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Abstract—Electric vehicles and plug-in hybrid electric vehicles and plug-in hybrid electric vehicles ranges from
vehicles are two concepts that are gaining popularity in order to around 200 V to 360 V. For the converter proposed in the
reduce our dependence on fossil fuels. In this paper, a full bridge, paper, an intermediate charging voltage of 270 V is assumed.
current fed, interleaved, isolated DC-DC converter is proposed A low input voltage of 36 V is taken, considering the worst
for battery charging of electric vehicles from solar PV or fuel
case scenario. A power level that corresponds with existing
cells. It boosts voltage of around 36 V to 270 V. Interleaving leads
to lesser input current ripple, a factor crucial for sources like Level 2 charging system is taken. Therefore our basic
solar PVs and fuel cells and lesser stress on switches. The concept objective is to design a DC-DC converter that will boost 36 V
of soft switching is used to reduce switching losses. Simulation to 270 V at a power level of 3.45 kW.
results are presented for a power level of 3.45 kW. A scaled Since the converter has a high voltage gain, the first pre
down, 200 W hardware model of the circuit was built and tested. requisite that it must have is electrical isolation between the
A closed loop feedback system was also designed using k factor input and output sides. There are many isolated DC-DC
method to provide constant output voltage. converters to choose from. The simplest one is the flyback
converter which is basically a buck boost converter with a
Keywords— electric, vehicle, hybrid, battery, charger, micro
grid, renewable, energy
transformer for isolation. [2] However, this converter is not
suitable for heavy loads because it has a single switch which is
put under too much stress and hence, doesn’t perform as well
I. INTRODUCTION as desired. The next two topologies are of half bridge boost
Electric vehicles and plug-in hybrid electric vehicles are converter [3] and full bridge boost converter [4]. These exist
mostly charged from the domestic electricity supply available in voltage fed and current fed versions. The difference being
from the grid. There are two kinds of power sockets in India, the presence of an input inductor in the current fed version
ones that can supply 5 A and ones which can give 15 A which is absent in the voltage fed counterpart. The next
current. Using the 5 A charging socket, it’s possible to get a topology is of interleaved converters. [5] Interleaving
charging power of 1.2 kW considering a voltage of 230 V. basically means giving the input current additional parallel
This is known as Level 1 charging. Similarly, using a 15 A paths so that the entire current doesn’t pass through a single
socket, the charging power is 3.45 kW and this is known as inductor and switch.
Level 2 charging. Over the last few years, a new charging Considering the positive and negative aspects of all these
technology has been developed called DC fast charging. In topologies and keeping in mind the needs of our application,
DC fast charging, DC power is directly fed to the vehicle and we can zero in on the topology of choice. The basic
to the batteries. These DC fast charging stations can fully requirements of our application are:
charge the batteries of most electric vehicles in less than half • High voltage gain
an hour. All these DC fast charging standards combined are • Electrical isolation between the input and output side
known as Level 3 charging. • Low input current ripple
In the near future, DC micro grids will start to get more
• High power density
popular and we can expect homes or colonies to have their
own DC micro grid which is fed from renewable energy • Good efficiency
sources. [1] These grids will primarily be low voltage grids. In
Keeping in mind the above factors, the topology that
this scenario, we will need a battery charger for that can
would suit the application best would be the interleaved,
charge the vehicle when it is parked at home, from the low current fed, full bridge, isolated DC-DC converter. The
voltage DC micro grid. The proposed converter tackles this schematic diagram of the converter is shown in Fig. 1. Since
challenge. The battery voltage of most existing electric the input voltage of the converter is less and power level is
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International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)
pretty high, the input current will be close to 100 A. second leg are shorted. Therefore input inductor L2 gets
Interleaving helps in this large input current getting shared charged and there is no conduction in the transformer or the
between the two sets of input side inverters. By operating the diode bridge rectifier of the second leg. The load is supplied
two inverters with a phase shift of 90 degrees, we can cancel from the rectifier of the first leg and the capacitor Co2.
out the ripple in the input currents of the two inverters which
is a crucial feature when used with fuel cell or solar panel as
input. [6] [7] Therefore, sum total input current has negligible
ripple content. The output of the inverters is given to two high
frequency transformers which provide the electrical isolation
of the output and input sides. The output of the transformers is
connected to two full bridge diode rectifiers connected in
series. The load is connected across there two rectifiers. Since
the rectifiers are in series, the overall voltage gain is doubled
compared to a non-interleaved full bridge converter. The
magnetic components, i.e. the inductors and the transformers
add the major part of bulk to the circuit. In order to achieve
high power density, it is crucial that magnetic size is kept low
without sacrificing on the power level. This is possible only
when the circuit is operated at a high switching frequency.
Therefore, a high switching frequency of 100 kHz is selected
for the circuit. Switching losses play a major role in Fig. 2. Mode 1 conduction path
determining the overall efficiency of the circuit. To minimize
switching losses, the concept of soft switching is used and
zero current switching is implemented for all the switches.
Hence as we can see, the choice of converter suits the
application well.
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International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)
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International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)
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International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)
• IMPP: 5.40 A 50
Input Voltage
• VOC: 48.3 V 40
30
• ISC: 5.80 A 20
10
40
Leg1InputCurrent = 43.3452
100
InputCurrent = 87.43948 OutputCurrent = 12.45934
SwitchCurrent = 42.28716
235uH 50
A A A A
V
SwitchVoltage = 0.00042287 0
0.5uH
Output Current
20
100uF 1.2uF 20uF
15
InputVoltage = 39.28078
10
5
Leg2InputCurrent = 44.07993
235uH 22.09
A 0
OutputVoltage = 275.22689
0.02 0.04 0.06 0.08 0.1
Time (s)
0.5uH
1.2uF 20uF
Fig. 15. Output voltage and current
M7 and has a 180 degree phase shift from the third pulse.
Switch Current
80
40
Switch 1 Pulse
0
0.8
-40
0.4
0 Switch Voltage
Switch 2 Pulse 80
40
0.8
0
0.4
0 0.01771 0.01772 0.01773
Switch 5 Pulse
Time (s)
0.8
0.4
Fig. 16. Switch pulse, switch current and switch voltage in simulation
0
0.8
Switch 6 Pulse
One of the main benefits of going for the interleaved
0.4
0 topology is the input current ripple reduction which an
0.01222 0.01223 0.01224 0.01225
Time (s)
important necessity for using renewable energy sources like
Fig. 13. Gate pulses solar PV or fuel cells as source. This is shown in Fig. 17. The
total input current is shown along with the input current of the
two legs. It can be seen that the ripple of both the legs is
Fig. 14 shows the input voltage and current of the effectively cancelled out. The overall input current has an
converter. The output voltage and current of the converter are exponential wave shape rather than a linearly rising and falling
shown in Fig. 15. It is seen that the voltage settles at a steady one because there is an input capacitor which charges and
state value of §270 V quickly with very little ripple. discharges.
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International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)
87.4492
Overall Input Current
about the voltage and current overshoots while starting, turn
on and turn off times. The maximum values of the parameters
87.449
87.4488
87.4486
87.4484
are seen on the screenshot too.
Leg 1 Input Current
43.8
43.6
43.4
Leg 2 Input Current
44
43.8
43.6
43.4
0.01295 0.012952 0.012954 0.012956 0.012958 0.01296
Time (s)
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International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)
and current, consequently no switching loss when the switch is that will keep the output voltage constant irrespective of the
turned off. However, a slight issue that occurred was that the variations in the input voltage. The controller is developed
body diode of the switch wasn’t able to carry the entire using the k factor method and by taking help of the SmartCtrl
negative current in the intermediate stages of soft switching feature of PSIM.
and as a result soft spikes in voltage were noted. Therefore it
is recommended to connect few external diodes in anti-parallel The first step in designing the controller is to choose the
with each switch so as to enable it to carry the negative desired bandwidth and phase margin. The guidelines for this
current. are that bandwidth should be 1/10th or lesser of switching
frequency while a phase margin of 30o to 60o is desirable.
Next, we need to use the get the bode plot of the open loop
circuit. We can make use of the AC Sweep block available in
PSIM to do this job. In the AC Sweep block, we can set the
VGS frequency range for which we want the Bode plot and the
amplitude of the perturbation signal.
ZCS Once we put in these values and run the simulation, we get
IDS
the bode plot of the open loop circuit. Next, we need to find
the phase of the existing open loop circuit, known as ĭsys from
the bode plot. The Bode plot obtained is shown in Fig. 22. ĭsys
VDS
is the angle that corresponds to the crossover frequency on the
phase plot. For this circuit, a crossover frequency of 250 Hz is
selected. It can be seen that ĭsys obtained is -135o.
Fig. 21. Switch pulse, switch current and switch voltage in hardware Next, we need to calculate the phase boost required to be
provided by the controller, known as ĭboost. This is given by
The details of all the hardware components used are the formula:
tabulated below in Table II.
ĭboost = Phase margin desired - ĭsys – 90o (4)
amp(Vo)
Input Inductor 10 mH / 10 A 0
-50
-100
Output Capacitor 20 μF / 1 kV -150
-200
Equivalent Load Resistance 400 -250
-300
Transformer Leakage Inductance 0.5 μH Fig. 22. Bode plot of the open loop system
Switch IRF640 / 200 V, 18 A
Diode MUR1560 / 600 V, 15 A
Opto-coupler IC HPCL 3120 The 90o term comes because every controller, be it type 1,
type 2 or type 3 has a pole at origin. For this circuit, we select
a bandwidth of 250 Hz, ĭsys = 135o and a phase margin of 60o.
As can be seen from the readings obtained in Fig, the input Therefore, the ĭboost required can be given by 105o. Since
power to the circuit is: 38 V * 5.3 A = 201.4 W while the ĭboost required is more than 90o, we need a type 3 controller.
output power is 269 V * 0.680 A = 182.9 W. Therefore, we The controller is designed using the SmartCtrl feature of
get an overall efficiency figure of: 182.9/201.4 = 91%. PSIM. The Bode plot obtained is imported into Smartctrl.
To conclude, satisfactory results have been obtained in the Once we select the switching frequency and desired output
hardware model testing. The efficiency obtained is decent and voltage, a window opens where we need to select the type of
will rise further when the circuit is mounted on a PCB instead controller, the type of voltage sensor and the phase margin and
of the crude plywood board. There were no major issues noted bandwidth required. Once we do this, SmartCtrl automatically
while testing. The circuit can easily be used for higher power designs the Op-Amp based controller for the given parameters.
applications by using the right components. The controller obtained from SmartCtrl and connected to the
circuit to complete the closed loop feedback system for
constant voltage is shown in Fig. 23. The AC sweep setup
V. CLOSED LOOP FEEDBACK SYSTEM used to perturb the duty cycle to get the Bode plot is also seen.
In order to make the converter suitable for real world
applications, it needs to possess certain additional features.
For this circuit, a closed loop voltage controller is developed
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International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)
InputCurrent Leg1InputCurrent
OutputCurrent
SwitchCurrent ac
235uH
A A A A
V
SwitchVoltage
Vg1 Vg2 Input Voltage
0.5uH
50
1.2uF 48
46
V
Vg2 Vg1 44
Leg2InputCurrent 42
235uH 22.09
Vo
A 40
OutputVoltage
Vg2 Vg1
0.5uH
Output Voltage
300
1.2uF
250
200
150
Vg1 Vg2 100
Type-3 controller
50
From power
circuit voltage
C3 0
File -50
Vg1 R1 C1
AC
Sweep
Ra
R2 C2 0 0.02 0.04 0.06 0.08 0.1
Vg2
0.97*Vp Time (s)
0 Vg2
R11 R Q
Rb
Vref fsw S Q Vg1
To switch Fig. 26. Output voltage with 45 V input voltage
controller
fsw
VI. CONCLUSION
Fig. 23. Closed loop voltage controller designed in PSIM This paper focuses on providing solutions for the need of
With this, the constant voltage closed loop feedback integrating renewable energy resources in our day to day and
system is ready to be tested. First we test it with the rated reducing our dependence on fossil fuels. The targeted area is
input voltage. The results can be seen in Fig. 24. It is seen that the transportation sector where the aim is to use solar PV and
the output voltage is almost constant barring a small ripple. fuel cells to provide energy. A DC-DC converter is designed
Also it is noted that the voltage is limited to 270 V and doesn’t which can be used for battery charging of electric vehicles and
exceed it. Next we test the circuit with an input voltage lesser plug-in hybrid electric vehicles from a low voltage solar panel
than the rated voltage. This condition can be expected often if layout or fuel cells. It is seen that the important requirements
a solar panel is used to provide the input voltage. In case of of this system are met by the proposed converter. Satisfactory
cloudiness in the sky, the voltage output of the solar panel can results were obtained in simulation of the circuit for the full
reduce. In this case, the converter should be able to adjust the rated power of 3.45 kW with a solar panel as input. Testing of
duty cycle such that the output voltage remains as desired. It is the hardware prototype also gave good results with no major
seen in Fig. 25 that this is achieved. Now next, the converter is issues. An efficiency of 91% was obtained for the hardware
tested with an input voltage higher than rated voltage. This model which is very encouraging. Simulations of the type 3
condition can occur in case of any fault or during light load controller designed using the k factor method also gave
conditions. Fig. 26 shows the performance of the converter satisfactory results. As a continuation of the work, the closed
with 45 V input. It can be seen that the output voltage doesn’t loop voltage controller can be implemented and tested in
exceed 270 V in any case. hardware. This was not done due to paucity of time.
Input Voltage
40
30
References
20
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[2] Spiazzi G., Mattavelli P., Gazoli J.R., Magaihes R., Frattini G. (2010).
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0 0.02 0.04
Time (s)
0.06 0.08 0.1
22.
Fig. 25. Output voltage with 35 V input voltage
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