Control Strategies of DC–DC Converter in Fuel Cell Electric Vehicle

There is a significant need to research and develop a compatible controller for the DC–DC converter used in fuel cells electric vehicles (EVs). Research has shown that fuel cells (FC) EVs have the potential of providing a far more promising performance in comparison to conventional combustion engine vehicles. This study aims to present a universal sliding mode control (SMC) technique to control the DC bus voltage under varying load conditions. Additionally, this research will utilize improved DC–DC converter topologies to boost the output voltage of the FCs. A DC–DC converter with a properly incorporated control scheme can be utilized to regulate the DC bus voltage–. A conventional linear controller, like a PID controller, is not suitable to be used as a controller to regulate the output voltage in the proposed application. This is due to the nonlinearity of the converter. Furthermore, this thesis will explore the use of a secondary power source which will be utilized during the start–up and transient condition of the FCEV. However, in this instance, a simple boost converter can be used as a reference to step–up the fuel cell output voltage. In terms of application, an FCEV requires stepping –up of the voltage through the use of a high power DC–DC converter or chopper. A control scheme must be developed to adjust the DC bus or load voltage to meet the vehicle requirements as well as to improve the overall efficiency of the FCEV. A simple SMC structure can be utilized to handle these issues and stabilize the output voltage of the DC–DC converter to maintain and establish a constant DC–link voltage during the load variations. To address the aforementioned issues, this thesis presents a sliding mode control technique to control the DC bus voltage under varying load conditions using improved DC–DC converter topologies to boost and stabilize the output voltage of the FCs

Design of an Integrated, Six-Phase, Interleaved, Synchronous DC/DC Boost Converter on a Fuel-Cell-Powered Sport Catamaran

This paper describes the preliminary analysis, design and implementation phases of a DC/DC boost converter dedicated to the Futura catamaran propulsion chain developed by the UniBoAT team at the University of Bologna. The main goal of the project was the reduction of the converter’s weight by eliminating the use of heat sinks and by reducing the component size, especially inductors and capacitors. The obtained converter is directly integrated into the structure containing the fuel-cell stack. The realized converter was based on an interleaved architecture with six phases controlled through the average current mode control. The design was validated through simulations carried out using the LT-Spice software, whereas experimental validations were performed by means of both bench tests and on-field tests. Detailed thermal and efficiency analyses were provided with the bench tests under the two synchronous and non-synchronous operating modes and with the adoption of the phase-shedding technique. Prototype implementation and performance in real operating conditions are discussed in relation to on-field tests. The designed converter can be used in other applications requiring a voltage-controlled boost converter

Analysis of a new family of DC-DC converters with input-parallel output-series structure

There is an increasing trend of development and installation of switching power supplies due to their highly efficient power conversion, fast power control and high quality power conditioning for applications such as renewable energy integration and energy storage management systems. In most of these applications, high voltage conversion ratio is required. However, basic switching converters have limited voltage conversion ratio. There has been much research into development of high gain power converters. While most of the reported topologies focus on high gain and high efficiency, in this thesis, the input and output ripple currents and reliability are also considered to derive a new converter structure suitable for high step-up voltage conversion applications. High ripple currents and voltages at the input and output of dc-dc converters are not desirable because they may affect the operation of the dc source or the load. A number of converters operating in an interleaved manner can reduce these ripples. This thesis proposes a dc/dc switching converter structure which is capable of reducing the ripple problem through interleaved action, in addition to high gain and high efficiency voltage conversion. The thesis analyses the proposed converter structure through a dual buck-boost converter topology. The structure allows different converter topologies and combinations of them for different applications to be configured. The study begins with a motivation and a literature review of dc/dc converters. The new family of high step-up converters is introduced with an interleaved buck-boost as an example, followed by small-signal analysis. Experimental verifications, conclusions and future work are discussed

Analysis of a new family of DC-DC converters with input-parallel output-series structure

There is an increasing trend of development and installation of switching power supplies due to their highly efficient power conversion, fast power control and high quality power conditioning for applications such as renewable energy integration and energy storage management systems. In most of these applications, high voltage conversion ratio is required. However, basic switching converters have limited voltage conversion ratio. There has been much research into development of high gain power converters. While most of the reported topologies focus on high gain and high efficiency, in this thesis, the input and output ripple currents and reliability are also considered to derive a new converter structure suitable for high step-up voltage conversion applications. High ripple currents and voltages at the input and output of dc-dc converters are not desirable because they may affect the operation of the dc source or the load. A number of converters operating in an interleaved manner can reduce these ripples. This thesis proposes a dc/dc switching converter structure which is capable of reducing the ripple problem through interleaved action, in addition to high gain and high efficiency voltage conversion. The thesis analyses the proposed converter structure through a dual buck-boost converter topology. The structure allows different converter topologies and combinations of them for different applications to be configured. The study begins with a motivation and a literature review of dc/dc converters. The new family of high step-up converters is introduced with an interleaved buck-boost as an example, followed by small-signal analysis. Experimental verifications, conclusions and future work are discussed

Advanced power converters for railway traction systems

This thesis presents a new traction drive suitable for fuel-cell powered light rail vehicles based on a multilevel cascade converter with full-bridge cells. The converter provides dc-ac power conversion in a single stage, while compensating for the variation of fuel cell terminal voltage with load power. The proposed converter can replace the conventional combination of dc-dc converter, as it benefits from having a multilevel ac voltage waveform and much smaller power inductors, compared to conventional solutions. The converter numerical and analytical models are derived showing that the converter can be modelled as a cascaded boost converter and 3-phase inverter. The design methodology for the energy storage capacitors and power inductors is presented, showing that inductance is reduced at a quadratic rate with the addition of more sub-modules, while total converter capacitance remains constant. A simulation of a full-scale traction drive in a fuel cell tram demonstrates that the proposed converter is a viable solution for light rail applications. The concept of a boost modular cascaded converter is fully validated through a bespoke laboratory prototype driving a small induction machine. The experimental inverter achieves operation from standstill, with full motor torque, to field weakening with constant power, boosting a 50V dc supply to 200V peak line-to-line voltage

Applications of Switch-Mode Rectifiers on Micro-grid Incorporating with EV and BESS

A switch-mode rectifier (SMR) can provide adjustable and well-regulated DC output voltage from the available AC source with good line drawn power quality. Depending on the input/output voltage transfer characteristics, the schematics, the operation quadrant, and control, SMRs possess many classifications and application. Typical potential application examples include grid powered motor drives, battery chargers, various power electronic facilities, micro-grids, and grid-connected battery energy storage system (BESS), etc. In micro-grids, the SMR can be employed as the AC generator-followed converter to yield better generating efficiency. The SMR operation of its grid-connected inverter let the grid-to-microgrid (G2M) operation be conductable in addition to the microgrid-to-grid (M2G) operation. As for the electric vehicle (EV), the bidirectional inverter can be arranged to perform G2V/V2G operations in idle case, wherein the SMR operation is made in G2V battery charging

Present and Future of Fault Tolerant Drives Applied to Transport Applications

An electric drive is an electromechanical conversion device, consisting of an electrical machine, a power electronic inverter, which interfaces between the machine and the electrical supply, a set of sensors and a digital electronic controller. Drives of this sort are manufactured in high volumes at power levels ranging from less than 1W to many MW. Reliability of the complete system depends upon the local environment, levels of thermal cycling and predictive maintenance schedules. Overall the drive system has a typical reliability of the order of 10-5 failures per hour, making it much more reliable than, say, an internal combustion engine. As part of the “electrical revolution” electric drives are increasingly being developed for safety critical applications, where their reliability is several orders of magnitude below the application requirements. This is particularly the case in electrical propulsion and actuation systems in aircraft, leading to intensive research into fault tolerant electric drives. This paper will illustrate some of the most common failure mechanisms and the consequences of such failures. It will then progress to examine architectures which are fault tolerant through partitioning of the drive into several independent lanes and examine the penalties of adopting such an approach. The paper will discuss pros and cons of different fault tolerant architectures and suggests future research and development steps that are required to increase the overall safety of electric drives

Convertisseurs à bobine variable pour applications de transport durables

Abstract: Power electronics converters are key components and enable efficient conversion and management of electrical energy in a wide range of applications. For vehicular use, there is an inevitable need to improve their performance and reducing their size. This is particularly important in case of powertrain DC-DC converters as they are required to have improved performance while respecting the specifications, characteristics and stringent space limitations. These objectives define research targets and a particular progress is essential in the field of passive components, semiconductor devices, converter topologies and control. At the current state of technologies, the passive components particularly the power inductors are dominant components which affect the overall volume, cost and performance of power electronic converters. Considering the aforementioned critical aspects, this thesis proposes a variable inductor (VI) concept in order to reduce the weight and size power inductors which are traditionally bulky and have fairly limited operating range. By modulating the permeability of the magnetic material, this concept enhances the current handling capability of power inductors, controls the current ripples, reduces the magnetic and switching losses, as well as the stresses applied to switching devices. Furthermore, it enables the use of smaller cores which leads to the reduction of mass and volume allowing improvements in the converter operation and its overall performance. However, to integrate it into powertrain DC-DC converters, it is fundamental, to question the design of the component itself, the selection of suitable magnetic core materials, and the control of current in the auxiliary winding and saturation management of magnetic cores. This thesis systematically addresses these different research challenges. A particular attention is paid to the experimental study of a VI prototype to demonstrate the concept on a small-scale in order to explore its viability. Subsequently a detailed characterization was developed using finite element analysis to determine the intrinsic functionality of the passive component. Furthermore, this thesis proposed an RMS current based VI design to reduce oversizing of power inductors for electric vehicles application. In this methodology, the selection of a suitable magnetic core material is a crucial step to assure smaller and efficient converters. Hence, this thesis proposes a simplified approach based on weighted property method (WPM) for an appropriate selection of magnetic core in accordance to the needs of the user. Furthermore, to validate the integration of this concept in DC-DC converter topology used in the powertrain of electrified vehicles, an affine parameterization method is used to design the control parameters and a simple management strategy is proposed to enable dynamic control of the VI. The converter control and the proposed strategy are evaluated through simulations of a complete powertrain of a three-wheel recreational vehicle. The small-scale experimental and simulations, and full-scale simulations have demonstrated an interesting capacity of the VI for improving the performance of DC-DC converters for electrified vehicles and manage the saturation of the magnetic core while reducing the size and weight of magnetic components.Les convertisseurs d’électroniques de puissance sont des composants clés de la conversion et gestion efficace de l’énergie électrique dans une large gamme d’applications. Pour des utilisations véhiculaires, il est inévitablement nécessaire d’améliorer leurs performances et de réduire leur taille. Ceci est particulièrement important dans le cas des convertisseurs à courant continu (CC) de la chaine de traction où des performances améliorées en réponse à une large gamme de variations de charge sont recherchées tout en respectant les spécificités, caractéristiques et limitation d’espace nécessaires aux véhicules électrifiés. Ces objectifs définissent une cible de recherche et en particulier des progrès sont essentiels dans le domaine des composants passifs, des dispositifs semi-conducteurs, des topologies des convertisseurs et leurs commandes pour généraliser l’utilisation de véhicules électriques. Les composants passifs, en particulier les inductances de puissance, sont des composants dominants qui affectent le volume global, le coût et les performances de ces convertisseurs d’électroniques de puissance. Compte tenu de ces aspects, cette thèse propose un concept de bobine variable afin de réduire le poids et la taille des inductances de puissance qui sont traditionnellement encombrantes et ont une gamme de fonctionnement assez limitée. En modulant la perméabilité du matériau magnétique, ce concept améliore la capacité de gestion du courant des bobines de puissance, contrôle les ondulations du courant et réduit les pertes magnétiques et par commutation, bien comme les contraintes appliquées aux dispositifs de commutation. En outre, il permet l’utilisation de noyaux plus petits, ce qui entraîne une réduction de masse et de volume, en permettant une amélioration du fonctionnement du convertisseur et de ses performances globales. Cependant, pour l’intégrer aux convertisseurs CC-CC utilisés dans la chaine de traction, il est fondamental de se questionner sur la conception du composant lui-même, la sélection du matériau magnétique, la commande du courant de l’enroulement auxiliaire et la gestion de la saturation du noyau magnétique. Cette thèse aborde de manière systématique ces différents défis de recherche. Une attention particulière est accordée à l’étude expérimentale d’un prototype de bobine variable pour faire la preuve de concept à petite échelle afin d’explorer sa viabilité. Par la suite, une large caractérisation par éléments finis a été développée pour déterminer le fonctionnement intrinsèque de ce composant passif. De plus, cette thèse propose une méthode systématique de design de bobine variable basée sur le courant RMS pour réduire le surdimensionnement traditionnellement associer aux inductances de puissance pour des applications véhiculaires. Dans cette méthodologie, la sélection appropriée du matériau pour le noyau magnétique est une étape cruciale pour garantir des convertisseurs plus petits et efficaces, donc une démarche de sélection simplifiée basée sur la méthode des propriétés pondérées pour le choix de noyau magnétique approprié au besoin de l’application a été mis au point. De plus, pour valider l’intégration de ce concept dans une topologie de convertisseur CC-CC traditionnellement utilisée dans la chaine de traction des véhicules électrifiés, une méthode de synthèse affine a été utilisée pour définir les paramètres des contrôleurs de courant et une stratégie de gestion de la saturation du noyau a été proposée pour permettre le contrôle dynamique de la bobine variable. La commande du convertisseur et la stratégie ont été évaluées par simulation d’une chaine de traction complète d’un véhicule récréatif réel. Les résultats expérimentaux à petite échelle et simulations à pleine échelle ont démontrés des capacités intéressantes de cette bobine variable pour l’amélioration des performances des convertisseurs CC-CC, ayant la capacité de gestion de la saturation du noyau magnétique tout en réduisant la taille et le poids de ces composants passifs, dans le but de son utilisation dans la chaine de traction des véhicules électrifiés

A comprehensive study of key Electric Vehicle (EV) components, technologies, challenges, impacts, and future direction of development

Abstract: Electric vehicles (EV), including Battery Electric Vehicle (BEV), Hybrid Electric Vehicle (HEV), Plug-in Hybrid Electric Vehicle (PHEV), Fuel Cell Electric Vehicle (FCEV), are becoming more commonplace in the transportation sector in recent times. As the present trend suggests, this mode of transport is likely to replace internal combustion engine (ICE) vehicles in the near future. Each of the main EV components has a number of technologies that are currently in use or can become prominent in the future. EVs can cause significant impacts on the environment, power system, and other related sectors. The present power system could face huge instabilities with enough EV penetration, but with proper management and coordination, EVs can be turned into a major contributor to the successful implementation of the smart grid concept. There are possibilities of immense environmental benefits as well, as the EVs can extensively reduce the greenhouse gas emissions produced by the transportation sector. However, there are some major obstacles for EVs to overcome before totally replacing ICE vehicles. This paper is focused on reviewing all the useful data available on EV configurations, battery energy sources, electrical machines, charging techniques, optimization techniques, impacts, trends, and possible directions of future developments. Its objective is to provide an overall picture of the current EV technology and ways of future development to assist in future researches in this sector

Power Quality Issues in Distributed Generation

This book deals with several selected aspects of electric power quality issues typically faced during grid integration processes of contemporary renewable energy sources. In subsequent chapters of this book the reader will be familiarized with the issues related to voltage and current harmonics and inter-harmonics generation and elimination, harmonic emission of switch-mode rectifiers, reactive power flow control in power system with non-linear loads, modeling and simulation of power quality issues in power grid, advanced algorithms used for estimating harmonic components, and new methods of measurement and analysis of real time accessible power quality related data