Design and implementation of a three-phase boost battery charger with PFC using CompactRIO control system : design, simulation and implementation of a 3-phase boost battery charger

In a plug-in hybrid electric vehicle, the utility grid charges the vehicle battery through a battery charger. For a three-phase grid supply voltage, three-phase boost rectifiers are commonly used as chargers. Bi-directional power transfer capability and unit power factor operation become desirable features due to the increasing power quality requirements on the grid-connected converters. The Voltage Oriented Control is one of the methods based on high performance dq-coordinate controllers which satisfies the increasing power quality requirements. The Voltage Oriented Control method for a three-phase boost rectifier has been designed, simulated and implemented. The system simulation is performed using Matlab/Simulink software as well as Labview. A feedforward decoupled current controller is designed along with a Pulse Width Modulation scheme to control the battery charging. The controller, consisting of a current controller and a DC-link voltage controller, is designed using a method called Internal Model Control. A National Instruments CompactRIO system is used for practical implementation. The system directly runs a Labview model to execute the control. The Labview files are developed for this purpose. A brief explanation of the system configuration is provided for the experimental system. ____________________________________________________________________________________________________________Los vehículos eléctricos e híbridos usan potencia de la red para cargar sus baterías y mientras lo hacen el sistema de tracción no está en uso. Debido a que el sistema de carga y el de tracción no están en uso al mismo tiempo, el inversor y el motor eléctrico pueden ser usados como rectificador evitando el uso redundante de componentes. Para hacer esto, un motor con dos juegos de devanados puede ser usado consiguiendo en el cargador una reducción considerable de peso, volumen y precio. El cargador propuesto en un cargador aislado de alta potencia que usa la mitad de los devanados del motor durante la carga usando el motor como si fuera un transformador. El uso de este motor especifico nos proporcionará aislamiento que será beneficioso por razones de seguridad. El objetivo principal de este proyecto fin de carrera es el diseño y la implementación de un cargador integrado para un coche eléctrico o híbrido con un nivel de potencia de 15 kW programando un control para el inversor que consiga tener un factor de potencia unitario.Ingeniería Industria

The state of the art of battery charging infrastructure for electrical vehicles: Topologies, power control strategies, and future trend

Electric vehicle battery (EVB) charger topologies play a vital role to increase the penetration of EVs. This paper reviews the status quo of EV battery (EVB) chargers in term of converter topologies, operation modes, and power control strategies for EVs. EVB Chargers are classified based on their power levels and power flow direction. Referring to power ratings, EV chargers can be divided into Level 1, Level 2 and Level 3. Level 1 and Level 2 are normally compatible with on-board chargers while Level 3 is used for an off-board charger. Unidirectional/bidirectional power flow can be obtained at all power levels. However, bidirectional power flow is usually designed for Level 3 chargers as it can provide the huge benefit of transferring power back to grid when needed. Moreover, the different operation modes of an EVB charger are also presented. There are two main modes: Grid-to-Vehicle (V1G or G2V) and Vehicle-to-Grid (V2G). The V2G mode helps bring EV batteries to become active distributed sources in smart grids and is the crucial solution for a high EV penetration. Future trend and authors\u27 recommendations with preliminary simulation and experimental results are demonstrated in this paper

Real-Time Simulation of Efficient Energy Management Algorithms for Electric Vehicle Chargers

Transportation electrification is happening at a rapid pace around the globe in response to the climate change mitigation measures taken by the regulatory agencies to curb tailpipe emissions. As the electric vehicle technology evolved, the size of on-board storage units has increased, which require charging from an external energy source. Renewable charging of electric vehicles is an attractive option to reduce the carbon footprint of an electric vehicle. The intermittent nature of the renewables necessitates a storage unit to provide continuous power. With a battery complementing solar generation, a power converter is deployed to interface these sources and storage units with the electric vehicle for charging. The converter shall now have to operate to quench the charging requirements by sourcing power from solar generation and storage elements. The converter also has to capture the generated solar power during the non-charging period and store it in the battery. All these functional requirements demand a robust energy management strategy to utilize all available sources and storage units efficiently without compromising load requirements. A Stateflow-based energy management algorithm for a three-port converter is proposed in this work. The proposed algorithm is implemented using OPAL-RT, and the real-time simulation results are presented

Efficient Digital System Management using IEEE 1451.0 Enabled Control Architecture

The IEEE and National Institute of Standards and Technology have formulated an open universal standard called IEEE 1451 for ‘Smart Transducer Interface’ with digital systems. The objectives of this paper is to propose IEEE 21450 enabled control architectures for efficient management of power system with embedded system parameters as electronic documentation. The control architecture accommodates appropriate number of transducer interface module along with transducer electronic data sheet, which enables active calibration, adaptive tuning and failure proof operation of system management

POWER QUALITY CONTROL AND COMMON-MODE NOISE MITIGATION FOR INVERTERS IN ELECTRIC VEHICLES

Inverters are widely utilized in electric vehicle (EV) applications as a major voltage/current source for onboard battery chargers (OBC) and motor drive systems. The inverter performance is critical to the efficiency of EV system energy conversion and electronics system electro-magnetic interference (EMI) design. However, for AC systems, the bandwidth requirement is usually low compared with DC systems, and the control impact on the inverter differential-mode (DM) and common-mode (CM) performance are not well investigated. With the wide-band gap (WBG) device era, the switching capability of power electronics devices drastically improved. The DM/CM impact that was brought by the WBG device-based inverter becomes more serious and has not been completely understood. This thesis provides an in-depth analysis of on-board inverter control strategies and the corresponding DM/CM impact on the EV system. The OBC inverter control under vehicle-to-load (V2L) mode will be documented first. A virtual resistance damping method minimizes the nonlinear load harmonics, and a neutral balancing method regulates the unbalanced load impact through the fourth leg. In the motor drive system, a generalized CM voltage analytical model and a current ripple prediction model are built for understanding the system CM and DM stress with respect to different modulation methods, covering both 2-level and 3-level topologies. A novel CM EMI damping modulation scheme is proposed for 6-phase inverter applications. The performance comparison between the proposed methods and the conventional solution is carried out. Each topic is supported by the corresponding hardware platform and experimental validation

Control and Optimization of Energy Storage in AC and DC Power Grids

Energy storage attracts attention nowadays due to the critical role it will play in the power generation and transportation sectors. Electric vehicles, as moving energy storage, are going to play a key role in the terrestrial transportation sector and help reduce greenhouse emissions. Bulk hybrid energy storage will play another critical role for feeding the new types of pulsed loads on ship power systems. However, to ensure the successful adoption of energy storage, there is a need to control and optimize the charging/discharging process, taking into consideration the customer preferences and the technical aspects. In this dissertation, novel control and optimization algorithms are developed and presented to address the various challenges that arise with the adoption of energy storage in the electricity and transportation sectors. Different decentralized control algorithms are proposed to manage the charging of a mass number of electric vehicles connected to different points of charging in the power distribution system. The different algorithms successfully satisfy the preferences of the customers without negatively impacting the technical constraints of the power grid. The developed algorithms were experimentally verified at the Energy Systems Research Laboratory at FIU. In addition to the charge control of electric vehicles, the optimal allocation and sizing of commercial parking lots are considered. A bi-layer Pareto multi-objective optimization problem is formulated to optimally allocate and size a commercial parking lot. The optimization formulation tries to maximize the profits of the parking lot investor, as well as minimize the losses and voltage deviations for the distribution system operator. Sensitivity analysis to show the effect of the different objectives on the selection of the optimal size and location is also performed. Furthermore, in this dissertation, energy management strategies of the onboard hybrid energy storage for a medium voltage direct current (MVDC) ship power system are developed. The objectives of the management strategies were to maintain the voltage of the MVDC bus, ensure proper power sharing, and ensure proper use of resources, where supercapacitors are used during the transient periods and batteries are used during the steady state periods. The management strategies were successfully validated through hardware in the loop simulation

Design Optimization of Inductive Power Transfer Systems for Contactless Electric Vehicle Charging Applications

Contactless Electric Vehicle (EV) charging based on magnetic resonant induction is an emerging technology that can revolutionize the future of the EV industry and transportation systems by enabling an automated and convenient charging process. However, in order to make this technology an acceptable alternative for conventional plug-in charging systems it needs to be optimized for different design measures. Specifically, the efficiency of an inductive EV charging system is of a great importance and should be comparable to the efficiency of conventional plug-in EV chargers. The aim of this study is to develop solutions that contribute to the design enhancement of inductive EV charging systems. Specifically, generalized physics-based design optimization methods that address the trade-off problem between several key objectives including efficiency, power density, misalignment tolerance, and cost efficiency considering critical constraints are developed. Using the developed design methodology, a 3.7kW inductive charging system with square magnetic structures is investigated as a case study and a prototype is built to validate the optimization results. The developed prototype achieves 93.65% efficiency (DC-to-DC) and a power density of 1.65kW/dm3. Also, self-tuning power transfer control methods with resonance frequency tracking capability and bidirectional power transfer control are presented. The proposed control methods enhance the efficiency of power converters and reduce the Electromagnetic Interference (EMI) by enabling soft-switching operations. Several simplified digital controllers are developed and experimentally implemented. The controllers are implemented without the use of DSP/FPGA solutions. Experimental tests show that of the developed simplified controllers can effectively regulate the power transfer around the desired value. Moreover, the experiments show that compared to conventional converters, the developed converters can achieve 4% higher efficiency at low power levels. Moreover, enhanced matrix converter topologies that can achieve bidirectional power transfer and high efficiency with a reduced number of switching elements are introduced. The self-tuning controllers are utilized to design and develop control schemes for bidirectional power transfer regulation. The simulation analyses and experimental results show that the developed matrix converters can effectively establish bidirectional power transfer at the desired power levels with soft-switching operations and resonance frequency tracking capability. Specifically, a direct three-phase AC-AC matrix converter with a reduced number of switches (only seven) is developed and built. It is shown that the developed converters can achieve efficiencies as high as 98.54% at high power levels and outperform conventional two-stage converters

Bidirectional Electric Vehicles Service Integration in Smart Power Grid with Renewable Energy Resources

As electric vehicles (EVs) become more popular, the utility companies are forced to increase power generations in the grid. However, these EVs are capable of providing power to the grid to deliver different grid ancillary services in a concept known as vehicle-to-grid (V2G) and grid-to-vehicle (G2V), in which the EV can serve as a load or source at the same time. These services can provide more benefits when they are integrated with Photovoltaic (PV) generation. The proper modeling, design and control for the power conversion systems that provide the optimum integration among the EVs, PV generations and grid are investigated in this thesis. The coupling between the PV generation and integration bus is accomplished through a unidirectional converter. Precise dynamic and small-signal models for the grid-connected PV power system are developed and utilized to predict the system’s performance during the different operating conditions. An advanced intelligent maximum power point tracker based on fuzzy logic control is developed and designed using a mix between the analytical model and genetic algorithm optimization. The EV is connected to the integration bus through a bidirectional inductive wireless power transfer system (BIWPTS), which allows the EV to be charged and discharged wirelessly during the long-term parking, transient stops and movement. Accurate analytical and physics-based models for the BIWPTS are developed and utilized to forecast its performance, and novel practical limitations for the active and reactive power-flow during G2V and V2G operations are stated. A comparative and assessment analysis for the different compensation topologies in the symmetrical BIWPTS was performed based on analytical, simulation and experimental data. Also, a magnetic design optimization for the double-D power pad based on finite-element analysis is achieved. The nonlinearities in the BIWPTS due to the magnetic material and the high-frequency components are investigated rely on a physics-based co-simulation platform. Also, a novel two-layer predictive power-flow controller that manages the bidirectional power-flow between the EV and grid is developed, implemented and tested. In addition, the feasibility of deploying the quasi-dynamic wireless power transfer technology on the road to charge the EV during the transient stops at the traffic signals is proven

Challenges of Inductive Electric Vehicle Charging Systems in both Stationary and Dynamic Modes

Inductive power transfer as an emerging technology has become applicable in wide power ranges including Electric Vehicle, Electric Aircraft, wheelchair, cellphone, scooter and so on. Among them, inductive Electric Vehicle (EV) charging has gained great interest in the last decade due to many merits namely contactless technology, more convenience, full automotive charging process. However, inductive EV charging systems could bring about so many issues and concerns which are addressed in this dissertation. One of the critical challenges addressed in this dissertation is a virtual inertia based IPT controller to prevent the undesirable dynamics imposed by the EVs increasing number in the grid. Another adverse issue solved in this dissertation is detecting any metal object intrusions into the charging zone to the Inductive Power Transfer (IPT) systems before leading to heat generation on the metal or risk of fire. Moreover, in this dissertation, a new self-controlled multi-power level IPT controller is developed that enables EV charging level regulation in a wide range of power; suitable for different applications from golf-cart charging system (light duty EV) to truck (heavy duty EV). The proposed controller has many merits including easy to be implemented, cons-effective, and the least complexities compared to conventional PWM methods. Additionally, in this dissertation, the online estimation of IPT parameters using primary measurement including coupling factor, battery current and battery voltage is introduced; the developed method can find immediate applications for the development of adaptive controllers for static and dynamic inductive charging systems. Finally, the last objective of this research is physics-based design optimization techniques for the magnetic structures of inductive EV charging systems for dynamic application (getting charged while in motion). New configuration of IPT transmitting couplers with objective of high-power density, low power loss, low cost and less electromagnetic emission are designed and developed in the lab