2012 IEEE Students Conference on Electrical, Electronics and Computer Science

Bi-directional DC-DC Converter for battery charging - discharging Applications using Buck-Boost switch
Jigar Patel(stu.)1, Dr.Hina Chandwani(Asso Prof)2
Electrical Engg, Faculty of Engg and Technology The Maharaja Sayajirao University of Baroda Baroda, Gujarat, India jigarpatel14@yahoo.com

Vinod Patel3, Hiren Lakhani4

Amtech Electronics (INDIA) Ltd R&D Department Gandhinagar, Gujarat, India

Abstract This paper describes the design and simulation of a 7.75-kW, full-bridge, bi-directional isolated dc-dc converter using a 12-kHz transformer and battery energy storage system. The full bridge scheme is widely used for the high power application. High frequency transformer is used for isolation purpose. The dc voltage at the high-voltage side is controlled from 650 to 700 V to low-voltage side battery voltage of fixed 310V. Software tool PSIM is used to obtain the simulation result of the converter. The voltage and current feedback are compared with their references. Keywords- Bi-directional dc-dc Converter, HF transformer, Battery, Buck converter, Boost converter

storage device such as a battery or a super capacitor, to provide clean and stable power to a dc load. [2]. Various bi-directional isolated dc-dc converters have been proposed as the interface to energy storage devices (battery) with focus on automotive, fuel cell and grid applications. Most of the presented dc-dc converters have asymmetrical circuit configurations to couple the two dc links having largely different voltages, several tens volts and several hundreds volts [3][9]. There are many topologies to design the dc-dc converter but most efficient method is using the full-bridge topology. The two-stage dc-dc Full bridge converter is proposed in this paper to achieve the required specification. The main objective is to reach a high efficiency, high power density and cheap topology in simple structure. In older days resistor was used to discharge the battery. So total energy wasted in the form of I2R losses. In the proposed topology, during the discharge mode of operation the battery power will flow in the reverse direction and it will feed into the supply grid. Bi-directional power flow is obtained by the same power components and provides a simple, efficient isolated boost converter. II. PROPOSED BI-DIRECTIONAL ISOLATED DC-DC CONVERTER

I.

INTRODUCTION

I-DIRECTIONAL dcdc converters allow transfer of power between two dc sources, in either direction. Due to their ability to reverse the direction of flow of current, and thereby power, while maintaining the voltage polarity at either end unchanged, they are being increasingly used in applications like dc uninterruptible power supplies, battery charger circuits, telecom power supplies and computer power systems [1]. Possible implementation of bi-directional converters using resonant soft switching and hard switching PWM has been implemented earlier. But, these topologies may often lead to an increase in component ratings, circuit complexity and conduction losses in resonant mode implementations, high output current ripple and loss of soft switching at light loads for soft-switched circuits, and lack of galvanic isolation in integrated topologies [1]. The transformer is indispensable for some applications that require voltage matching and/or galvanic isolation between the utility grid and the energy storage device. Replacing the linefrequency transformer with a high-frequency isolated dc-dc converter would make the energy storage system more compact and flexible [2]. High power isolated bi-directional dc/dc converters have become key components in alternative energy systems. Upon operation, the converter controls bi-directional direct current (DC) flow of electric power between a voltage bus that connects an energy generating device such as a fuel cell stack, a photovoltaic array, and a voltage bus that connects an energy

HF X'MER

Fig. 1 Block diagram of Bi-directional dc-dc converter

Fig.1 shows the block diagram of bi-directional battery charger. During the charging mode 650 to 700 volt D.C is given to the capacitor for getting the constant D.C. supply. The constant D.C. voltage from capacitor is given to the H-bridge inverter. The switching device used is the IGBT, which is used for high voltage medium frequency (<15 kHz) application. The IGBT has the advantage of a very low on-state voltage drop, excellent current conduction capability, and excellent forward and reverse blocking capabilities.

978-1-4673-1515-9/12/$31.00 2012 IEEE

There are 4 sections for proposed topology: Primary side full bridge converter, High frequency transformer, Secondary side Full bridge converter, Buck/Boost switches. A. Primary side Full bridge converter: The first stage is a pulse width modulated full-bridge inverter or a diode rectifier. During charging mode this bridge is working as a phase shifted Full bridge inverter. During discharging mode of operation, this bridge is working as full bridge diode rectifier. B. High frequency Transformer: HF transformer is step-down the voltages during charging mode and steps-up the voltages during discharging mode of operation. It is also provides isolation between two full bridges on primary and secondary side. C. Secondary side Full bridge converter: It is also a full-bridge converter. During charging mode of operation, this bridge is working as a full bridge diode rectifier. During discharging mode this bridge is working as a phase shifted Full bridge inverter. D. Buck/Boost converter: In the charging mode, the buck switch is ON; the boost switch works as a diode. So the input provides energy to the load via inductor. During the interval when the buck switch is off, the inductor release its energy through the boost diode, transferring stored energy to the load. In the discharging mode, the boost switch is on; the buck switch works as a diode. Battery voltage supplies energy to the inductor and boost switch. When the boost switch is off, the inductor transfers the energy to load through the buck diode. The output of buck IGBT during charging mode may contain A.C and D.C components. So in order to smooth the output current of buck IGBT, L-C filter is connected for the filtering purpose. The induced voltage across the inductor is calculated by determining the current flow during both ON time and OFF time individually by using the following equations.

A. Charging mode: The main two topologies for PWM generation are (1) The conventional full bridge PWM converter (2) The phase shifted full bridge PWM converter. In this paper phase shifted fullbridge topology used. TABLE I.
CIRCUIT PARAMETERS OF THE DC-DC CONVERTER IGBT 650-700 volt (D.C) 310 volt (D.C) 25 Amp 7.75 Kw 12kHz 1:0.5846 1uH 14mH

Switching Device Input Voltage Output Voltage Output Current Output Power Switching Frequency Transformer turns ratio Leakage Inductance Magnetizing Inductance

As shown in fig. 3 the switches S1 and S2 are on simultaneously. Similarly switches S3 and S4 on simultaneously. The switches S1 & S4 have 3 us dead time is given in their switching. Similarly S2 & S3 have 3 us dead time is given in their switching. In forward direction the high voltage side to low voltage side the circuit works in buck mode. Fig. 4 shows the primary and secondary side transformer waveforms respectively. Fig. 5 shows the gate pulses of Buck IGBT. Fig. 6 shows the battery voltage and current respectively.

Fig. 2 Simulation diagram during charging mode

G3 1 G4

0.8

0.6
G1 1 G2

0.4
0.8

(1) VL= L (di/dt) I=(VL/L)* T (2) The output of L-C filter circuit is D.C. In reverse direction the low voltage side to high voltage side the circuit works in boost mode. III. SIMULATION RESULTS

0.2
0.6 0.4

0 0.12 0.1201 0.1202 Time (s) 0.1203 0.1204

0.2

Fig. 3 Gate pulses across switch S1 to S4

Vpri 1000 500

-500

-1000

Vsec 1000

Circuit parameters are mentioned in Table 1. Fig.2 shows the basic circuit diagram to simulate the bi-directional dc-dc converter in PSIM 9.0 software tool. The phase-shifted full bridge topology is used for switching of IGBTs.

500

-500

-1000 0.12 0.1201 0.1202 Time (s) 0.1203 0.1204

Fig. 4 Voltage across primary and secondary of transformer

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Inductor current
Gate pulse of buck switch 1

28 27 26 25 24 23

0.8

0.6

0.4

0.2

Inductor current 27

26

22 0.12 0.1201 0.1202 Time (s) 0.1203 0.1204

25

Fig. 9 Voltage across boost switch and current through inductor

24
V p r i 1000 500 0

23 0.12 0.1201 0.1202 Time (s) 0.1203 0.1204

-500

-1000

Vsec 1000

Fig. 5 Gate pulse of boost switch and current through inductor

Vbatter y 310.1 310.05 310 309.95 309.9 309.85

500

-500

-1000
309.8

0.12

0.1201

0.1202 Time (s)

0.1203

0.1204

Ibattery 25.01 25.005

Output voltage

Fig. 10 Voltage across primary and secondary of transformer

680

25 24.995 24.99 24.985 24.98 0.12 0.1201 0.1202 Time (s) 0.1203 0.1204

675

670

665

660

655 0.12 0.1201 0.1202 Time (s) 0.1203 0.1204

Fig. 6 Voltage and current feed to battery

11.5

Output Current

B. Discharging Mode

11.45 11.4 11.35 11.3 11.25 11.2 11.15 0.12 0.1201 0.1202 Time (s) 0.1203 0.1204

Fig. 11 Voltage and current feed to grid when battery voltage is 310 volt
Batter y voltage 64.8 62.4

60

Fig. 7 Simulation diagram during discharging mode

57.6

55.2

Output voltage

As shown in fig.8 the switches S5 and S6 are on simultaneously. Similarly switches S7 and S8 on simultaneously. The switches S5 & S8 have 3 us dead time in their switching. Similarly S6 & S7 have 3 us dead time in their switching. In reverse direction the low voltage side to high voltage side the circuit works in boost mode. Fig. 10 shows the primary voltage and secondary voltage, which is, reversed compare to charging mode means battery voltage first fed to secondary. In the discharging mode the battery voltage down from 310 volt to 60 volt but at output we continue get the 650-700volt. By converting this voltage to 3- phase line voltage with help of inverter we can feed the voltage to grid. Fig. 11 shows output voltage and current at battery voltage 310 volt and fig12. Shows output voltage and current at 60 volt.
G 5 1 G 6 0. 8 0. 6 0. 4 0. 2 0

662

660

658

656

654

652

Output Current 2.205 2.2 2.195 2.19 2.185 2.18 2.175 0.12 0.1201 0.1202 Time (s) 0.1203 0.1204

Fig. 12 Voltage and current feed to grid when battery voltage is 60 volt CONCLUSION

G7 1

G8

0.8

In this paper, circuit topologies of the dc-dc converter with bi-directional power flow control and conversion capability and with electrical isolation between the two sides through a single transformer are evaluated for battery charging and discharging applications. In the discharging mode by connecting the active front-end converter (AFC), the output d.c power can converted to three phase a.c and feed to the grid. The overall system provides saving of energy. REFERENCES
[1]

0.6

0.4

0.2

0 0.12 0.1201 0.1202 Time (s) 0.1203 0.1204

Fig. 8 Gate pulses across switch S5 to S8

G ate 1 p u se l of b oost swi tch 0.8 0.6 0.4 0.2 0

[2]

Manu Jain, M. Daniele, and Praveen K. Jain, A Bidirectional DC DC Converter Topology for Low Power Application IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 15, NO. 4, JULY 2000. Lizhi Zhu, A novel soft-commutating isolated boost full-bridge ZVS-PWM dc-dc converter for bi-directional high power

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[9]

applications2004 35th annual IEEE power electronics specialists conference. Shigenori Inoue, Hirofumi Akagi, A bi-directional dcdc converter for an energy storage system with galvanic isolation IEEE transactions on power electronics, vol. 22, no. 6, november 2007. M. Jain, M. Daniele, and P. K. Jain, A bidirectional dc-dc converter topology for lowpower application, IEEE Trans. Power Electron., vol.15, no. 4, pp. 595606, Jul. 2000. A. D. Swingler and W. G. Dunford, Development of a bidirectional dc/dc converter for inverter/charger applications with consideration paid to large signal operation and quasi-linear digital control, in Proc.IEEE Power Electronics Specialists Conf. (PESC), 2002, vol. 2, pp.961966. F. Z. Peng, H. Li, G.-J. Su, and J. S. Lawler, A new ZVS bidirectional dc-dc converter for fuel cell and battery application, IEEE Trans.Power Electron., vol. 19, no. 1, pp. 5465, Jan. 2004. L. Shi, L. Sun, D. Xu, and M. Chen, Optimal design and control of 5kWPWMplus phase-shift (PPS) control bidirectional dc-dc converter, in Proc. IEEE Appl. Power Electron. Conf. Expo (APEC), Dallas, TX, Mar. 2006. Y. Hu, J. Tatler, and Z. Chen, A bi-directional dc/dc power electronic converter for an energy storage device in an autonomous power system, in Proc. Power Electron. Motion Cont. Conf. (IPEMC), 2004, vol. 1, pp. 171176. H.-J. Chiu and L.-W. Lin, A bidirectional dc-dc converter for fuel cell electric vehicle driving system, IEEE Trans. Power Electron., vol. 21, no. 4, pp. 950958, Jul. 2006.

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