Abstract

This paper presents a battery-aware control framework for a single-phase integrated battery charger (IBC) for electric vehicles, in which the traction system is reused as part of the charging hardware. The proposed charger consists of a stator-assisted bridgeless totem-pole power-factor-correction AC–DC stage and a bidirectional buck–boost DC–DC stage connected to a 48 kWh, 400 V lithium-ion battery pack. The battery pack is modeled using a lookup-table-based equivalent circuit model with state-of-charge- and temperature-dependent open-circuit voltage and impedance parameters. A conventional double-loop PI controller is used as the baseline, while the proposed strategy combines nonlinear model predictive control, an extended Kalman filter, and lookup-table-based battery parameterization to regulate charging current under electrical and thermal constraints. The system is evaluated under 7 kW, 230 V/32 A and 22 kW, 230 V/96 A charging cases using average-model simulations, switching-model transient simulations, and finite element thermal assessment of the induction motor stator. The average-model results show stable charging from 20% to 80% SOC, with charging times of approximately 275 min at 7 kW and 90 min at 22 kW. The EKF provides bounded battery state estimation, with maximum SOC estimation errors of approximately 1.3% and 2.0% for the 7 kW and 22 kW cases, respectively, while the core-temperature estimation error converges close to zero. The switching-model results confirm feasible duty-command behavior, bounded battery-current tracking error, and a representative DC-link ripple of approximately 8 Vpp. During grid-voltage reduction, the charging current is reduced to keep the grid-current envelope within the intended limit. FEM results show that charging-only motor temperatures remain low, reaching approximately 27.39 °C at 7 kW and 38.82–38.85 °C at 22 kW. The most critical charging-related thermal case occurs at 22 kW after one hour of full-load motor operation with a 40 °C initial condition, reaching approximately 92.32 °C. Overall, these simulation-based findings support the feasibility of the proposed NMPC–EKF–LUT framework as a battery-aware supervisory control strategy for single-phase IBC operation. The proposed controller improves constraint-aware, battery state-based decision-making, while switching ripple and motor thermal response are mainly governed by the power stage, feasible current trajectory, and initial thermal condition.

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