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ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT DUAL ACTIVE BRIDGE-BASED BATTERY CHARGER FOR PLUG-IN HYBRID ELECTRIC VEHICLE WITH CHARGING CURRENT CONTAINING LOW FREQUENCY RIPPLE By A PROJECT REPORT Submitted to the Department of electronics & communication Engineering in the FACULTY OF ENGINEERING & TECHNOLOGY In partial fulfillment of the requirements for the award of the degree Of MASTER OF TECHNOLOGY IN ELECTRONICS & COMMUNICATION ENGINEERING APRIL 2016 OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT CERTIFICATE Certified that this project report titled “DUAL ACTIVE BRIDGE-BASED BATTERY CHARGER FOR PLUG-IN HYBRID ELECTRIC VEHICLE WITH CHARGING CURRENT CONTAINING LOW FREQUENCY RIPPLE” is the bonafide work of Mr. _____________Who carried out the research under my supervision Certified further, that to the best of my knowledge the work reported herein does not form part of any other project report or dissertation on the basis of which a degree or award was conferred on an earlier occasion on this or any other candidate. Signature of the Guide Signature of the H.O.D Name Name OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT DECLARATION I hereby declare that the project work entitled “DUAL ACTIVE BRIDGE-BASED BATTERY CHARGER FOR PLUG-IN HYBRID ELECTRIC VEHICLE WITH CHARGING CURRENT CONTAINING LOW FREQUENCY RIPPLE” Submitted to BHARATHIDASAN UNIVERSITY in partial fulfillment of the requirement for the award of the Degree of MASTER OF APPLIED ELECTRONICS is a record of original work done by me the guidance of Prof.A.Vinayagam M.Sc., M.Phil., M.E., to the best of my knowledge, the work reported here is not a part of any other thesis or work on the basis of which a degree or award was conferred on an earlier occasion to me or any other candidate. (Student Name) (Reg.No) Place: Date: OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT ACKNOWLEDGEMENT I am extremely glad to present my project “DUAL ACTIVE BRIDGE-BASED BATTERY CHARGER FOR PLUG-IN HYBRID ELECTRIC VEHICLE WITH CHARGING CURRENT CONTAINING LOW FREQUENCY RIPPLE” which is a part of my curriculum of third semester Master of Science in Computer science. I take this opportunity to express my sincere gratitude to those who helped me in bringing out this project work. I would like to express my Director, Dr. K. ANANDAN, M.A.(Eco.), M.Ed., M.Phil.,(Edn.), PGDCA., CGT., M.A.(Psy.) of who had given me an opportunity to undertake this project. I am highly indebted to Co-Ordinator Prof. Muniappan Department of Physics and thank from my deep heart for her valuable comments I received through my project. I wish to express my deep sense of gratitude to my guide Prof. A.Vinayagam M.Sc., M.Phil., M.E., for her immense help and encouragement for successful completion of this project. I also express my sincere thanks to the all the staff members of Computer science for their kind advice. And last, but not the least, I express my deep gratitude to my parents and friends for their encouragement and support throughout the project. OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT ABSTRACT: Manufacturers want high power density for the onboard battery chargers of plug-in hybrid electric vehicles. Wide bandgap devices can be used to shrink other passive components by increasing the switching frequency, but the bulk dc link capacitor of the ac–dc power factor correction stage, becomes one of the major barriers to higher power density, because its volume depends on the ripple power at the double line frequency in a dc current charging system. However, if this double line frequency ripple flows into the battery, the dc link capacitance can be significantly reduced. This charging scheme, named as sinusoidal charging in this paper, is analyzed and implemented based on a two-stage battery charging system, which is comprised of one full bridge ac–dc stage and one dual active bridge dc–dc stage.We further find that converter loss causes ripple power imbalance and bigger dc link capacitance. Therefore, the impact of converter loss on the ripple power balance is analyzed, and a feedback control on the dc link voltage ripple is proposed based on this analysis in order to further reduce the dc link capacitance. The effectiveness of the proposed solutions is verified in both Si-based and GaNbased charging systems. OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT INTRODUCTION: The batteries of PHEVs are charged by connecting a plug to the wall socket if the battery charger is on-board. As such, achieving high efficiency and a small size for the battery charger is very important, as these factors will help to improve overall performance of the PHEV. Wide band-gap power switches, such as Gallium Nitride (GaN) and Silicon Carbide (SiC), outperform silicon counterparts in terms of switching speed and on-resistance, and therefore can improve the power density of various converters by shrinking the size of passive components. Researchers have made large efforts to reduce the dc link capacitance in order to avoid using an electrolytic capacitor for a longer lifetime, while meanwhile keeping a high power density in different single-phase ac–dc energy conversion applications. In LED driver applications, the overall ripple energy at double line frequency can be reduced by moderately distorting the ac input current, while the resultant power factor can still fulfill the standard requirement . Inductive storage can be used to replace the low-lifetime capacitor, but in actuality will reduce the overall power density due to its lower energy density as compared to capacitive storage (i.e., capacitors) Given the same ripple energy, capacitance is reduced by enlarging the capacitor voltage ripple. This concept can be implemented directly to the dc link capacitor, as shown in a gridinterface bidirectional converter, which increases device voltage stress. Alternatively, it can be implemented in the auxiliary capacitors, with increased realization complexity. OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT Specifically for battery chargers, if the battery pack can take the low frequency charging current ripple, the dc link capacitance will be significantly reduced because the capacitors only need to filter the current ripple at the switching frequency. and compare battery capacity under dc charging and pulse charging with similar current waveform that this paper will use, and the difference is minor: 0.55% and −1.4%, respectively. shows an around 2°C temperature rise due to increased RMS value. OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT EXISTING SYSTEM: This dc–dc full-bridge converter uses resonant techniques in which resonant elements such as capacitors and inductors are used to shape the current through a converter switch so that it can fall to zero to allow the switch to turn off with ZCS. The resonant elements, however, are large and bulky, which makes their use impractical for many applications, and the converter is operated with variable frequency control, which makes the design of the converter more difficult and also increases the size of the converter as it must operate with low switching frequencies at lighter loads OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT PROPOSED SYSTEM: This paper synthesizes the idea of this sinusoidal charging scheme and gives in-depth analysis of ripple power balance and control realization. In addition, this paper also analyzes the converter loss impact on the increase of DC link voltage ripple under ideal sinusoidal charging. This DC link voltage ripple can be suppressed by a direct control path on the voltage ripple. OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT ADVANTAGES: Good performance and simplicity. OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT BLOCK DIAGRAM: Single phase AC supply Control Rectifier Filter Single phase inverter High frequency transformer Control rectifier and filter Load Gate driver circuit BUFFER circuit 5 V DC 12 V DC PIC controller circuit OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT TOOLS AND SOFTWARE USED: MPLAB – microcontroller programming. ORCAD – circuit layout. MATLAB/Simulink – Simulation OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT APPLICATIONS: Plug-in Hybrid Electric Vehicles (PHEVs). OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT CONCLUSION: In a PHEV battery charger, the dc link capacitor occupies a large portion of the total volume, even if other passive components can be significantly shrunk by using wide band gap semiconductor devices at high frequency, mainly because the required capacitance is largely determined by ripple power at two times the line frequency. In this paper, sinusoidal charging scheme was proposed to reduce the dc link capacitance by balancing the ripple power from input and output. However, pure sinusoidal charging control cannot eliminate the dc link voltage ripple. It was found that the converter loss with sinusoidal charging has a dc component and also a second-order harmonic component, whose difference results in ripple energy in the dc link capacitors. OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: ECWAY TECHNOLOGIES IEEE SOFTWARE | EMBEDDED | MECHANICAL | ROBOTICS PROJECTS DEVELOPMENT REFERENCES: M. Kasper, D. Bortis, and J. W. Kolar, “Classification and comparative evaluation of PV panelintegrated DC-DC converter concepts,” IEEE Trans. Power Electron., vol. 29, no. 5, pp. 2511– 2526, May 2014. [2] M. Rodriguez, M. Roberg, A. Zai, E. Alarcon, Z. Popovic, and D. Maksimovic, “Resonant pulse-shaping power supply for radar transmitters,” IEEE Trans. Power Electron., vol. 29, no. 2, pp. 707–718, Feb. 2014. [3] Z. Xuan, Y. Chengcheng, L. Cong, F. Lixing, G. Feng, and W. Jin, “A wide bandgap devicebased isolated quasi-switched-capacitor DC/DC converter,” IEEE Trans. Power Electron., vol. 29, no. 5, pp. 2500–2510, May 2014. [4] R. Mitova, R. Ghosh, U. Mhaskar, D. Klikic, W. Miao-Xin, and A. Dentella, “Investigations of 600-V GaN HEMT and GaN diode for power converter applications,” IEEE Trans. Power Electron., vol. 29, no. 5, pp. 2441–2452, May 2014. OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE / BANGALORE / HYDRABAD 9894917187 | 875487 1111 / 2111 / 3111 / 4111 / 5111 / 6111 www.ecwaytechnologies.com | www.ecwayprojects.com Mail to: [email protected] CELL: Visit: