Design Approaches to Enhance Power Density in Power Converters for Traction Applications

This dissertation presents a design strategy to increase the power density for automotive Power Conversion Units (PCUs) consisting of DC-DC and DC-AC stages. The strategy significantly improves the volumetric power density, as evident by a proposed PCU constructed and tested having 55.6 kW/L, representing an 11.2 % improvement on the Department of Energy’s 2025 goal of 50 kW/L for the same power electronics architecture. The dissertation begins with a custom magnetic design procedure, based on optimization of a predetermined C-core geometrical relationship and custom Litz wire. It accounts for electrical and thermal tradeoffs to produce a magnetic structure to best accomplish volume and thermal constraints. This work is coupled with a control strategy for the DC-DC converter whereby a variable-frequency Discontinuous Conduction Mode (DCM) control is used to further reduce the required values of the passive components, to provide an increase in power density and a large improvement of low-power-level efficiency, experimentally demonstrated at full power through an 80 kW Interleaved Boost Converter. Integration of this enhanced DC-DC stage to the DC-AC stage requires a DC-Link capacitor, which hinders achieving power density targets. Increasing the switching frequency is an established method of reducing the size of passives. However, it is the RMS current sizing requirements that diminishes any gains achieved by raising the switching frequency. A synchronous carrier phase shift-based control algorithm, that aligns the output current of the boost stage with the input current of an inverter, is proposed to reduce the RMS current in the DC-Link capacitor by up to 25% and an average 20% smaller capacitor volume. Lastly, a new electrothermal platform based on paralleled discrete devices is presented for a 50 kW traction inverter. Embedded capacitors within the vacant volume of the hybrid material thermal management structure enables higher power density (155 kW/L) and significantly reduces cost

Design Approaches to Enhance Power Density in Power Converters for Traction Applications

This dissertation presents a design strategy to increase the power density for automotive Power Conversion Units (PCUs) consisting of DC-DC and DC-AC stages. The strategy significantly improves the volumetric power density, as evident by a proposed PCU constructed and tested having 55.6 kW/L, representing an 11.2 % improvement on the Department of Energy’s 2025 goal of 50 kW/L for the same power electronics architecture. The dissertation begins with a custom magnetic design procedure, based on optimization of a predetermined C-core geometrical relationship and custom Litz wire. It accounts for electrical and thermal tradeoffs to produce a magnetic structure to best accomplish volume and thermal constraints. This work is coupled with a control strategy for the DC-DC converter whereby a variable-frequency Discontinuous Conduction Mode (DCM) control is used to further reduce the required values of the passive components, to provide an increase in power density and a large improvement of low-power-level efficiency, experimentally demonstrated at full power through an 80 kW Interleaved Boost Converter. Integration of this enhanced DC-DC stage to the DC-AC stage requires a DC-Link capacitor, which hinders achieving power density targets. Increasing the switching frequency is an established method of reducing the size of passives. However, it is the RMS current sizing requirements that diminishes any gains achieved by raising the switching frequency. A synchronous carrier phase shift-based control algorithm, that aligns the output current of the boost stage with the input current of an inverter, is proposed to reduce the RMS current in the DC-Link capacitor by up to 25% and an average 20% smaller capacitor volume. Lastly, a new electrothermal platform based on paralleled discrete devices is presented for a 50 kW traction inverter. Embedded capacitors within the vacant volume of the hybrid material thermal management structure enables higher power density (155 kW/L) and significantly reduces cost

Digital Control of Power Converters and Drives for Hybrid Traction and Wireless Charging

In the last years environmental issues and constant increase of fuel and energy cost have been incentivizing the development of low emission and high efficiency systems, either in traction field or in distributed generation systems from renewable energy sources. In the automotive industry, alternative solutions to the standard internal combustion engine (ICE) adopted in the conventional vehicles have been developed, i.e. fuel cell electric vehicles (FCEVs), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEV) or pure electric vehicles (EVs), also referred as battery powered electric vehicles (BEV). Both academic and industry researchers all over the world are still facing several technical development areas concerning HEV components, system topologies, power converters and control strategies. Efficiency, lifetime, stability and volume issues have moved the attention on a number of bidirectional conversion solutions, both for the energy transfer to/from the storage element and to/from the electric machine side. Moreover, along with the fast growing interest in EVs and PHEVs, wireless charging, as a new way of charging batteries, has drawn the attention of researchers, car manufacturers, and customers recently. Compared to conductive power transfer (usually plug-in), wireless power transfer (WPT) is more convenient, weather proof, and electric shock protected. However, there is still more research work needs to be done to optimize efficiency, cost, increase misalignment tolerance, and reduce size of the WPT chargers. The proposed dissertation describes the work from 2012 to 2014, during the PhD course at the Electric Drives Laboratory of the University of Udine and during my six months visiting scholarship at the University of Michigan in Dearborn. The topics studied are related to power conversion and digital control of converters and drives suitable for hybrid/electric traction, generation from renewable energy sources and wireless charging applications. From the theoretical point of view, multilevel and multiphase DC/AC and DC/DC converters are discussed here, focusing on design issues, optimization (especially from the efficiency point-of-view) and advantages. Some novel modulation algorithms for the neutral-point clamped three-level inverter are presented here as well as a new multiphase proposal for a three-level buck converter. In addition, a new active torque damping technique in order to reduce torque oscillations in internal combustion engines is proposed here. Mainly, two practical implementations are considered in this dissertation, i.e. an original two-stage bi-directional converter for mild hybrid traction and a wireless charger for electric vehicles fast charge

Cost-Effective Model Predictive Control Techniques for Modular Multilevel Converters

In this thesis, model predictive control (MPC) techniques are investigated with their applications to modular multilevel converters (MMCs). Since normally a large number of submodule (SM) capacitor voltages and gate signals need to be handled in an MMC, the MPC schemes studied in this thesis are employed for determining only the voltage levels of converter arms, while gate signals are subsequently generated by the conventional sorting method. Emphasis is given to inner-loop current control in terms of phase current and circulating current, aiming at performance enhancement and computation reduction. A variable rounding level control (VRLC) approach is developed in this thesis, which is based on a modification of the conventional nearest level control (NLC) scheme: instead of the conventional nearest integer function, a proper rounding function is selected for each arm of the MMC employing the MPC method. As a result, the simplicity of the NLC is maintained while the current regulating ability is improved. The VRLC technique can also be generalized from an MPC perspective. Different current controllers can be considered to generate the arm voltage references as input of the VRLC block, thus refining the control sets of the MPC. Based on the decoupled current models, the accumulated effect of SM capacitor voltage ripples is investigated, revealing that the VRLC strategy may not achieve a proper performance if the accumulated ripple is nontrivial compared to the voltage per level. Two indexes are also proposed for quantifying the current controllability of the VRLC. Benefiting from this analysis, A SM-grouping solution is put forward to apply such MPC techniques to an MMC with a large number of SMs, leading to an equivalent operation of an MMC with much reduced number of SMs, which significantly increases the current regulating capability with reduced complexity. As an example, the SM-grouping VRLC proposal is analyzed and its system design principles are described. This thesis also develops another MPC technique which directly optimizes the cost function using quadratic programming technique. Both a rigorous and a simplified procedure are provided to solve the optimization problem. Compared with the conventional finite control set (FCS)-MPC method which evaluates all voltage level combinations, the proposed scheme presents apparent advantage in terms of calculation cost while achieving similar performance

Development of Multiport Single Stage Bidirectional Converter for Photovoltaic and Energy Storage Integration

The energy market is on the verge of a paradigm shift as the emergence of renewable energy sources over traditional fossil fuel based energy supply has started to become cost competitive and viable. Unfortunately, most of the attractive renewable sources come with inherent challenges such as: intermittency and unreliability. This is problematic for today\u27s stable, day ahead market based power system. Fortunately, it is well established that energy storage devices can compensate for renewable sources shortcomings. This makes the integration of energy storage with the renewable energy sources, one of the biggest challenges of modern distributed generation solution. This work discusses, the current state of the art of power conversion systems that integrate photovoltaic and battery energy storage systems. It is established that the control of bidirectional power flow to the energy storage device can be improved by optimizing its modulation and control. Traditional multistage conversion systems offers the required power delivery options, but suffers from a rigid power management system, reduced efficiency and increased cost. To solve this problem, a novel three port converter was developed which allows bidirectional power flow between the battery and the load, and unidirectional power flow from the photovoltaic port. The individual two-port portions of the three port converter were optimized in terms of modulation scheme. This leads to optimization of the proposed converter, for all possible power flow modes. In the second stage of the project, the three port converter was improved both in terms of cost and efficiency by proposing an improved topology. The improved three port converter has reduced functionality but is a perfect fit for the targeted microinverter application. The overall control system was designed to achieve improved reference tracking for power management and output AC voltage control. The bidirectional converter and both the proposed three port converters were analyzed theoretically. Finally, experimental prototypes were built to verify their performance

Development of alternative pulse width modulation methods for conventional and multilevel voltage source inverters

This thesis was submitted for the award of Doctor of Philosophy and was awarded by Brunel University LondonMultilevel inverters have attracted wide interest in both the academic community and the industry for the past decades. Therefore, the investigation and development of modulation strategies in multilevel inverters emerges as a necessity for the industry and researchers. In this doctoral thesis, alternative modulation methods suitable for three-level conventional single-phase inverters and especially for cascade H-bridge multilevel inverters are discussed and proposed. The theory of Equal Areas is reformed and presented and its modifications are proposed. These modifications are compared with other well-known modulation schemes, such as carrier-based modulation schemes and programmed pulse width modulation techniques. The advantage of the modified Equal Areas Pulse Width Modulation (EAPWM) is its algorithmic simplicity due to simple algebraic relationships, which results in less computational effort. A fully mathematical formulation for the Equal Areas modulation is proposed for both conventional and multilevel inverters. The EAPWM is shown to produce well-formed switched output voltages that have low total harmonic distortion at even low switching frequencies. The importance of this thesis is complimented by the results, produced after the implementation of EAPWM in multilevel inverters, which can be used as a more accurate reference when compared with other modulation strategies. Moreover, this direct modulation strategy has been extended to work on higher amplitude modulation ratios, in a linear manner, while entering the over modulation region. In this context, modified algorithms have been developed using different criteria for the calculation of the pulses’ width and their placement inside the time interval. The equal areas method, implemented in conventional single-phase inverters, uses odd pulse numbers per half cycle, holding integer frequency ratios in contrast to its implementation in multilevel inverters, where non-integer frequency ratios occur due to the level-by-level application. The application of the method is verified by simulations together with experimental work using a full-scale prototype inverter

Contributions to Modulation and Control Algorithms for Multilevel Converters

Las actuales tendencias de la red eléctrica han lanzado a la industria a la búsqueda de sistemas de generación, distribución y consumo de energía eléctrica más eficientes. Generación distribuida, reducción de componentes pasivos, líneas DC de alta tensión son, entre otras, las posibles líneas de investigación que están actualmente siendo consideradas como el futuro de la red eléctrica. Sin embargo, nada de esto sería posible si no fuera por los avances alcanzados en el campo de la electrónica de potencia. El trabajo aquí presentado comienza con una breve introducción a la electrónica de potencia, concretamente a los convertidores de potencia conectados a red, sus estrategias de control más comunes y enfoques ante redes desbalanceadas. A continuación, las contribuciones del autor sobre el control y modulación de una topología particular de convertidores, conocidos como convertidores multinivel, se presentan como el principal contenido de este trabajo. Este tipo de convertidores mejoran la eficiencia y ciertas prestaciones, en comparación con convertidores más tradicionales, a costa de una mayor complejidad en el control al incrementar la cantidad de los componentes hardware. A pesar de que existen numerosas topologías de convertidores multinivel y algunas de ellas son brevemente expuestas en este trabajo, la mayoría de las aportaciones están enfocadas para convertidores del tipo diode-clamped converter. Adicionalmente, se incluye una aportación para convertidores del tipo multinivel modular, y otra para convertidores en cascada. Se espera que el contenido de la introducción de este trabajo, junto a las contribuciones particulares para convertidores multinivel sirva de inspiración para futuros investigadores del campo

Industrial and Technological Applications of Power Electronics Systems

The Special Issue "Industrial and Technological Applications of Power Electronics Systems" focuses on: - new strategies of control for electric machines, including sensorless control and fault diagnosis; - existing and emerging industrial applications of GaN and SiC-based converters; - modern methods for electromagnetic compatibility. The book covers topics such as control systems, fault diagnosis, converters, inverters, and electromagnetic interference in power electronics systems. The Special Issue includes 19 scientific papers by industry experts and worldwide professors in the area of electrical engineering