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This paper proposes a drive train topology with a dynamically reconfigurabledc battery, which breaks hard-wired batteries into smaller subunits. It canrapidly control the output voltage and even contribute to voltage shaping ofthe inverter. Based upon the rapid development of low-voltage transistors andmodular circuit topologies in the recent years, the proposed technology usesrecent 48 V power electronics to achieve higher-voltage output and reducelosses in electric vehicle (EV) drive trains. The fast switching capability andlow loss of low-voltage field effect transistors (FET) allow sharing themodulation with the main drive inverter. As such, the slower insulated-gatebipolar transistors (IGBT) of the inverter can operate at ideal duty cycle andaggressively reduced switching, while the adaptive dc battery provides anadjustable voltage and all common-mode contributions at the dc link with lowerloss. Up to 2/3 of the switching of the main inverter is avoided. At high drivespeeds and thus large modulation indices, the proposed converter halves thetotal loss compared to using the inverter alone; at lower speeds and thussmaller modulation indices, the advantage is even more prominent because of thedynamically lowered dc-link voltage. Furthermore, it can substantially reducethe distortion, particularly at lower modulation indices, e.g., down to 1/2compared to conventional space-vector modulation and even 1/3 for discontinuouspulse-width modulation with hard-wired battery. Other benefits includealleviated insulation stress for motor windings, active battery balancing, andeliminating the vulnerability of large hard-wired battery packs to weak cells.We demonstrate the proposed motor drive on a 3-kW setup with eight batterymodules.

A Smart Adaptively Reconfigurable DC Battery for Higher Efficiency of Electric Vehicle Drive Trains