Design, Control and Management of High-Power Electric Vehicles Using a Hybrid Storage System

Abstract

As electric vehicle adoption grows, the demand for traction systems capable of delivering high peak power also increases. In this work, an integrated electric-vehicle powertrain is developed by combining a permanent-magnet synchronous motor (PMSM) traction drive controlled by field-oriented control (FOC) with a hybrid energy storage system (HESS) composed of a battery pack and a supercapacitor bank. The storage sources are connected to a common DC bus through two bidirectional DC/DC converters, while a voltage-source inverter (VSI) and a second-order LC low-pass filter supply the PMSM. The main contribution is the coordinated system-level evaluation of traction control, battery–supercapacitor power sharing, DC-bus regulation, regenerative-energy flow, and motor-terminal voltage quality under the same transient operating profile. The PMSM drive achieves accurate speed tracking, with an RMSEω of 0.5788 rad/s and a normalized RMSE of 0.3793%. The overshoot at 250 rad/s remains limited to 0.4667%, while the peak electromagnetic torque reaches 121.81 N·m. Compared with a battery-only configuration under identical operating conditions, the HESS reduces the peak battery current from 274.90 A to 200 A, corresponding to a 27.25% reduction, while the RMS battery current decreases from 169.84 A to 159.61 A. The estimated battery ohmic losses are also reduced from 4.98 Wh to 4.43 Wh, while the total battery energy supplied over the profile remains nearly unchanged. The DC-bus voltage remains closely regulated around its 700 V reference. During the investigated regenerative interval, the supercapacitor absorbs 4.02 Wh from 5.85 Wh of braking energy, corresponding to a 68.71% recovery ratio. Overall, the results show that the HESS redistributes transient power and reduces peak and RMS battery current while maintaining satisfactory traction-drive and DC-bus performance.