Modular DC-DC Converters

DC-DC converter is one of the mostly used power electronic circuits, and it has applications in various areas ranging from portable devices to aircraft power system. Various topologies of dc-dc converters are suitable for different applications. In high power applications such as the bi-directional dc-dc converter for dual bus system in new generation automobiles, several topologies can be considered as a potential candidate. Regardless of the topology used for this application, the reliability of the converter can be greatly enhanced by introducing redundancy of some degree into the system. Using redundancy, uninterrupted operation of the circuit may be ensured when a fault has occurred. The redundancy feature can be obtained by paralleling multiple converters or using a single modular circuit that can achieve this attribute. Thus, a modular dc-dc converter with redundancy is expected to increase the reliability and reduce the system cost. Recently, the advancement in power electronics research has extended its applications in hybrid electric automobiles. Several key requirements of this application are reliable, robust, and high efficiency operation at low cost. In general, the efficiency and reliability of a power electronic circuit greatly depend on the kind of circuit topology used in any application. This is one of the biggest motivations for the researchers to invent new power electronic circuit topologies that will have significant impact in future automobile industry. This dissertation reviews existing modularity in power electronic circuits, and presents a new modular capacitor clamped dc-dc converter design that has many potential uses in future automotive power system. This converter has multilevel operation, and it is capable of handling bi-directional power. Moreover, the modular nature of the converter can achieve redundancy in the system, and thereby, the reliability can be enhanced to a great extent. The circuit has a high operating efficiency (\u3e95%), and it is possible to integrate multiple voltage sources and loads at the same time. Thus, the converter could be considered as a combination of a power electronic converter and a power management system. In addition to the new dc-dc converter topology, a new pair of modular blocks defined as switching cells is presented in this dissertation. This pair of switching cells can be used to analyze many power electronic circuits, and some new designs can be formed using those switching cells in various combinations. Using these switching cells, many power electronic circuits can be made modular, and the modeling and analysis become easier

Multiple-output DC–DC converters: applications and solutions

Multiple-output DC–DC converters are essential in a multitude of applications where different DC output voltages are required. The interest and importance of this type of multiport configuration is also reflected in that many electronics manufacturers currently develop integrated solutions. Traditionally, the different output voltages required are obtained by means of a transformer with several windings, which are in addition to providing electrical isolation. However, the current trend in the development of multiple-output DC–DC converters follows general aspects, such as low losses, high-power density, and high efficiency, as well as the development of new architectures and control strategies. Certainly, simple structures with a reduced number of components and power switches will be one of the new trends, especially to reduce the size. In this sense, the incorporation of devices with a Wide Band Gap (WBG), particularly Gallium Nitride (GaN) and Silicon Carbide (SiC), will establish future trends, advantages, and disadvantages in the development and applications of multiple-output DC–DC converters. In this paper, we present a review of the most important topics related to multiple-output DC–DC converters based on their main topologies and configurations, applications, solutions, and trends. A wide variety of configurations and topologies of multiple-output DC–DC converters are shown (more than 30), isolated and non-isolated, single and multiple switches, and based on soft and hard switching techniques, which are used in many different applications and solutions.info:eu-repo/semantics/publishedVersio

Isolated Single-stage Power Electronic Building Blocks Using Medium Voltage Series-stacked Wide-bandgap Switches

The demand for efficient power conversion systems that can process the energy at high power and voltage levels is increasing every day. These systems are to be used in microgrid applications. Wide-bandgap semiconductor devices (i.e. Silicon Carbide (SiC) and Gallium Nitride (GaN) devices) are very promising candidates due to their lower conduction and switching losses compared to the state-of-the-art Silicon (Si) devices. The main challenge for these devices is that their breakdown voltages are relatively lower compared to their Si counterpart. In addition, the high frequency operation of the wide-bandgap devices are impeded in many cases by the magnetic core losses of the magnetic coupling components (i.e. coupled inductors and/or high frequency transformers) utilized in the power converter circuit. Six new dc-dc converter topologies are propose. The converters have reduced voltage stresses on the switches. Three of them are unidirectional step-up converters with universal input voltage which make them excellent candidates for photovoltaic and fuel cell applications. The other three converters are bidirectional dc-dc converters with wide voltage conversion ratios. These converters are very good candidates for the applications that require bidirectional power flow capability. In addition, the wide voltage conversion ratios of these converters can be utilized for applications such as energy storage systems with wide voltage swings

A Comprehensive Review of DC-DC Converters for EV Applications

DC-DC converters in Electric vehicles (EVs) have the role of interfacing power sources to the DC-link and the DC-link to the required voltage levels for usage of different systems in EVs like DC drive, electric traction, entertainment, safety and etc. Improvement of gain and performance in these converters has a huge impact on the overall performance and future of EVs. So, different configurations have been suggested by many researches. In this paper, bidirectional DC-DC converters (BDCs) are divided into four categories as isolated-soft, isolated-hard, non-isolated-soft and non-isolated-hard depending on the isolation and type of switching. Moreover, the control strategies, comparative factors, selection for a specific application and recent trends are reviewed completely. As a matter of fact, over than 200 papers have been categorized and considered to help the researchers who work on BDCs for EV application

High-Frequency Bidirectional DC-DC Converters for Electric Vehicle Applications

As a part of an electric vehicle (EV) onboard charger, a highly efficient, highly compact, lightweight and isolated DC-DC converter is required to enable battery charging through voltage/current regulation. In addition, a bidirectional on-board charger requires the DC-DC converter to achieve bidirectional power flow: grid-to-vehicle (G2V) and vehicle-to-grid (V2G). In this work, performance characteristics of two popular DC-DC topologies, CLLC and dual active bridge (DAB), are analyzed and compared for EV charging applications. The CLLC topology is selected due to its wide gain range, soft-switching capability over the full load range, and potential for a smaller and more compact size. This dissertation outlines the feasibility, analyses, and performance of a CLLC converter investigated and designed to operate at 1 MHz and 3.3 kW for EV onboard chargers. The proposed design utilizes the emerging wide bandgap (WBG) gallium nitride (GaN) based MOSFETs to enable high-frequency switching without sacrificing the conversion efficiency. One of the major challenges in MHz-level power converter design is to reduce the parasitic components of printed circuit boards (PCBs), which can cause faulty triggering of switches leading to circuit failure. An innovative gate driver is designed and optimized to minimize the effect of parasitic components, which includes a +6/-3 V driving logic enhancing the noise immunity of the system. Another challenge is the efficient design of magnetic components, which requires minimizing the impacts of skin and proximity effects on the transformer winding to reduce the conduction loss at high frequencies. A novel MHz-level planar transformer with adjustable leakage inductance is modeled, designed, and developed for the proposed converter. A comprehensive system level power loss analysis is completed and confirmed with the help of experimental results. This is the first prototype of a 3.3 kW power bidirectional CLLC converter operating at 1 MHz operating frequency with 400-450 V input voltage range, 250-420 V output voltage range. The experiment results have successfully validated the feasibility of the proposed converter conforming to the analysis carried out during the design phase. With an appropriate design of driving circuit and control signal, the prototype achieves a peak efficiency of 97.2% with 9.22 W/cm3 (151.1 W/in3) power density which is twice more power dense than other state-of-the-art isolated DC-DC converters

Multiport DC-DC Converters for Hybrid Energy Systems

Renewable energy sources (RESs) like solar and wind have gained attention for their potential to reduce reliance on fossil fuels and mitigate climate change. However, integrating multiple RESs into a power grid is challenging due to their unpredictable nature. Power electronic converters can manage hybrid energy systems by controlling power flow between RESs, storages, and the grid. Conventional single input dc-dc converters have limitations such as low efficiency, bulky designs, and complex control systems. Multiport dc-dc converters (MPCs) have emerged as a solution for hybridizing multiple sources, storages, and load systems by providing a common interface. Existing MPCs have limitations such as high component count, limited operational range, complex control strategies and restrictions on the number of inputs to list a few. Thus, there is a need to develop new MPCs that combine the advantages of existing designs while overcoming their limitations. Isolated MPCs with unipolar or bipolar outputs are needed that can accommodate any number of inputs, offer high voltage gain, use fixed magnetic components for galvanic isolation (regardless of the number of ports), and have a simplified control strategy. Additionally, new non-isolated MPCs with unipolar or bipolar outputs are required, featuring reduced component count, simultaneous power transfer and power flow between input ports, high voltage gain, low control complexity, and modular design allowing for arbitrary increase in the number of input ports. There is also an opportunity to apply MPCs in the integration of RESs and storages to ac grids through multilevel inverters for low component count, high efficiency, low harmonics, and higher power density. Further, advances in bipolar MPCs provide the chance to balance the dc bus without requiring a complex control system.acceptedVersio

Packaging Design of IGBT Power Module Using Novel Switching Cells

Parasitic inductance in power modules generates voltage spikes and current ringing during switching which cause extra stress in power electronic devices, increase electromagnetic interference (EMI), and degrade the performance of the power converter system. As newer power devices have faster switching speeds and higher power ratings, the effect of the parasitic inductance of the power module is more pronounced. This dissertation proposes a novel packaging method for power electronics modules based on the concepts of novel switching cells: P-cell and N-cell. It can reduce the stray inductance in the current commutation path in a phase-leg module and hence improve the switching behavior. Taking an insulated gate bipolar transistor (IGBT) as an example, two phase-leg modules, specifically a conventional module and a P-cell and N-cell based module were designed. Using Ansoft Q3D Extractor, electromagnetic simulation was carried out to extract the stray inductance from the two modules. An ABB 1200 V / 75 A IGBT model and a diode model were built for simulation study. Circuit parasitics were extracted and modeled. Switching behavior with different package parasitics was studied based on the Saber simulation. Two prototype phase-leg modules were fabricated. The parasitics were measured using a precision impedance analyzer. The measurement results agree with the simulation very well. A double pulse tester was built in laboratory. Several approaches were used to reduce the circuit and measuring parasitics. From the switching characteristics of the two modules, it was verified that the larger stray inductance in the layout causes higher voltage overshoot during turn off, which in turn increases the turn off losses. Multichip (two in parallel) IGBT modules applying novel switching cells was also designed. The parasitics were extracted and compared to a conventional design. The overall loop inductance was reduced in the proposed module. However, the mismatch of the paralleled branches was larger

Vehicle electrification: technologies, challenges and a global perspective for smart grids

Nowadays, due to economic and climate concerns, the private transportation sector is shifting for the vehicle electrification, mainly supported by electric and hybrid plug-in vehicles. For this new reality, new challenges about operation modes are emerging, demanding a cooperative and dynamic operation with the electrical power grid, guaranteeing a stable integration without omitting the power quality for the grid-side and for the vehicle-side. Besides the operation modes, new attractive and complementary technologies are offered by the vehicle electrification in the context of smart grids, which are valid for both on-board and off-board systems. In this perspective, this book chapter presents a global perspective and deals with challenges for the vehicle electrification, covering the key technologies toward a sustainable future. Among others, the flowing topics are covered: (1) Overview of power electronics structures for battery charging systems, including on-board and off-board systems; (2) State-of-the-art of communication technologies for application in the context of vehicular electrification, smart grids and smart homes; (3) Challenges and opportunities concerning wireless power transfer with bidirectional interface to the electrical grid; (4) Future perspectives about bidirectional power transfer between electric vehicles (vehicle-to-vehicle operation mode); (5) Unified technologies, allowing to combine functionalities of a bidirectional interface with the electrical grid and motor driver based on a single system; and (6) Smart grids and smart homes scenarios and accessible opportunities about operation modes.Fundação para a Ciência e Tecnologia (FCT

Single-Sensor DCM PFC Based Onboard Chargers for Low Voltage Electric Vehicles

Grid-connected plug-in electric vehicles (PEVs) are considered as one of the most sustainable solutions to substantially reduce both the oil consumption and greenhouse gas emissions. Electric vehicles (EVs) are broadly categorized into low power EVs (48/72 V battery) and high power EVs (450/650 V battery). Low power EVs comprise two-wheelers, three-wheelers (rickshaws), golf carts, intra-logistics equipment and short-range EVs whereas high power EVs consist of passenger cars, trucks and electric buses. Charger, which is a power electronic converter, is an important component of EV infrastructures. These chargers consist of power converters to convert AC voltage (grid) to constant DC voltage (battery). The existing chargers are bulky, have high components’ count, complex control system and poor input power quality. Henceforth, to overcome these drawbacks, this thesis focuses on the onboard charging solutions (two-stage isolated and single-stage non-isolated) for the low voltage battery EVs. Power factor correction (PFC) is the fundamental component in the EV charger. Considering the specific boundaries of the continuous conduction mode (CCM) operation for AC-DC power conversion and their complexity, the proposed chargers are designed to operate in discontinuous conduction mode (DCM) and benefiting from the characteristics like built-in PFC, single sensor, simple control, easy implementation, inherent zero-current turn-on of the switches, and inherent zero diode reverse recovery losses. Proposed converters can operate for the wide input voltage range and the output voltage is controlled by a single sensor-based single voltage control loop making the control simple and easy to implement, and improves the system reliability and robustness. This thesis studies and designs both single-stage non-isolated and two-stage isolated onboard battery chargers to charge a 48 V lead-acid battery pack. At first, a non-isolated single-stage single-cell buck-boost PFC AC-DC converter is studied and analyzed that offers reduced components’ count and is cost-effective, compact in size and illustrates high efficiency. While the DCM operation ensures unity power factor (UPF) operation at AC mains without the use of input voltage and current sensors. However, they employ high current rated semiconductor devices and the use of diode bridge rectifier suffers from higher conduction losses. To overcome these issues, a new front-end bridgeless AC-DC PFC topology is proposed and analyzed. With this new bridgeless front-end topology, the conduction losses are significantly reduced resulting in improved efficiency. The low voltage stress on the semiconductor devices are observed because of the voltage doubler configuration. Later, an isolated two-stage topology is proposed. The previously proposed bridgeless buck-boost derived PFC converter is employed followed by an isolated half-bridge LLC resonant converter. Loss analysis is done to determine optimal DC-link voltage for the efficient operation of the proposed conversion. The converters' steady-state operation, DCM condition, and design equations are reported in detail. The small-signal models for all the proposed topologies using the average current injected equivalent circuit approach are developed, and detailed closed-loop controller design is illustrated. The simulation results from PSIM 11.1 software and the experimental results from proof-of-concept laboratory hardware prototypes are provided in order to validate the reported analysis, design, and performance

Improving the performance of hybrid wind-diesel-battery systems

Off-grid hybrid renewable energy systems are known as an attractive and sustainable solution for supplying clean electricity to autonomous consumers. Typically, this applies to the communities that are located in remote or islanded areas where it is not cost-effective to extend the grid facilities to these regions. In addition, the use of diesel generators for electricity supply in these remote locations are proven to be uneconomical due to the difficult terrain which translates into high fuel transportation costs. The use of renewable energy sources, coupling with the diesel generator allows for the diesel fuel to be offset. However, to date, a common design standard for the off-grid system has yet to be found and some challenges still exist while attempting to design a reliable system. These include the sizing of hybrid systems, coordination between the operation of dissimilar power generators and the fluctuating load demands, optimal utilisation of the renewable energy resources and identifying the underlying principles which reduce the reliability of the off-grid systems. In order to address these challenges, this research has first endeavoured into developing a sizing algorithm which particularly seeks the optimal size of the batteries and the diesel generator usage. The batteries and diesel generator function in filling the gap between the power generated from the renewable energy resources and the load demand. Thus, the load requirement is also an important factor in determining the cost-effectiveness of the overall system in the long run. A sensitivity analysis is carried out to provide a better understanding of the relationship between the assessed renewable energy resources, the load demand, the storage capacity and the diesel generator fuel usage. The thesis also presents the modelling, simulation and experimental work on the proposed hybrid wind-diesel-battery system. These are being implemented with a full-scale system and they are based on the off-the-shelf components. A novel algorithm to optimise the operation of a diesel generator is also proposed. The steady-state and dynamic analysis of the proposed system are presented, from both simulation and an experimental perspective. Three single-phase grid-forming inverters and a fixed speed wind turbine are used as a platform for case studies. The grid-forming inverters adopt droop control method which allows parallel operation of several grid-forming sources. Droop control-based inverters are known as independent and autonomous due to the elimination of intercommunication links among distributed converters. Moreover, the adopted fixed speed wind turbine employs a squirrel cage induction generator which is well known for its robustness, high reliability, simple operation and low maintenance. The results show a good correlation between the modelling, the experimental measurements, and the field tested results. The final stage of this research explores the effect of tower shadow on off-grid systems. Common tower designs for small wind turbine applications, which are the tubular and the lattice configurations, are considered in this work. They generate dissimilar tower shadow profiles due to the difference in structure. In this research, they are analytically modelled for a wind turbine which is being constructed as a downwind configuration. It is proven that tower shadow indeed brings negative consequence to the system, particularly its influence on battery lifetime within an off-grid system. This detrimental effect occurs when power generation closely matches the load demand. In this situation, small frequent charging and discharging cycles or the so called microcycles, take place. The battery lifetime reduction due to these microcycles has been quantified and it is proven that they are not negligible and should be taken into consideration while designing an off-grid hybrid system