Mission Profile Based Optimization of a Synchronous-Buck DC-DC Converter for a Wearable Power System

A Wearable Power System (WPS) is a portable fuel-to-electrical energy converter that is carried on the body and is able to supply an average of 20 W for 4 days and has a total weight of less than 4 kg. Due to limited total weight of the system, each system part must have the highest efficiency to weight ratio. This paper presents the optimization of a synchronous buck DC-DC converter that is used to regulate the variable power source to a constant 14 VDC for the load. Higher switching frequency leads to smaller components and low weight, but at the same time, to higher losses that are compensated through additional fuel weight. If low switching frequency is applied, the weight of the converter will increase due to a larger inductor, but the power losses will be lower. Therefore, an optimal switching frequency should exist that results in the total weight of the DC-DC converter and additional fuel being a minimum. The paper first explains the proposed solution for WPS, the load pattern that is used to test the system and then the algorithm that decides on the number of converters to be used and how to find the optimal switching frequency. Additionally, two prototypes have been constructed. First prototype has nominal power of 20 W and is used in the analysis regarding the optimal number of converters. The second one has rated power of 200 W and it is built to support the conclusions based on the optimization process

Mission profile based optimization of a wearable power system

A Wearable Power System (WPS) is a portable power source utilized primarily to power the modern soldier’s electronic equipment. Such a system has to satisfy output power demands in the range of 20 W...200 W, specified as a 4-day mission profile and has a weight limit of 4 kg. To meet these demands, an optimization of a WPS, comprising an internal combustion (IC) engine, permanent magnetic three-phase electrical motor/generator, inverter, Li-batteries, DC-DC converters, and controller, is performed in this paper. The mechanical energy extracted from the fuel by IC engine is transferred to the generator that is used to recharge the battery and provide the power to the electrical output load. The main objectives are to select the engine, fuel and battery type, to match the weight of fuel and the number of battery cells, to find the optimal working point of engine and to minimize the system weight. To provide the second output voltage level of 14 VDC, a separate DC-DC converter is connected between the battery and the load, and optimized for the specified mission profile. A prototype of the WPS based on the optimization presented in the paper results in a total system weight of 3.9 kg and fulfils the mission profile

Switching control strategy for full ZVS soft-switching operation of a dual ctive bridge AC/DC converter

A switching control strategy to enable Zero-Voltage-Switching (ZVS) over the entire input-voltage interval and the full power range of a single-stage Dual Active Bridge (DAB) AC/DC converter is proposed. The converter topology consists of a DAB DC/DC converter, receiving a rectified AC line voltage via a synchronous rectifier. The DAB comprises primary and secondary side full bridges, linked by a high-frequency isolation transformer and inductor. Using conventional control strategies, the soft-switching boundary conditions are exceeded at the higher voltage conversion ratios of the AC input interval. Recently we presented a novel pulse-width-modulation strategy to fully eliminate these boundaries, using a half bridge - full bridge DAB configuration. In this papers the analysis is extended towards a full bridge - full bridge DAB setup, providing more flexibility to minimize the component RMS currents and allowing increased performance (in terms of efficiency and volume). Experimental results are given to validate the theoretical analysis and practical feasibility of the proposed strategy