Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

CHAPTER-1

INTRODUCTION

In the last few years the pollution problems and the increase of the cost of fossil energy
(oil, gas) have become planetary problems. The car manufacturers started to react to the
urban pollution problems in nineties by commercializing the electric vehicle. But the
battery weight and cost problems were not solved. The batteries must provide energy and
peaks power during the transient states. These conditions are severe for the batteries. To
decrease these severe conditions, the super capacitors and batteries associate with a good
power management present a promising solution in order to ensure a good power
management in Electric vehicle, the multi boost and multi full bridge converters design
and their control are developed. Two Designs are proposed for the power management:-

Fig.1a: Solution for Energy Storage-1

Fig.1b: Solution for Energy Storage-2

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

CHAPTER-2

OBJECTIVES

• Study of the management of the energy provided by Ultra Capacitor/Battery packs.

Where Each Ultra Capacitor module is made of 108 cells with a maximum voltage of
270V.
• Propose a good power management strategy by using the Multi boost and the Multi
full bridge converter.
• Provide Eco-friendly Energy storage System by Ultra Capacitor/Battery packs for
Electric vehicle load Requirements.

• Aim is the evaluation of the stability margins at the extreme operative conditions, so
that the control strategy can be accepted on the whole working range of the converter.

2.1 PROBLEM STATEMENT

• Essential requirement to discover a cost-effective, long-lasting and environmental

friendly technique to save the energy that attained from a various array of resources.
• Regularly the batteries do not initiate at zero voltage and even if they ensure only a
small amount of charge is essential to get them to a huge fraction of the open circuit
voltage.
• Load requirement of the EV (Electric Vehicle) Investigated is restricted to the
Propulsion load type. Even though the non-propulsion load requirements have been
considered as part of study.

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

CHAPTER-3
LITERATURE SURVEY

3.1 Energy management of fuel cell/battery/ ultracapacitor in Electric vehicle [1]:

• Hajer Marzougui demonstrated an energy management algorithm for an electrical

hybrid vehicle.
• Proposed hybrid vehicle presents a fuel cell as the main energy source, the storage
system, comprises of a battery and Ultra-Capacitor (UC) as the secondary energy
source.
• Addition of battery and UC in fuel cell-based vehicles has excessive prospective
since it permits a substantial decrease of the hydrogen ingestion and an
enhancement of the vehicle efficiency.
• Some chemical reactions are mixed with the fuel cell, such that fuel cell response
time is high.

Fig.3.1: Energy management algorithm

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

3.2 Compound control for energy management of hybrid ultra-capacitor-battery

Electric drive system [2]:

• Hui Peng proposed a compound control framework for energy management of hybrid
ultra-capacitor-battery Electric drive system.
• Design Guarantees that the ultra-capacitor current and the battery current can be
controlled individually. In calculation, the management of the hybrid source is
connected through electrical drives.
• Advantages of the proposed compound control are that ultra-capacitor supplies peak
and ripple current while battery supplies smooth and steady current.

• Main current is supplied by the battery, but the ultra-capacitor cannot supply enough
current to reject disturbance.

Fig.3.2: Control framework for the hybrid ultra-capacitor-battery electric drive

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

3.3 Battery-Ultra capacitor Combination used Energy Storage System in EV [3]:

• M R Rade proposed the Battery-Ultra capacitor combination as energy storage for

Electric Vehicle (EV). The vehicle performance is mainly depends on Energy
Storage System (ESS) so more importance has been given in this paper.
• Ultra capacitor can capture and provide quick bursts of energy as it has high power
density. So battery/ultra-capacitor combination as a hybrid energy storage system
for EV is one of best solution.

• Hybrid Energy Storage System is economical as costs of replacing the batteries are
greater than the cost of addition of super capacitor (ultra-capacitor).
• Optimal combination of both the battery/Ultra-capacitor reduces the Stress on EV
& also reduces from damage of Electric Vehicle.

Fig.3.3: Modes of Operation of Hybrid Energy Storage System

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

3.4 Control of a battery/super capacitor hybrid energy storage system for EV [4]:

• Lijun Zhang proposed the power flow control of a battery/super-capacitor hybrid energy
storage system when applied to electric vehicles. The controller is based on advanced model
predictive control method and aims at smoothing the power flow from/to the battery to
protect it from undesirable fast discharging/charging.
• Objective of the controller is to control the electric vehicle to track a predefined speed profile
as the dynamics of the vehicle and the super-capacitors are modeled from first principles to
facilitate the controller design.
• Controller in Electric Vehicle is used to optimize the power flows of the hybrid Energy
storage system instead of controlling the power converters.
• Focus is on power flow control, it is assumed that the battery, the primary power source &
Ultra-capacitor as Secondary power source are properly sized & able to power the EV
throughout the driving range.

sc EV

BAT

Fig.3.4: Diagram of an EV powered by HESS

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

CHAPTER-4

BLOCK DIAGRAM OF PROPOSED SYSTEM

Fig.4: Block Diagram

A hybrid vehicle is a vehicle which can run the mechanism by using multiple sources such as
diesel, petrol, gas, electricity. A hybrid vehicle is combination of different components and so that
it will provide flexibility, reliability, safe and secured target. Figure.4 shows the operation of hybrid
vehicle in two modes. One is motoring mode and the other is regenerative braking mode. The blue
arrow marks indicates the flow of current in the motoring mode and the red mark indicates the flow
of current in the regenerative braking mode. During the motoring mode the hybrid vehicle takes
electric energy from both battery and super capacitor the steady state energy is supplied by battery.

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

During the regenerative mode hybrid vehicle supplies the electrical energy to both
super capacitor and battery. Since this process is recycled electrical energy is
utilized efficiently. Therefore the weight of the battery decreases and life gets
increased.

4.1 POWER FLOW

The load power, coming from the outer parts of the HEV, can be both positive and
negative. A positive load power is in this work defined as that there is a surplus of
power in the outer system and the power is therefore flowing into the ESU
(generator reference). If the load power is negative there is a demand for power in
the external system and power is flowing out from the ESU. Inside the ESU the load
power is divided between the power to the battery and power to the super capacitor,
which is demonstrated in Figure.4.1

Fig.4.1: Power Flow

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

CHAPTER-5

METHODOLOGY

• Possible architecture of the battery/UCs system is shown. Two bi-directional

DC-DC converters connect the battery and the UCs to a common bus.

• Bus voltage is generated by means of the battery-connected DC-DC converter,

which also regulates the average current required by the load.

• UCs-connected DC- DC converter deals with the peak power load demands:

• If load requires a power peak, the Ultra-capacitors are discharged

• If Ultra-capacitors require to be recharged, the energy is recovered from bus

• Here the terms Ultra-Capacitor or Super-Capacitor are the same names of the Capacitor.

Fig.5: Methodology

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

CHAPTER-6

COMPONENTS OF PROPOSED SYSTEM

6.1 Energy storage unit [ESU] :-

• Energy storage unit constitutes of Battery and Ultracapacitor which delivers or recieves
power through motor of Electric vehicle Engine.
• Energy storage unit (ESU) in a car handles the storage of the electrical energy and
functions as a buffer for the electrical machine (and the generator in the series hybrid
configuration).
• ESU has the possibility to either receive or deliver power from or to the electrical
machine (via a DC/AC
• It can be possible or necessary to install a converter in series with the battery or the
super capacitor or both. If the converter is installed in series with the battery it is
possible, with the ability of power control, to get a direct control over the power to the
battery.
• Another possible combination is to install two converters, one in series with the super
capacitor and one in series with the battery, but this would lead to an unnecessary
complexity of the system.
• In this system converter has been installed in series with the Ultra-capacitor & also
with Battery.

Fig.6: Overview of Energy Storage Unit

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

6.1.1 ULTRA-CAPACITOR :-

• Problems with batteries are mainly the cost, lifetime and size. Super capacitors also
called Ultra capacitors and electric double layer capacitors (EDLC) are capacitors with
capacitance values greater than any other capacitor type available today.

Function Ultra capacitor Lithium-ion (general)

Charge time 1–10 seconds 10–60 minutes

Cycle life 1 million or 30,000h 500 and higher

Cell voltage 2.3 to 2.75V 3.6 to 3.7V

Specific energy (Wh/kg) 5 (typical) 100–200

Specific power (W/kg) Up to 10,000 1,000 to 3,000

Cost per Wh $20(typical) $2 (typical)

Service life (in vehicle) 10 to 15 years 5 to 10 years

Charge temperature –40 to 65°C (–40 to 149°F) 0 to 45°C (32°to 113°F)

Discharge temperature –40 to 65°C (–40 to 149°F) –20 to 60°C (–4 to 140°F)

Table.6.1.1: Comparison of Ultra capacitor with lithium-ion (general capacitor)

• A super capacitor is a component which has relatively high specific power ability in
Comparison to batteries much like a capacitor, while it has much higher specific energy
than a conventional capacitor, more like a battery.

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

6.1.1a Voltage levels of Charging & Discharging of Ultra-Capacitor:

Energy stored by a Capacitor E = CV^2/ 2 (1), Energy ΔE provided to a load connected to

the capacitance arises from the voltage excursion from the maximum Vmax to the minimum
Vmin:
∆E = CV^2max/2 – CV^2min/2 (2)

According to (2), a 50% ΔV variation leads to a delivered energy amount equal to the 75%
of the initial energy. In this case the energy capability would be proportional to the
maximum voltage according to the following:

Fig.6.1.1a: Voltage levels of Ultra Capacitor obtained by Buck-boost Inverter

Vuc O.C. (the open-circuit UCs voltage) is the UC voltage at the maximum, charge,
without current flowing.Vuc (the UCs voltage) decreases goes down below the bus voltage.
It can be noted that not only the discharge contributes to decrease the ultra-capacitance
voltage, but also its equivalent series resistance Ruc, whose value depends on the chosen
commercial ultra-caps and on the specific series-parallel connection required to assemble
the whole stack. Each selected ultra-capacitor is the BCAP0310, showing a 310F
capacitance and a 2.2mΩ equivalent series resistance (ESR).

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

6.1.1b Advantages and limitations of Ultra capacitors:

Virtually unlimited cycle life; can be cycled millions of time

High specific power; low resistance enables high load currents

Charges in seconds; no end-of-charge termination required

Advantages
Simple charging; draws only what it needs; not subject to
overcharge

Safe; forgiving if abused

Excellent low-temperature charge and discharge performance

Low specific energy; holds a fraction of a regular battery

Linear discharge voltage prevents using the full energy

spectrum

Limitations High self-discharge; higher than most batteries

Low cell voltage; requires serial connections with voltage

balancing

High cost per watt

Table.6.1.1b: Advantages & Limitations of Ultra Capacitor

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

6.1.2 Battery:-

• Use of only battery technology for ensuring the peak power pulses requested during
acceleration and braking of the vehicle is possible, but at the price of a severe
degradation of the battery performances in terms of weight, cost and lifetime .
• Different studies have proven the importance of the ultra-capacitors integration in order
to reduce the battery ageing-effects without oversizing the battery itself.
• Nevertheless, a significant economical convenience of the UC/battery integration is still
far to be proven, being strongly dependent on external factors, such as the price
fluctuations.

6.1.3 Battery Banks:-

• Batteries are quite difficult to model they undergo thermally-dependent electrochemical

processes while delivering and accepting energy.
• Electrical behavior of a battery is a nonlinear function of a number of constantly
changing parameters, such as internal temperature, state-of charge, rate of
charge/discharge.
• Approximate model that is often used for batteries is a Thevenin’s equivalent circuit that
consists of the open circuit voltage in series with an effective internal resistance.
• Voltage and resistance values are functions of the battery SOC, and these relations are
generally supplied the manufacturer. SOC is defined the percentage of energy left in a
battery (after supplying a certain amount of amp-hours) relative to its full capacity.

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

6.1.4 Ultra-Capacitor Banks:-

• Conventional capacitors have resistance and inductance of the terminal wires

and electrodes of super capacitors are represented by a series R-L circuit.
• Further, non- perfect insulation between the device electrodes results in leakage
current that is represented by a large shunt resistance. The difference between
conventional and super capacitors is that the latter are much more efficient, i.e.,
the series resistance is a lot lower and the shunt resistance is much higher in
value.
• Self-discharge time constant of super capacitors several orders of magnitude
larger than that of conventional capacitors. More sophisticated models suitable
for dynamic studies are found.
• Study under investigation is a short-duration analysis of the power (or current)
distribution between the battery bank and super capacitor bank during
acceleration and deceleration. Hence, the leakage resistance can be ignored
without much error, and the super capacitor bank can simply be represented by a
series R-C circuit.

Fig.6.1.4: Equivalent Circuit of Ultra-Capacitor

6.1.5 Electrical Load:-

• Electrical load in electric vehicles consists mainly of an inverter-fed induction motor for
motive power. During regenerative breaking, the motor is turned into a generator by
reducing the frequency of its terminal voltage, thus reversing power flow and producing
braking torque.

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

6.2 Effectiveness of Battery/Ultra-Capacitor Combination in EV

• Significant portion of energy is dissipated in the brakes when driving conventional

gasoline-powered vehicles in urban areas, where periodic acceleration- deceleration
cycles are required.
• Recovering this energy through regenerative breaking is an effective approach for
improving vehicle driving range and this can only be accomplished by electric vehicles
(EV) or hybrid-electric vehicles (HEV).
• Regenerative breaking in these vehicles captures some of the kinetic energy stored in the
vehicle’s moving mass by operating the vehicle’s traction motor as a generator that
provides braking torque to the wheels and recharges the batteries.
• Auxiliary power unit (APU) of an HEV is designed to provide the normal average
power required by the vehicle, while the battery is sized to provide power surges needed
during acceleration and hill climbing and to accept momentary powers during breaking.
• EVs and HEVs are more efficient than conventional vehicles in urban areas, the electric
load profile consists of high peaks and steep valleys due to repetitive acceleration and
deceleration.
• Adding a super capacitor bank will assist the battery during vehicle acceleration and hill
climbing, and with its quick recharge capability, it will assist the battery in capturing the
regenerative braking energy.
• Direct connection of the Ultra capacitor across the battery terminals does reduce
transient currents in an out of the battery, the best way to utilize the super capacitor bank
is to be able control its energy content through a power converter.
• Connection is done by using a DC/DC converter in the boost mode when discharging,
and in the buck mode when charging the super capacitor bank.

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

6.3 Energy Management

Power Supply Management (PSM):

• PSM is about Control of the alternator set in conventional electrical systems, aiming at
optimizing all of the following: electrical function availability, battery life, vehicle
performance (e.g. reduced alternator load when maximum acceleration is demanded), or
fuel consumption (e.g. reduce alternator output at idle to allow for lower idle speed).
• Decoupling the electric generation from the load demands can significantly reduce this
specific fuel consumption contribution by optimizing the system efficiency of engine
and alternator at any point in time.
• This will introduce supply voltage fluctuations into the electrical system and
systematically exploit the battery as a short-term energy buffer.

Power Distribution Management (PDM):

• PDM is used to schedule the allocation of available power and energy to electric loads
on a subsystem or component level.
• Whenever a power deficiency occurs, the PDM algorithm aims at ensuring voltage
stability, charge balance and robustness, as well as minimizing battery charge
throughout in the case of peak loads.
• Electric energy management actively uses the energy storage system (battery, super
capacitor, etc.) and hence relies on precise status information about this device. A
battery monitoring system (BMS) has to deliver these essential inputs to the energy
management control system.

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

6.4 Vehicle energy storage system using Ultra capacitor:

• To control the energy stored in Ultra capacitor bank, it is need that the voltage of the
Ultra capacitor bank should be controlled. If not, the Ultra-capacitor voltage depends on
the battery voltage, so that there is no possibility to control the energy stored in Ultra
capacitor bank. Thus, DC/DC converter is indispensable to regulate the bank voltage
level.

• DC/DC converter has Bi-directional nature. Figure.6.4 shows the system configuration
with battery pack and super capacitor bank as energy storage. The DC/DC converter is
on boost-mode operation as the inverter supplies traction power to the motor. On the
other hands, the DC/DC converter is on buck-mode operation as the regenerative energy
come to super capacitor bank.

Fig.6.4: System Configuration of the Ultra-Capacitor implemented

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

6.5 Design of Bi-directional DC/DC converter:

• Bi-directional DC/DC converter has single-stage buck/boost type and full-bridge type as
a typical one. Full-bridge type topology has merits compared to single-stage buck/boost
type Design.
• 1) Electrical isolation between input and output is guaranteed.
• 2) Higher boost ratio can be implemented.
• 3) System protection is possible.

Fig.6.5: Bi-directional DC/DC converter (Full-Bridge Design)

• Bi-directional full-bridge Design of DC/DC converter is operated on boost mode at

the time electric power is supplied from super capacitor stage (low voltage stage) to
battery stage (high voltage stage).
• Voltage control is necessary to match to DC bus voltage of the inverter. Also, soft
switching technique of zero voltage-zero current switching is applied.

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

6.5.1 Working of Buck-Boost DC/DC Converter:-

• In figure.6.5.1 Four MOSFETs ensure a bi-directional operation, meaning that the

current can be either Positive or Negative Respectively in case of discharge or charge of
The UC’s considering Vin as the UC’s Voltage & Vout as the Bus Voltage.
• Two possible modes are present: in the discharging mode, the inductance current is
positive; in the charging mode, the inductance current is negative. When no current
flows, the Ratio conversion M of the power converter is:
M = (Vout/Vin) = (D /1-D) = (D1/D2)
• Where D is the duty-cycle of the M1-M3 gate signals whereas (1-D) is the duty-cycle of
the M2-M4 gate signals, also named as D1 and D2 respectively. To have a positive or
negative current, the duty-cycle is required to be higher or lower than the one.
• In Fig.6.5.1 a complete scheme of the DC-DC converter is shown, along with the LC
filters, connecting the converter to the UCs and to the bus. The resistances R1 and R2
respectively represent the equivalent series DC resistances seen by the converter
towards the UC side and the bus side.
• V1 and V2 are the Thevenin’s equivalent voltages of the ultra-capacitor stack and of the
bus, whereas RL is the equivalent series resistance of the inductance L.
• The inductance current IL is dependent on the voltage sources, the duty-cycle and the
losses as follows:
IL = (V1*D1 – V2*D2)/ (RL+R1D1^2+R2D2^2)

Fig.6.5.1: Schematic Diagram off Buck-Boost Converter and filters

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

CHAPTER-7
Simulation Results

Fig.7a: Control Strategy of Bus Current Regulation

• Control is achieved by PWM Control of Bus current Reference is Ibus, set. The error e
is the input of a chain of stages respectively showing the Laplace transfer functions
Gc(s), GPWM and Gio, d(s).
• First stage is the compensation network
• Second stage is the PWM stage, where the duty-cycle is generated
• Third stage is the duty-to-current power stage.
• Following Bode diagrams, shown in Fig.7b referring to the power stage Gio, d(s) of the
considered Buck-Boost Converter, to the introduced correction Gc(s) and to the open-
loop transfer function F(s), are simulated in MATLAB.
• Stability Margins from Bode Plot provide Control Strategy on working of Converter.

Fig.7b: Bode Diagram

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

CHAPTER-8

ADVANTAGES:-

• Ultra capacitors are being tested in some vehicles as they capture the energy generated
by braking and quickly release it for Reacceleration; this approach promises to improve
fuel efficiency.
• Hybrid lithium-ion ultra-capacitor/Battery Energy Storage System could improve fuel
efficiency further by storing more energy. Its life cycle will be improved, as vehicle
breaking systems need to be recharged hundreds of thousands of times.

8.1 CONCLUSIONS:-

• Multi boost and multi full bridge converter Designs and their control strategies for
Batteries and Ultra Capacitors coupling in the hybrid vehicle applications are proposed.
• Simplicity and cost of the multi boost converter is the most interesting regarding the
multi full bridge converter Design. It enables a good power management in hybrid
vehicle.
• Buck-Boost DC-DC converter for the power management of a stack of ultra-capacitors,
in a Battery/Ultra Capacitor hybrid storage system for EV applications, has been
described.
• Possible connection has been proposed for the management of a 5kW power level. The
total power level is 40kW with 8 stacks of 24 series-connected ultra-capacitors.

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Design of Battery/Ultra Capacitor Energy Storage System for Electric Vehicle Applications 2019-20

9 REFERENCES:-

1. Hajer Marzougui , Mansour Amari , Ameni Kadri , Faouzi Bacha , Jamel Ghouili
“Energy management of fuel cell/battery/ ultra-capacitor in electrical hybrid Vehicle”
“International Journal of Hydrogen Energy” Issue 42 (2017) 8857 e8869: Elsevier

2. Hui Peng , Junzheng Wang ,Wei Shen , Dawei Shi , Yuan Huang
“Control for energy management of hybrid ultra-capacitor/battery electric drive”
Energy Issue 175 (2019) 309e319: Elsevier website: www.Science Direct.com

3. K. K. Wagh, M. R. Rade, Prof. S. S. Dhamal , Department of Electrical Engineering

“Battery/Ultra capacitor Combination used as energy storage system electric vehicle”,
IEEE-2017.

4. Lijun Zhang, Xiaohua Xia “Control of a battery/super capacitor hybrid energy storage
system for EV” IEEE July Issue 26-28 (2017).

5. H.Yoo, Y.Park, and J.Jeong, “System integration and power-flow management for a
series hybrid electric vehicle using super capacitors and batteries” IEEE Transactions
on Industry Applications, vol. 44, no. 1, pp. 108–114 (2008).

6. R.Timerski and V.Vorperian, “Generation, classification and analysis of switched-

mode DC-to-DC converters by use of converter cells,” in Proc.IEEE Int.
Telecommunications Energy Conf. INTELEC 86, Oct. 1986, pp. 181–195.

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