Innovative Bidirectional Isolated High-Power Density On-Board Charge for Vehicle-to-Grid
Abstract
:1. Introduction
- A description of the implementation of the first prototype and its problems related to the circuit topology and parasitic properties of the elements encountered and their solutions not reported in the literature;
- Describe the elimination of voltage spikes using passive disconnectors (RCDs) proved inappropriate due to the significant power losses;
- The introduction of an innovative approach that eliminates voltage spikes based on the use of an applied active clamp in this situation;
- Proposed and described a switching control method that eliminates unwanted HF oscillations on both the primary and secondary sides of the transformer in the on-board charger;
- Description of the development, implementation and testing of a bidirectional charger with galvanic isolation, whose parameters were 4 kW/kg and 2.46 kW/dm3 and the maximum power of the charger is 7.2 kW, which uses a switching frequency of 150 kHz.
2. Verification of Selected Topology of Bidirectional Charger
2.1. Calculation of Accumulating Inductor Inductance
2.2. Experimental Results Measured on the First Prototype of Bidirectional Charger
- Microcontroller EFM8LB12F64E-QFP32 from Silicon Labs.
- Supporting circuits for logic of control pulses and elimination of various switching failure modes.
- Regulated power supplies with various output voltages.
- Power transistors, capacitors, planar transformer and inductor. With respect to the required dimensions and overall weight of the device cores, E64/10/50-3F36 and PLT64/50/5-3F36 were used. A detailed list of the used components is given in Section 4.
3. Selected Topology Troubleshooting
3.1. Root Cause Description of Overvoltage on the Primary Side of Transformer and Solution
3.2. Principle of the New Strategy of Bidirectional Charger Control in the Charging Mode
3.2.1. Time Interval t0 ≤ t < t1
3.2.2. Time Interval t1 ≤ t < t2
- Between switching off transistor pair Q5, Q8 and switching on Q3, while transistors Q6, Q7 remain switched off. Simultaneous switching on of all transistors in bridge “B” would mean short circuit of capacitor C13.
- Guarantees that voltage generated across the secondary winding of the transformer is greater than battery voltage uBAT.
3.2.3. Time Interval t2 ≤ t < t3
3.2.4. Time Interval t3 ≤ t < ½T
3.2.5. Time Interval ½T ≤ t < (t1 + ½T)
3.2.6. Time Interval (t1 + ½T) ≤ t < (t2 + ½T)
3.2.7. Time Interval (t2 + ½T) ≤ t < (t3 + ½T)
3.2.8. Time Interval (t3 + ½T) ≤ t < T
3.3. Principle of the New Strategy of Bidirectional Charger Control in the Discharging Mode
3.3.1. Time Interval t0 ≤ t < t1
3.3.2. Time Interval t1 ≤ t < t2
3.3.3. Time Interval t2 ≤ t < t3
3.3.4. Time Interval t3 ≤ t < t4
3.3.5. Time Interval t4 ≤ t < ½T
3.3.6. Time Interval ½T ≤ t < (t1 + ½T)
3.3.7. Time Interval (t1 + ½T) ≤ t < (t2 + ½T)
3.3.8. Time Interval (t2 + ½T) ≤ t < (t3 + ½T)
3.3.9. Time Interval (t3 + ½T) ≤ t < (t4 + ½T)
3.3.10. Time Interval (t4 + ½T) ≤ t < T
4. New Prototype of a Bidirectional Charger Enhanced with Active Element “D”
5. The Experimental Microgrid Platform
6. Results and Discussion
6.1. Experimental Measurement Results Acquired in Charging Mode
6.2. Experimental Measurement Results Acquired in Discharging Mode
- CE02—Conducted Emission, Voltage method (IEC CISPR 25)
- RE01, Radiated Emission, ALSE method (IEC CISPR 25)
- ESD02, Unpowered test (ISO 10605)
- TP01, Immunity to transient pulse 1 and 1b (ISO 7637-2)
- TP02, Immunity to transient pulse 2 (ISO 7637-2)
- TP03, Immunity to transient pulse 3a and 3b (ISO 7637-2)
- TP04, Immunity to transient pulse 4 (ISO 7637-2)
- TP05, Immunity to transient pulse 5 (ISO 7637-2)
7. Conclusions
- The single-stage inverter topology was modified to eliminate undesirable phenomena.
- Bidirectional power control and galvanic insulation from the power grid.
- Owing to the novel switching strategy of Q9 to Q12 transistors’ control, the charger does not need RCD snubbers in order to limit the voltage spikes caused by leakage inductance of the transformer. This has the effect of reducing losses, increasing efficiency and also reducing weight and volume.
- The proposed transistor switching control method eliminates unwanted HF oscillations on both the primary and secondary sides of the transformer in the on-board charger.
- In order to reduce the size and weight of the inductor and transformer, high switching frequency of 150 kHz was used.
- The charger allows V2G technology.
- The power density of the new charger was 4 kW/kg and 2.46 kW/dm3, and the maximum efficiency was 96.4% at 3.4 kW.
- The new charger has an output of either 7.2 kW if it uses only single-phase, or 21.6 kW if it uses three-phases.
8. Patents
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Patent Annotation
References
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Parameter | Value |
---|---|
Grid AC Voltage | 230 V + 10% |
Battery DC Voltage | 300 to 420 V |
Maximum grid current | 32 A RMS |
Maximum battery current | 20 A |
Nominal input power | 7.2 kW |
AC grid frequency | 50 Hz |
Switching frequency | 150 kHz |
Inductance L | 25 μH |
Capacity C1 | 3.01 μF |
Capacity C2 | 12.1 μF |
Capacity C13 | 270 nF |
Transformer windings | 4 primary turns, 3 secondary turns |
Weight | 1.8 kg |
Volume | 2.92 dm3 |
Q1–Q4, CoolMOS PowerTransistor IPW60R017C7XKSA1 | (600 V, 129 A, RDS(on) = 17 mΩ, USD = 0.9 V 1 @ IF = 58.2 A) |
Q5–Q8, Q13, Silicon Carbide Power MOSFET C3M0032120K | (1200 V, 63 A, RDS(on) = 32 mΩ, USD = 4.6 V 1 @ IF = 20 A) |
Q9–Q12, Silicon Carbide Power MOSFET C3M0030090K | (900 V, 63 A, RDS(on) = 30 mΩ, USD = 4.8 V 1 @ IF = 17.5 A) |
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Hrbac, R.; Hrdina, L.; Kolar, V.; Slanina, Z.; Blazek, V.; Vantuch, T.; Bartłomiejczyk, M.; Misak, S. Innovative Bidirectional Isolated High-Power Density On-Board Charge for Vehicle-to-Grid. Sensors 2022, 22, 8473. https://doi.org/10.3390/s22218473
Hrbac R, Hrdina L, Kolar V, Slanina Z, Blazek V, Vantuch T, Bartłomiejczyk M, Misak S. Innovative Bidirectional Isolated High-Power Density On-Board Charge for Vehicle-to-Grid. Sensors. 2022; 22(21):8473. https://doi.org/10.3390/s22218473
Chicago/Turabian StyleHrbac, Roman, Libor Hrdina, Vaclav Kolar, Zdenek Slanina, Vojtech Blazek, Tomas Vantuch, Mikołaj Bartłomiejczyk, and Stanislav Misak. 2022. "Innovative Bidirectional Isolated High-Power Density On-Board Charge for Vehicle-to-Grid" Sensors 22, no. 21: 8473. https://doi.org/10.3390/s22218473