Cascaded multilevel inverter based power and signal multiplex transmission for electric vehicles

Zhang, Yixuan; Chen, Guipeng; Hu, Yihua; Gong, Chao; Wang, Yangang · 2020 · DOAJ

DOI: 10.30941/CESTEMS.2020.00017

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Summary

This paper addresses the inefficiencies in electric vehicle (EV) powertrain architectures, specifically the high switching losses, bulky components, and wiring costs associated with conventional systems that use separate DC/DC boost converters, two-level inverters, and Controller Area Network (CAN) buses for communication. To resolve these issues, the authors propose a Power and Signal Multiplex Transmission (P&SMT) system based on a three-phase cascaded multilevel inverter. This approach integrates power conversion and data communication into a single circuit, eliminating the need for a dedicated CAN bus and a separate DC/DC converter, thereby reducing system cost and complexity while improving power density. The proposed system utilizes a topology where each phase consists of four series-connected H-bridge cells. Three cells are powered by batteries for energy transmission, while one cell is powered by a DC voltage source dedicated to signal transmission. The system employs a combined modulation scheme: Pulse Width Modulation (PWM) handles power conversion and motor speed regulation, while Frequency Shift Keying (FSK) modulates communication signals onto the power lines. Specifically, motor speed control signals and Battery State of Charge (SOC) data are transmitted via Phase A and Phase B, respectively. The motor speed is regulated by varying the power frequency (40 Hz for digital '0' and 60 Hz for digital '1'), which directly controls the Permanent Magnet Synchronous Motor (PMSM) speed. Additionally, the system implements a battery balance discharging mechanism by periodically rearranging PWM carrier levels based on transmitted SOC values to ensure uniform battery depletion. The study validates the proposed method through simulations in Matlab/Simulink. The simulation parameters include 48 V batteries, a 30 V DC source for signaling, and carrier frequencies ranging from 2 kHz to 10 kHz. Results demonstrate successful simultaneous transmission of power and signals. The system achieved a maximum signal rate of 600 bit/s, determined by evaluating the bit error rate. The simulations confirmed that the motor speed correctly adjusted between 1200 r/min and 1800 r/min in response to the transmitted control signals. Furthermore, the extraction of communication signals from the phase current using band-pass filters and envelope detectors proved effective, with error detection facilitated by Cyclic Redundancy Code (CRC) verification. The battery balancing function was also verified, showing that carrier level rearrangement successfully equalized the discharge rates of the battery cells. The significance of this work lies in its demonstration of a viable method to simplify EV powertrain design by merging power and communication channels. By leveraging the cascaded multilevel inverter’s inherent ability to boost voltage and its low switching losses, the proposed P&SMT system offers a more efficient and cost-effective alternative to traditional EV architectures. The successful simulation of motor control, data transmission, and battery balancing highlights the potential for reducing wiring costs and improving system reliability in future electric vehicle applications.

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• v2x connected vehicle