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

A comprehensive review on Bidirectional traction converter for Electric vehicles

In this fast-changing environmental condition, the effect of fossil fuel in vehicle is a significant concern. Many sustainable sources are being studied to replace the exhausting fossil fuel in most of the countries. This paper surveys the types of electric vehicle’s energy sources and current scenario of the on-road electric vehicle and its technical challenges. It summarizes the number of state-of-the-art research progresses in bidirectional dc-dc converters and its control strategies reported in last two decades. The performance of the various topologies of bidirectional dc-dc converters is also tabulated along with their references. Hence, this work will present a clear view on the development of state-of-the-art topologies in bidirectional dc-dc converters. This review paper will be a guide for the researchers for selecting suitable bidirectional traction dc-dc converters for electric vehicle and it gives the clear picture of this research field

Modeling and Optimization Algorithm for SiC-based Three-phase Motor Drive System

More electric aircraft (MEA) and electrified aircraft propulsion (EAP) becomes the important topics in the area of transportation electrifications, expecting remarkable environmental and economic benefits. However, they bring the urgent challenges for the power electronics design since the new power architecture in the electrified aircraft requires many benchmark designs and comparisons. Also, a large number of power electronics converter designs with different specifications and system-level configurations need to be conducted in MEA and EAP, which demands huge design efforts and costs. Moreover, the long debugging and testing process increases the time to market because of gaps between the paper design and implementation. To address these issues, this dissertation covers the modeling and optimization algorithms for SiC-based three-phase motor drive systems in aviation applications. The improved models can help reduce the gaps between the paper design and implementation, and the implemented optimization algorithms can reduce the required execution time of the design program. The models related to magnetic core based inductors, geometry layouts, switching behaviors, device loss, and cooling design have been explored and improved, and several modeling techniques like analytical, numerical, and curve-fitting methods are applied. With the developed models, more physics characteristics of power electronics components are incorporated, and the design accuracy can be improved. To improve the design efficiency and to reduce the design time, optimization schemes for the filter design, device selection combined with cooling design, and system-level optimization are studied and implemented. For filter design, two optimization schemes including Ap based weight prediction and particle swarm optimization are adopted to reduce searching efforts. For device selection and related cooling design, a design iteration considering practical layouts and switching speed is proposed. For system-level optimization, the design algorithm enables the evaluation of different topologies, modulation schemes, switching frequencies, filter configurations, cooling methods, and paralleled converter structure. To reduce the execution time of system-level optimization, a switching function based simulation and waveform synthesis method are adopted. Furthermore, combined with the concept of design automation, software integrated with the developed models, optimization algorithms, and simulations is developed to enable visualization of the design configurations, database management, and design results

A comprehensive review on Bidirectional traction converter for Electric vehicles

In this fast-changing environmental condition, the effect of fossil fuel in vehicle is a significant concern. Many sustainable sources are being studied to replace the exhausting fossil fuel in most of the countries. This paper surveys the types of electric vehicle’s energy sources and current scenario of the on-road electric vehicle and its technical challenges. It summarizes the number of state-of-the-art research progresses in bidirectional dc-dc converters and its control strategies reported in last two decades. The performance of the various topologies of bidirectional dc-dc converters is also tabulated along with their references. Hence, this work will present a clear view on the development of state-of-the-art topologies in bidirectional dc-dc converters. This review paper will be a guide for the researchers for selecting suitable bidirectional traction dc-dc converters for electric vehicle and it gives the clear picture of this research field

Development of a multilevel converter topology for transformer-less connection of renewable energy systems

The global need to reduce dependence on fossil fuels for electricity production has become an ongoing research theme in the last decade. Clean energy sources (such as wind energy and solar energy) have considerable potential to reduce reliance on fossil fuels and mitigate climate change. However, wind energy is going to become more mainstream due to technological advancement and geographical availability. Therefore, various technologies exist to maximize the inherent advantages of using wind energy conversion systems (WECSs) to generate electrical power. One important technology is the power electronics interface that enables the transfer and effective control of electrical power from the renewable energy source to the grid through the filter and isolation transformer. However, the transformer is bulky, generates losses, and is also very costly. Therefore, the term "transformer-less connection" refers to eliminating a step-up transformer from the WECS, while the power conversion stage performs the conventional functions of a transformer. Existing power converter configurations for transformer-less connection of a WECS are either based on the generator-converter configuration or three-stage power converter configuration. These configurations consist of conventional multilevel converter topologies and two-stage power conversion between the generator-side converter topology and the high-order filter connected to the collection point of the wind power plant (WPP). Thus, the complexity and cost of these existing configurations are significant at higher voltage and power ratings. Therefore, a single-stage multilevel converter topology is proposed to simplify the power conversion stage of a transformer-less WECS. Furthermore, the primary design challenges – such as multiple clamping devices, multiple dc-link capacitors, and series-connected power semiconductor devices – have been mitigated by the proposed converter topology. The proposed converter topology, known as the "tapped inductor quasi-Z-source nested neutral-point-clamped (NNPC) converter," has been analyzed, and designed, and a prototype of the topology developed for experimental verification. A field-programmable gate array (FPGA)-based modulation technique and voltage balancing control technique for maintaining the clamping capacitor voltages was developed. Hence, the proposed converter topology presents a single-stage power conversion configuration. Efficiency analysis of the proposed converter topology has been studied and compared to the intermediate and grid-side converter topology of a three-stage power converter configuration. A direct current (DC) component minimization technique to minimize the dc component generated by the proposed converter topology was investigated, developed, and verified experimentally. The proposed dc component minimization technique consists of a sensing and measurement circuitry with a digital notch filter. This thesis presents a detailed and comprehensive overview of the existing power converter configurations developed for transformer-less WECS applications. Based on the developed 2 comparative benchmark factor (CBF), the merits and demerits of each power converter configuration in terms of the component counts and grid compliance have been presented. In terms of cost comparison, the three-stage power converter configuration is more cost-effective than the generatorconverter configuration. Furthermore, the cost-benefit analysis of deploying a transformer-less WECSs in a WPP is evaluated and compared with conventional WECS in a WPP based on power converter configurations and collection system. Overall, the total cost of the collection system of WPP with transformer-less WECSs is about 23% less than the total cost of WPP with conventional WECs. The derivation and theoretical analysis of the proposed five-level tapped inductor quasi-Z-source NNPC converter topology have been presented, emphasizing its operating principles, steady-state analysis, and deriving equations to calculate its inductance and capacitance values. Furthermore, the FPGA implementation of the proposed converter topology was verified experimentally with a developed prototype of the topology. The efficiency of the proposed converter topology has been evaluated by varying the switching frequency and loads. Furthermore, the proposed converter topology is more efficient than the five-level DC-DC converter with a five-level diode-clamped converter (DCC) topology under the three-stage power converter configuration. Also, the cost analysis of the proposed converter topology and the conventional converter topology shows that it is more economical to deploy the proposed converter topology at the grid side of a transformer-less WECS

Efficient, High Power Density, Modular Wide Band-gap Based Converters for Medium Voltage Application

Recent advances in semiconductor technology have accelerated developments in medium-voltage direct-current (MVDC) power system transmission and distribution. A DC-DC converter is widely considered to be the most important technology for future DC networks. Wide band-gap (WBG) power devices (i.e. Silicon Carbide (SiC) and Gallium Nitride (GaN) devices) have paved the way for improving the efficiency and power density of power converters by means of higher switching frequencies with lower conduction and switching losses compared to their Silicon (Si) counterparts. However, due to rapid variation of the voltage and current, di/dt and dv/dt, to fully utilize the advantages of the Wide-bandgap semiconductors, more focus is needed to design the printed circuit boards (PCB) in terms of minimizing the parasitic components, which impacts efficiency. The aim of this dissertation is to study the technical challenges associated with the implementation of WBG devices and propose different power converter topologies for MVDC applications. Ship power system with MVDC distribution is attracting widespread interest due to higher reliability and reduced fuel consumption. Also, since the charging time is a barrier for adopting the electric vehicles, increasing the voltage level of the dc bus to achieve the fast charging is considered to be the most important solution to address this concern. Moreover, raising the voltage level reduces the size and cost of cables in the car. Employing MVDC system in the power grid offers secure, flexible and efficient power flow. It is shown that to reach optimal performance in terms of low package inductance and high slew rate of switches, designing a PCB with low common source inductance, power loop inductance, and gate-driver loop are essential. Compared with traditional power converters, the proposed circuits can reduce the voltage stress on switches and diodes, as well as the input current ripple. A lower voltage stress allows the designer to employ the switches and diodes with lower on-resistance RDS(ON) and forward voltage drop, respectively. Consequently, more efficient power conversion system can be achieved. Moreover, the proposed converters offer a high voltage gain that helps the power switches with smaller duty-cycle, which leads to lower current and voltage stress across them. To verify the proposed concept and prove the correctness of the theoretical analysis, the laboratory prototype of the converters using WBG devices were implemented. The proposed converters can provide energy conversion with an efficiency of 97% feeding the nominal load, which is 2% more than the efficiency of the-state-of-the-art converters. Besides the efficiency, shrinking the current ripple leads to 50% size reduction of the input filter inductors