Design and Implementation of Micro controller based Four Level Converter for Energy Storage System Used in Electric/

Hybrid Electric Vehicle

1
1

Srinivasa Rao.Gorantla, 2Dr.Keseva Rao.G, 3Dr Siva Naga Raju.S

.Associate.Professor, Electrical Department ,Vignan Engineering College, Vadalmudi , India, 2 .Professor & Dean , Electrical Department, LBREC , Mylavarum , India 3. Professor , Electrical Department, JNTU , Kakinada , India

Abstract - The Hybrid Electric Vehicle (HEV) is the first step in reducing the environmental impacts of automobile use without losing comfort, performance and extended driving range. The success of the transition to Hybrid Vehicles depends on battery capabilities, converter system and cost. This paper proposes a new isolated Dual bridge Four-level pulse width modulated dcdc converter (DBPWMC) with small inductance and no dead time operation for Energy storage system (composed of several Batteries) of Electric/ Hybrid Electric Vehicle. With no dead time operation, energy is continuously transmitted from input DC source to Battery in whole switching period, which causes lower input ripple current and hence the smaller size of input filter. Detailed analysis shows the proposed converter can have either lower voltage stress on all primary side power switches or soft switching properties when different driving schemes are applied. The 48V/100-W DC DC to converter with PWM oscillator with a frequency of 20 KHz has been tested for the verification of the principle. The simulation and experimental results ensure the feasibility and advantages of the new approach. Keywords- Hybrid Electric Vehicle, D.CD.C converter, No dead time, PWM oscillator.

I. INTRODUCTION With increasing interest to decrease vehicle pollution and consumption of fossil fuels Electric / Hybrid Electric vehicle (EV/HEV) has taken on an accelerated pace. The dream of having commercially viable Electric vehicles and Hybrid electric vehicles is becoming a reality. The success of hybrid technology depends up on battery capabilities, power controller (D.C to D.C converter) and cost. Converters for 12V to 36V analog power supply applications supports many commercial designs of Electric and Hybrid Electric Vehicles. [1-2]. Improvements in the power density of DC-DC converters are realized through extensive miniaturization and integration of active components and reducing the size of the passive components. So it requires an increase in the frequency at which the converter operates, since intermediate energy storage requirements are inversely proportional to operating frequency. In this paper, a new isolated pulse width modulation (PWM) dcdc converter topology is proposed. This topology alternates between two stages of operation. In Stage I, it operates similar to a fullbridge converter at the operation stage so that the power transmits through the transformer to the output. In Stage II, it behaves similar to a half-bridge converter. When operating in the half-bridge-like stage, the inductor releases and sends the stored energy together with the energy from the dc source to the load. The input-tooutput voltage transfer ratio of the new topology is makes the transfer of energy from the input dc source to the load is continuous in the whole operating period, thus achieving no dead time operation. II. ANALYSIS OF THE PROPOSED TOPOLOGY The full- bridge converter as shown, in fig-1, is a popular design for both buck and boost applications and has become a basis for numerous resonant zero voltage and zero current switching (ZVS, ZCS) schemes. In the

Full bridge Pulse width modulated (FB-PWM) converter, when all four switches (QA, QB ,QC, Q D) are turned OFF, the load current freewheels through the rectifier diodes and energy stored in the leakage inductance of the power transformer causes severe ringing with MOSFET junction capacitances [3-5]. This creates the need for using snubbers. If snubbers are not used, the selection of the devices becomes more difficult as the voltage rating for these switches has to be much higher.

Fig.1 Full bridge converter

Fig.2 Idealized waveforms of Full bridge DC-DC converter

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From the characteristics of the conventional fullbridge converter, as shown in figure-2, it is observed that it has a dead time during its operation Besides preventing switches A and B (or C and D) from conducting simultaneously, this dead time is essential for conventional dual-end (half- and full-bridge.) converters to obtain a regulated output voltage when the input voltage changes. During the dead time, the input current becomes zero and this discontinuity causes a large input ripple current. This dead time also needs a large output inductor to smooth the output voltage and limit the ripple current through it. The large output inductor slows the output response time. Full bridge converter with large inductor operating in discontinuity current mode (DCM) causes current ripple in a converter operating at light load. The ripple magnitude depends on the applied voltage, the inductance value and the transistor conduction time. Full bridge converter operating in continuous current mode (CCM) have no dead time and results in energy being continuously transmitted from the input DC source to the Battery in the whole switching period. Because of the lower input ripple current in a no dead time DC-DC converter, the conducted filter is relatively smaller. Lower output inductance value improves the output transient speed and reduces the output filter size, thus improves the power density (power-to-volume ratio) of the DC-DC converter. Voltage and current waveforms of the converter are shown in figure-3.

Fig.4 Proposed Dual Bridge converter with PWM controller

Fig.5(a) Mode 1(t0 < t < t1 )

Here, voltage across the primary side of transformer is Vp = Vin voltage across the secondary side of transformer is Vs=nVin and the primary winding current equal to ip.

Fig. 5(b) Mode 2 (t1 < t < t2 )

Fig.3 Output voltage and input current wave forms of CCM and DCM Full Bridge converter

In mode 2, as shown in figure-5 (b) , the switch S4 is off and S5 is on. The current ip flows through S1, load and S5 and charges C2 while the capacitor C1 discharges. The voltages, Vp = Vin/2 and Vs = nVp: = nVin/2. At t2, S1 and S5 turn off and S2 and S3 turn on.

Here, a six level Dual bridge converter, as shown in Figure-4,which is the combination of Full bridge (S1, S2, S3 and S4) and Half bridge (S1, S2 and capacitors C1, C2 ) has been proposed for Electric and Hybrid Electric Vehicle. The two bridges are connected by S5 for bidirectional control of current. Dual bridge can be operated in four different modes (t0 < t < t4). In mode 1 as in Figure 5 (a), the switches S1 and S4 are turned on. The Load Current flows through S1, load and S4.

Fig.5(c) Mode 3 (t2 < t < t3 )

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Fig.5 (d) Mode 4 (t3 < t < t4 )

The mode 3 operation, as in Figure-5(c ), is in symmetry with time interval t0 < t< t1 and the voltage, Vs= nVp=nVin. The operation of mode 4, as in figure-5 (d), is in symmetry with time interval t1< t< t2 and now the voltage, Vs= nVp =-nVin/2. Figure- 9 shows the waveforms of Dual bridge D.C to D.C converter.

Fig.7 block diagram for micro controller based Four-Level Dual Bridge DC - DC Converter

Here 89C51 micro controller with PWM converter is used for realizing different D.C voltage levels.. In this paper duel inverted outputs are taken from the PWM IC, so that the drive stage is designed in push-pull configuration with two power MOSFETs. [10-11]

Fig.6 Idealized waveforms of Dual bridge DC-DC converter

VS1 and VS2 as shown in figure-6 are two 50% duty ratio complementary control signals of S1 and S2. VS3 and VS4 are control signals of switches S3 and S4 with duty ratio D and switching frequency, f. VS5 operates at f0 = 2f (T0 = T/2). The values of D and (1-D) are obtained from the equations 1 and 2. D = (t1 - t0) / T0 = (t3 t2) / T0 .(1) 1 - D = (t2 - t1)/ T0 = (t4 t3 ) / T0 -(2) From the characteristics of the both full bridge and dual bridge converters as shown in figure 3 & figure 6, it can be concluded that Dual bridge topology exhibits the following advantages over the Full bridge topology.1.No dead time. 2.One power transformer and no magnetic tapping on the primary winding. 3. Significantly reduced input current ripple.4. Significantly reduced output filter inductance value. 5.Less stress on switching components. III.MICRO CONTROLLER BASED DUAL BRIDGE SIX-LEVEL DC - DC CONVERTER Here the Voltage output of the converter is programmed to obtain the required voltage level. The basic oscillator of the converter is designed with PWM (Pulse Width Modulation) IC (3524). The block diagram for micro controller based Four-level Dual Bridge DC - DC Converter is shown in figure-7.

Fig. 8 Circuit diagram of PWM Oscillator

In the PWM oscillator (IC 3524), as shown in figure-8, desired frequency is realized by connecting 50K potentiometer in addition to 10K resistor. The oscillator frequency fout = 1 / RT CT. Here the inverting input of Error amplifier (Pin No.2) is fed from Vref, built in 5V regulator through a voltage divider of two 4.7K resistors. . Here pulse width modulation is accomplished by steering the resulting modulated pulse output of the high gain comparator to the PWM latch along with the pulse steering Flip-Flop,Which is synchronously toggled by the oscillator. The approximate frequency of the output

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signals of PWM oscillator is about 20 KHz. PWM output, is further amplified using class B push- pull stages. The time constant RC is designed with 82K x 10F = 820m sec. To reduce this delay a 6.8K and 10K potentiometer are connected as a voltage divider. By varying the voltage at Pin no.9 (Compensation Pin) output duty cycle can be changed their by output voltage is controlled.
Fig-11(b) Transformer Primary and Secondary Waveforms HB Converter

Fig-9 Circuit diagram of rectifier & filter

Fig-11(c) Output Voltage Waveform HB Converter

In the rectifier, as shown in fig -9, the choke is designed with ferrite core, to reduce the noise levels of 20 KHz frequency converter. The final output of the converter is 30V DC, which is fed to variable regulator for obtaining the different DC levels. Here LM 317 positive voltage regulator (variable) is used, to regulate the voltage. IV. SIMULATION RESULTS The simulation is done for conventional 2-level Half bridge, Full bridge and Dual Bridge D.C-D.C Converter systems Simulation circuit for half bridge DC-DC converter is shown in figure-10. [13]. Figure-11(a) 11(c) show the various waveforms of half bridge converter.

Fig-12 Two-Level Full Bridge DC-DC Converter

Simulation circuit for 2-level full bridge DC-DC converter is shown in figure-12. Figure 13(a) 13(c) show the waveforms of full bridge converter.

Fig-10 Two-level Half Bridge DC-DC Converter

Fig-13(a) Input and Output Voltage Waveforms of FB Converter

Fig-11(a) Input Voltage Wave Form of HB Converter

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Fig-13(b) Transformer & Secondary Waveforms of FB Converter

Fig.15(b) Transformer Primary & Secondary Waveforms

Fig-13(c ) Output Voltage Waveform of FB Converter

Fig-15(c) Output Voltage Waveform of Dual bridge converter

Simulation circuit for 4-level Dual bridge DC-DC converter for multiple outputs is shown in figure-16 Fig17(a) 17(c) shows the various waveforms of 4-level output Dual bridge converter. The complete diagram and experimental setup of a micro controller based Current Fed Dual Bridge DC - DC Converter are shown in figure- 19 & 20 respectively.

Fig-17(a) Switching Pulses for M1, M2, M3, M4, M5, M6

Fig-14 Two-Level Dual-Bridge DC-DC Converter

Simulation circuit for 2 level Dual bridge DC-DC converter is shown in figure- 14. Figure 15(a) 15(c) shows the waveforms of Dual bridge converter.

Fig-15(a) Switching Pulses for M1, M2, M3, M4, M5, M6

Fig-16 Simulation of Dual-Bridge DC-DC converter for 4-level Outputs

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Fig-17(b) Transformer Secondary Waveforms

Fig-18 Comparison between simulated and Experimental Results REFERENCES [1] G.Srinivasa Rao, Dr.G.K.Rao ,Dr.G.R.K.Murhty , Sensor less control of induction drive in Hybrid Electric vehicle, in the proceedings of ICEESPEEE 2009,pp 992-997 April 16 , 2009, Chennai, India [2] G.Srinivasa Rao, Dr.G.K.Rao ,Dr.G.R.K.Murhty , Design and implementation of automated multi source charging system for Hybrid Electric Vehicle , International Journal of Electric and Hybrid Vehicles,vol.2 ,No.2, 2009,pp 137-158 [3] W. Song and B. Lehman, Dual-bridge dcdc converter: a new topology Characterized with no dead time dcdc converters, IEEE Transactions on Power Electronics. vol. 19, no. 1, pp. 94 103, Jan. 2004. [4] Wei song, Brad Lehman Current-Fed-Dual Bridge D.C- D.C converter, IEEE Transactions on Power Electronics , Vol 22, No2 ,March 2007.pp451-459 [5] Lizhi. Zhu,K.Wang,F.C LeeNew start-up schemes for isolated full bridge boost converters, IEEE Transactions on Power Electronics ,Vol 18,No4 ,July2003,pp 946-951 [6] A.Domingo, Ruiz-caballero A new Fly back current-Fed push pull D.C-D.C converter IEEE Transactions on Power Electronics ,Vol 14, No.6 , Nov 1999, pp 1056-1064 [7] Peter Mantovanelli,Ivo Barbi A new current fed isolated PWM D.C-D.C converter, in the proceedings of IEEE international conference on the Power Electronics,pp290- 296,1995 [8] Riccardo Borgatti, Renato Stefani, Onorio Bressan1 KW, 9KV DC-DC Converter Module with Time-sharing Control of Output Voltage and Input Current, IEEE Transactions on Power Electronics Vol. 4, 1993 [9] Wang, F. C. Lee, and J. Lai, Operation principles of bi-directional full-bridge Dc- Dc converter with unified soft switching scheme and soft-starting capability, In Proc. IEEE PESC, 2000, pp. 111118. [10] G.Srinivasa Rao, Dr.G.K.Rao, Dr.G.R.K Murthy Power management policies and control of Hybrid Electric Vehicle,International journal of renewable Energy technology,vol1, 2009 pp-101-113 [11] G.Srinivasa Rao ,Dr.G.K.Rao, Dr.G.R.K.Murhty Design of Power Controller for Hybrid Electric Car is published in the in the proceedings of Inter National Conference on Modeling & Simulation (MS-09) held at College of Engineering ,Trivendrum, in Association with AMSE France from December 1st to 3rd 2009,pp 147-151 [12] G.Srinivasa Rao, Dr.S.Sao, Automated Electric Locomotive proceedings of Inter National Conference on Modeling and Simulation, MS 07 held at University of Kolkatha in association with AMSE France pp.435-439 December 2007.

Fig-17(c) Output Voltage Waveform of 4-level Dual bridge converter

V.EXPERIMENTAL RESULTS The prototype of the proposed Micro processor based six-level dual bridge converter was built with the specifications: input voltage 48 Vd.c (12-24-48 VDC), three outputs of 12, 24 36 and 48Vd.c with total output power of 100 W, and 20 kHz. The components used in fabrication of converter are 89C51 Micro controller Chip, 74LS573 Latch, SGS 3524 Pulse width modulator, LM 317 3-Terminal Adjustable Regulator, Voltage Regulator, Z44 Power MOSFETS, Relay and BC 547 Transistor. Self-driven synchronous rectifiers of MOSFETs were used for the 48 -V output. The voltage spikes may be limited by applying a RC snubber across the inductor between source and drain, if necessary. VI. CONCLUSION A new topology, isolated Micro cntroller based Fourlevel dual bridge dcdc converter, characterized by small inductor and no dead time operation, is presented. Here converter is designed to generate Four different DC levels. The advantage of PWM IC based converters are their compactness design, ease in maintenance and in troubleshooting The 48V/100-W DC DC converter with PWM oscillator with a frequency of 20 KHz has been tested for the verification of the principles. Both simulations and experiments verify the feasibility and advantages of the new approach

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Fig-19 Complete Circuit diagram for micro controller based Four-level (12V,24V,36V,48V) Dual Bridge DC - DC converter

Fig-20 Experimental setup of a micro controller based Four-level Dual Bridge DC - DC Converter

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