allow the charger to talk to energy
management systems or the grid for demand side management and load balancing thus
helping curtailing peak energy demand which has implications on energy stability.

4.3 Final Project Output

The last and the culmination of this project will yield a working charger circuit model
type that can be implemented in charging stations for electric autos or even in home
charging systems. The charger circuit will consist of both hardware and software com-
ponents, with the following key features:
Abbreviations 11

• Hardware Components:Power Conversion Unit: Except for the power electron-

ics to convert the AC power extracted from the grid into the DC power that charges
the EV battery; MOSFETs, SiC transistors, and other components. Equipping
a microcontroller for real-time supervision and control over the charging process,
SoC estimation, faults, and protection systems[11]. Composite cooling systems to
avoid thermal issues in cases of high power charging in the proposed electric cars
to operate in different climate conditions.

• Software Components:As developed software will be used, multiple-stage charg-

ing algorithms will be employed to ensure efficient delivery of power and also to
avoid overloading the battery.A simple interface to check the status of charging,
battery consumption, and overall health of the battery at a real-time.To allow com-
munications with the grid or management of smart systems for load and renewable
energy management.

The project will also incorporate a proper packaging design that covers the charger circuit
in a compact, durable and portable ways suitable for outdoor and indoor applications.

4.4 Proposed Research is Better Than the State-of-the-

Compared to existing solutions, the proposed charger circuit offers several key improve-
ments.By employing the latest SiC-based converters and optimizing the charging pro-
cess, the proposed circuit offers superior energy efficiency, significantly reducing power
losses.With the new multi-stage charging algorithm, further protection of the battery
from overcharging will be achieved, and thus the battery’s life will be lengthened.Some
of the protection systems include, and the charger shall meet and or exceed the current
charger solutions in terms of safety aspects such as overvoltage protection, overcurrent,
and an onboard temperature sensor that will trigger a warning: Beep and flashing LEDs
in case they are detected.The proposed solution is scalable, thus the solution can fit both
residential as well as commercial charging station applicable for the growing market of
electric vehicles.

4.5 Project Objectives

Research and design an enhanced electrical circuit for an advanced EV charger to accom-
plish a fast charging efficiency power conversion without damaging the battery.Likewise,
integrate an efficient charging model that takes into account, the different stage charge
regarding the state of charge in order to minimize the battery degradation and energy
loss.The general safety factors researched for inclusion incorporated into the charger cir-
cuit should be effective with respect to environmental and electrical changes.The product
development should create a prototype that works effectively irrespective of the battery
type in EVs and charging standards in the market[10].
Chapter 5

Project Development
Methodology/Architecture

5.1 Photovoltaic (PV) Module Integration

The initial step of the method adopted entails choosing and enhancing photovoltaic or
PV modules as the principal input power. While these modules are similar to those of a
typical solar photovoltaic power plant, they function to convert sunlight directly to direct
current (DC) electricity. First, we determine the power demands of the EV battery and
identify suitable PV modules that can adequately serve this power demand. Simulation
tools are employed to evaluate performance characteristics of the PV modules in different
lighting and environmental conditions in order to achieve maximum productivity[9].

5.2 Design and Implementation of the DC-DC Converter

After the PV modules have produced direct current power, this has to be converted to
the correct voltage required in charging an EV battery. A DC-DC converter is intended
to regulate the output voltage and transform it either to increase or to decrease. The
methodology includes:

• Selecting the suitable converter topology (e.g., buck, boost, or buck-boost con-
verter) based on input and output voltage requirements.

• Simulating the converter circuit using software tools like MATLAB/Simulink or

PSpice to ensure stable output voltage.

• Developing the hardware circuit and testing its real-time performance, ensuring
proper voltage regulation.

5.3 Development of Bidirectional DC Converter

During this phase, a bi-directional DC converter is incorporated to support both, which
is needed for example in V2G mode. The converter enables energy to be supplied from
12
Abbreviations 13

Figure 5.1: Bi-directional dc-dc converter

the PV modules or utility to the EV battery during charging and from the battery to
the utility during discharging. Key steps include:

• Specifying the right bidirectional converter topologies that best serve the power
levels required.

• Challenging the seamless and effective utilization of charging and discharging pro-
cesses of the converter.

• Connecting a control signals from microcontroller to charge storage and discharge

operation perfectly[2].

5.4 Rectifier Design for Grid Power Conversion

For the purpose of flexibility in power supply apart of the solar energy the charger circuit
can get power supply from the grid. The use of a rectifier circuit is to convert the AC
received from the grid to DC. The rectifier design process includes:

• Choosing an appropriate rectifier topology (e.g., full-wave or bridge rectifier) based

on the grid’s AC voltage and the required DC output.

• Performing simulations to ensure low ripple and stable DC output.

• The application of an EMI (Electromagnetic Interference) filter in conjunction

with the rectifier circuit to reduce unwanted noise that could in turn interfere with
the output of the circuit.

5.5 Pulse Width Modulation (PWM) Control

The Pulse Width Modulation (PWM) generator IC represents one of the main control
chips to drive the switching of power converters, either for DC to DC or bidirectional.
The methodology includes:
Abbreviations 14

Figure 5.2: Electromagnatic Interference

• Programmatically setting up the PWM generator to output high accurate control

signals to control the duty cycle of the converters for realizing the power conversion.

• Therefore, the study seeks to fine tune the operation of the PWM frequency and
the duty cycle in order to achieve maximum performance under any possible load.

• To check the stability of the control signals the oscilloscopes and power analyzers
were used in conducting the test.

5.6 Microcontroller Unit (MCU) Integration and Control

Algorithm
This MCU is the central control unit for the overall main system. Its functions will
involve controlling power flow from the PV modules, the grid as well as the converters.
The methodology for this phase includes:

• Establishing control strategies to enhance the energy control by directing power

from the PV modules before using the electrical energy from the grid power supply.
Abbreviations 15

• Implementing these algorithms in the MCU, to enable real time decision making
for the change over of energy sources.

• Evaluating MCU functionality using different inputs to exposing it to different

circumstances like changes in solar input and grid power availability.

5.7 Testing and Validation

After all the elements have been developed and incorporated into the whole system, the
subsequent process implies the evaluation of the entire complex. This includes:

• Conducting tests under various operating conditions to ensure the system works
efficiently with both solar and grid power.

• Performing load tests to evaluate the charging time and energy efficiency of the
EV charger.

• Confirming the performance of the system in transitioning from PV power to the

grid power, V2G converted power and vice versa, as a function of testing the
reliability and stability of the system in the real world.

5.8 Grid Integration and Final Assembly

In the last phase, the charger circuit is connected with the grid in order to perform full
operation of the system. This includes:

• Ensuring that the grid-tied system meets all relevant safety standards and electrical
codes.

• To assess grid connection and bidirectional power flow to check on the efficiency
and safety of operation.

• Finalizing the assembly of the complete charging system and preparing it for
deployment[6].
Chapter 6

Project Milestones and

Deliverables

Figure 6.1: Project gantt chart

16
Abbreviations 17

Figure 6.2: Project gantt chart

Chapter 7

Block Diagram

Figure 7.1: Project Block Diagram

18
Abbreviations 19

Figure 7.2: Ev charger circuit

Chapter 8

Flow Chart

Figure 8.1: Project Flow Chart

20
Chapter 9

Work Division

Clear work division among group members must be indicated. (1 page)

Work Name Roll No.

1.fabrication of DC-DC con- Muhammad Sohail Tahir 2021-EE-27
verter,interfacing with PV module
and set up the technical dialogue.
2. Studied about Bi-Directional Nazeer Hussain 2021-EE-045
DC-DC converter and PWM gener-
ator
3. Handled the Microcontroller Unit Umar Gondal 2021-EE-78
(MCU) and EMI filter..
4. Work on the Rectifier and Ijlal Haider 2021-EE-183
Grid Interface configured Ac to
Dc converter

Table 9.1: Work Division

21
Chapter 10

Costing

Component Specifications Estimated Price

(PKR)
Photovoltaic PV (Mod- 100W, Monocrystalline 10,000 - 15,000 per unit
ule)
DC-DC Converter 12V-24V input, 24V 2,000 - 4,000
output, 1kW
Bidirectional DC Con- 24V input/output, 1kW 3,000 - 5,000
verter
Rectifier (AC-DC) Single-phase, Bridge 300 - 700
Rectifier, 10A
EMI Filter Single-phase, 250V AC, 800 - 1,500
6A
Microcontroller Unit ESP32 or Raspberry Pi 150 - 300
(MCU)
Power Cables and Con- Standard DC and AC 1,000 - 2,000
nectors cables
Miscellaneous Compo- Resistors, capacitors, 1,500 - 2,500
nents inductors, diodes, etc.
PWM Generation IC PWM controller, e.g., 150 - 300
SG3525 or equivalent

Table 10.1: Costing

22
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