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Abstract- In this paper, a new three-phase converter topology takes 4-6 hours for full battery charging in the normal
based on a 3xl matrix converter (MC) is proposed for Plug-in (overnight) power level. Research shows that hybrid/battery
Hybrid or Battery (PHEV/BEV) electric transit buses. In the electric buses provide higher fuel economy, lower emissions
proposed approach, the MC directly converts the low frequency
and extended range compared to conventional diesel buses. If
(50/60 Hz, three-phase) input to a high frequency (6 kHz, one
the system and maintenance costs are reduced, electric buses
phase) AC output without a dc-link. The output of the matrix
can be very attractive for the next generation commercial fleet
converter (MC) is then processed by a PWM rectifier via a high
frequency (HF) isolation transformer to interface with the EV [9]. Moreover if the concept of V2G becomes more prevalent
battery system. The MC-PWM rectifier system is made to in the future, the fleet owner can choose to transfer energy
operate like a dual active bridge (DAB), facilitating bi-directional back to the grid when a bus is idle and improve the revenue.
power flow suitable for charging and Vehicle-to-Grid (V2G)
A typical 3-phase isolated AC-DC converter consists of a
application. The digital control of the system ensures that the
input currents are of high quality under both charging and 3-phase diode rectifier and an isolated DC-DC converter with
discharging operations. Due to the absence of dc-link electrolytic high frequency (HF) transformer (see Fig. 1) [10]. These
capacitors, power density of the proposed rectifier is expected to power supplies draw significant lower order harmonic currents
be higher. Analysis, design example and extended simulation from the utility, resulting in poor input power factor with high
results are presented for a three-phase 208 VLL, 50kW charger. total harmonic distortion (THO), going even up to 40% [10].
This increases the input filter size required for smoothening
Keywords - Electric bus battery charger, High frequency
the DC. The presence of multiple power conversion stages
transformer, Power factor correction, 3xl Matrix Converter, V2G.
contributes to lower efficiency. Moreover, the entire system
I. INTRODUCTION will have to be re-designed if V2G power conversion also
needs to be considered [11].
Automobile and transportation sectors are constantly
being subjected to tougher pollution standards and are urged to More sophisticated converter configurations have also
improve the e-mobility infrastructure of modem day vehicles. been proposed in the literature [11, 12]. Some concepts
This has initiated a growing interest in the industry to build propose the use of current source rectifiers followed by
more electric vehicles (EVs). The commercial EVs can be inverter stage. This accounts for good input power quality, but
hybrid (HEV), plug-in hybrid (PHEV) or battery (BEV) based still requires large electrolytic capacitors. The diodes in series
on what the electric power train is designed for. The with switches in a current source rectifier contribute to higher
applications range from golf cart to fleet buses and trucks [1]. losses. Some other concepts involving multiple single phase
It has opened up an entirely new world of opportunities and power factor correction (PFC) stages [13], active power filters,
challenges in power electronics' research [2]. Electric vehicles line commutated rectifiers, etc. have also been proposed [11].
can potentially provide valued services to the power grid [3, But all these add to the component count in the path of current
4]. The prospect of distributed regeneration (or microgrid) that increases the overall system size and lowers the
using EVs has further enhanced the opportunities by evolving efficiency. The control of these converters leads to larger
the 'Vehicle-to-Grid' (V2G) frameworks to integrate electric system complexity.
vehicles into the grid and analyzing economic impact on the
In order to overcome the drawbacks of the existing 3-
consumers and power grid [5-8].
phase high power PHEV/BEV battery charging power
The charging in EVs can be on-board or off-board. The supplies, a new matrix converter (MC) based architecture has
chargers can vary in their power levels (normal-overnight, been proposed in this paper that can also support V2G power
semi-fast and fast), charging modes (I-phase AC, 3-phase AC, transfer (see Fig. 2). With the availability of faster power
DC, etc) and charging mechanisms (conductive or inductive). semiconductor devices, MCs have become more efficient and
On-board AC charging offers flexibility and simplicity in the simpler to design. The 3-phase utility power input is fed to a
infrastructure as complicated communication protocol is not 3xl MC through an LC filter. This converts the utility grid
necessary. The normal or semi-fast chargers for electric cars voltage to single-phase high frequency (HF) square wave,
are typically less than 1 OkW, I-phase; whereas they can be which is interfaced to a HF transformer, followed by a PWM
more than 20kW, 3-phase for electric buses used in fleet. It rectifier. The rectifier's phase shift is controlled to regulate the
1� T 4
Utility Grid
VBat11
VBat21
VBatM1
Fig. I: Conventional 3-phase EV battery high power converter system using diode rectifier and I-phase inverter [10]
EV Battery Bank
1
VB,t
Fig. 2: Proposed 3-phase EV battery charging power converter system using 3xl Matrix Converter based dual active bridge
j
battery DC current. The advantages of the proposed EV power inverter as shown in Fig. 3. The rectifier can be operated as a
converter topology are as follows: diode rectifier or a current source based PWM rectifier (CSR).
The latter is chosen as it gives better input power quality. The
• The proposed topology allows for bi-directional power flow
fictitious DC is assumed to be a large DC inductor. The
between grid and EV battery banl(, facilitating V2G
inverter is operated in voltage source mode (VSI). The two
infrastructure.
converters are bridged by a fictitious DC link current, Ide.
• The use of a high-frequency-linl( transformer provides
The switching scheme for the MC is a product of a
galvanic isolation and also reduces the system size [II].
unipolar sinusoidal PWM (obtained by interfacing a sinusoidal
• MCs being direct AC-AC converters, there is no need for an wave of frequency Is with the triangular carrier wave of
electrolytic capacitor on the converter side, which increases frequency!c as in a CSR) and a HF square wave Cfsq) [14].
the converter power density, reliability and reduces the size. The entire switching scheme is explained by (1-6). A bipolar
• The input power factor (PF) can be regulated to near unity. line-to-neutral wave SA is created when the reference sine
wave, Sgrid with frequency /grid overlays the triangular carrier
• The PWM rectifier operated in high-frequency square wave wave Sc with frequency !c. The signal and carrier signals are
phase-shift mode produces a high-quality DC output that described by (1) and (2), respectively.
makes the DC-link filter size small.
Curre,. Source Rectifier (CSR) Fictitious Vottage Source Inverter
• As the charge is regulated in the current control mode, the Mode Operafion DC Link (VSI) Mode Ope""ion
'-
battery current is high quality and the control loop is robust.
I;!>
II. PROPOSED ELECTRIC VEHICLE BATTERY CHARGING 51 53 55
+
SW1 5W4
LowFrequency
High Freque ncy
SYSTEM WITH MATRIX CONVERTER AC �
AC
a
2867
(n-1)
(-1)-2- . 2 F 2(JFc)
The transformer is discussed in more detail in section (ii).
( t) .
8 ,\,00
Sc
-
(b). Ul - � : �
S BC =
1 S BC =
-1 S BC = 0
"
.
"
.
�-!jI - -- -- -- .
- - - -- -- - -- '. ._---- -- --------- -- ------ -- ------ + -- --------- --------- -- --------
-- ," ------_.._-- ----------_..__.._--------_.._--------,' _..-------------_.._------------_.._---------
..:'
- .
. ...
.
. .
. ' . .. ...... .. ... .•. ... .. .. VgB+=1 VgB+=0 VgB+=0
Ssq
- -- ->- - - --- ------_.._-- ----------_..__...•
.
·UD
=
1
(C) UI
" ____ . .. . _ ___ ____________ •c. . ..
______ ___ _ ___ _________
. ... .. ......... .. ... .. .. ...... ...
.___ ___ ___ _.,._ ___ _....
... ___ _.. __
... __ __ _ _ __ _ . ... _.. ..
__ ...
__ c•• _________
.. ...... .. --------- .. - �
--------- ---
...... ... .. ......... :
V:qB-=0 V:qB-=1 VaB-=0
VgB+=0 VgB+=1 VgB+=0
" _
.
Ssq 0
of,iII :. . .
"
·1.00 f i f. =
(e) f,� S eA =
1 S eA =
-1 S eA = 0
Vge+=1 Vge+=0 Vge+=0
. . . . . . .
Ssq 1
:,; --- - - ..-- - .- - .-- ..-- .- --. --..- ..--�--... . --. .- . . - .. .. . ....
. . ...
. . .
.
.. . . . . . .. .. . . . . .
�c-=O �c-=1 V:QC-=0
=
(f) ::
. . . . . . ..
. -..- .. ...
. .---.
. .--. . .--. .--. --. -.' . .. . .. .. -..- .. ..
. .- .---.
. . . . .. .. . .. . .. ..,
"
" . .. ..
. ..
" '
-- - --
" .
- -- - -- - -- --
. -- --- - - - -
- - -- - - -- - - -- - - - -- --- -- - --- --- --
.
- -- -- --- - -;
. . . . . . . . . . .. .
Vgc+=0 Vgc+=1 Vgc+=0
. .
Ssq 0
VaC-=0
=
2868
(iO High Frequency Transformer Ct = 150l1F
Lt 30l1H
High frequency (HF) transformer forms a very critical
=
portion of the system. While a 60Hz transformer is bulky, a [n addition to the input filter, the output filter also needs
HF transformer can pose challenges in terms of hysteresis, to be designed to restrict the second harmonic frequency (12
eddy current and skin affect losses. So the selection of kHz) and higher order harmonics in battery current to less than
appropriate transformer core becomes very important to avoid [5% of DC current (see Fig. 6). Based on the calculations, the
these losses. Amorphous alloys, ferrite, powdered iron and following values have been used:
Nano-crystalline offer high performance characteristics for
transformer core at frequencies in the range of 3 kHz to 20 CR = 220l1F
kHz [16]. Powdered iron core has been popularly accepted as LR = 80l1H
a viable solution for EV application and can be employed for jhXL,n
the design of the 6 kHz transformer used [2].
jhXL,n
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for
III. SIMULATION RESULTS
400.00
200.00
1-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ..
Ibat
_
Vbat
I. Charging operation
I
voltage (Vhat). hat was regulated at 100A at a battery voltage of
450V. As evident, the DC battery current is of good quality
(ripple < 15%). Fig. 8 (b) shows the utility phase-A voltage
(Va) and phase-A current drawn by the system (la). The input 0.0 16.70 3,3_40 Frequency (KHz)
power factor is > 0.99. The currents in other phases also follow
Fig. 9: Frequency spectrum (FFT) of waveforms in Fig. 8
similar waveform. Fig. 8 (c) shows the transformer secondary
current (l,ee)' The Fig. 9 shows FFT of waveforms in Fig. 8. It
(a) Ibat Vb at
can be seen that the transformer current is of high frequency
(6kHz). Due to the leakage inductance in the transformer, the
, ,, ,
b--� ----](---:::----------- --mJ------(- - - - - - - - !(------------------- - ---ior----nd--------------
transformer current has some transients 233.333 _______ .J______________________ L _____________________ -'. ____________
, , ,
, , ,
(a} lbat Vb at
, , ,
, , ,
, ,
, , ,
200.00 ----------�-
: ---------------�-
:
(b}la Va
� �
I
:
.... I
...- � �......
:
I
0.0 ----------;--------------------------------;---------------------------
,
--.--
133.333
0.0
-133.333
0.50K Fig. 10: Discharging operation (a) Battery current and voltage, and (b) Grid
phase-A current and voltage
O.OK
3. Variable output DC voltage
-0.50K
As the battery charges, the output voltage will increase. To
888.00 896.00 904.00 912.00 Time
(ms) check the performance in this case, the battery banl<- was
Fig. 8: Charging operation (a) DC current into the battery and battery voltage, simulated as a large capacitor (C "" 0.1 F). As observed from
(b) Grid phase-A current and voltage and (c) Transformer current on the
Fig. 11, the controller is able to regulate current in case of
secondary side
increasing output voltage (shown in Fig. 11 (a) from 375V to
2. V2G: Discharging operation 450V). During charging at constant current, the battery voltage
increases. In order to supply this increased power, the utility
As discussed before, the proposed system is capable of bi
grid currents also have to increase. The charging currents are
directional power transfer. The system performance during
varied depending on the State of Charge (SOC) in the battery
power transfer from vehicle to grid (V2G), i.e. discharging
for storing the maximum possible energy in the cells.
operation, is shown in Fig. 10. The negative battery current in
Fig. 10 (a) and the 1800 phase shift between the grid phase-A 4. Step response of controller
voltage and current in Fig. 10 (b) make it evident that power is
The step response of the controller is shown in Fig. 12. A step
being transferred to the grid. It may be noted that the
change of DC current set-point from 100A to 40A (with a time
magnitude of DC current required during V2G operation is
constant of 0.1 seconds) was provided to observe the stability
smaller than that during charging operation. It is generally done
of the control scheme (see Fig. 12 (a)). It can be seen that
to avoid rapid dumping of energy onto the grid and to reduce
control scheme keeps the system stable even at such fast
the wear and tear in the battery system. But it can be seen from
changes in battery current reference. Fig. 12 (b) shows that the
Fig. 10 that the proposed converter can handle large currents
utility grid current (/a) magnitude reduces with battery current
even during V2G operation.
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and yet maintains near unity power factor. In practical power conversion. Moreover, V2G operation can be performed
applications, though any such rapid changes in current set with the same ease as charging operation in the MC based
point are not expected, this experiment shows that the proposed topology; which makes the converter even more attractive for
control scheme is robust enough to handle sudden changes in commercial EV infrastructure.
set-point.
VI. REFERENCES
(a) Ibat Vbat
1. Association, N.E.C., Draft Standard: Standard for Installing and
Maintaining Electric Vehicle Supply Equipment (EVSE), 2011.
400.00 Ll...---+--''''''''
' ''''''''''''
'' '''*
'' ·:·�·· �·· �·· �·· �·· �·· ':'':'·· t ...:":"..1.
..:":'
·: :":'·· :-:-·· :":' 2. Aggeler, D., et al. Ultra-fast DC-charge infrastructures for EV
·
·
·
.
.
.
mobility and future smart grids. in Innovative Smart Grid
. .
·
.
.
133.333 II . 1I� �. J1
. . ... � .. J .." . .
�
. " ... JI...
transformers for electric power distribution system. Power
Electronics, IEEE Transactions on, 1999.14(6): p. 1133-1141.
� � � � : : i 13. Chapman, D., D. James, and C.J. Tuck. A high density 48 V 200 A
I'I : � � rectifier with power factor correction-an engineering overview. in
0.0
Telecommunications Energy Conference, INTELEC '93. 15th
'" � � � j.II International. 1993.
··.,; · · � �··· � i I' � : ... ... ; '-- --'
-133 . 333 "
· V · �--·� u�"'lJ '", .. �\j \l � II v v
14. Krishnamoorthy, H.S., et al. A new multilevel converter for Megawatt
scale solar photovoltaic utility integration. in Applied Power
0.16 0.20 0.24 0.28 Electronics Conference and Exposition (APEC), 2012 Twenty
Seventh Annual IEEE. 2012.
15. Mohan, N., T.M. Undeland, and W.P. Robbins, Power electronics :
Fig. 12: Step response of control scheme(a) Battery current and voltage, and
converters, applications, and design. 3rd ed. 2003, Hoboken, NJ:
(b) Grid phase-A current and voltage
John Wiley & Sons. xvii, 802 p.
16. Leung, c.-k., Design Considerations of High Voltage and High
IV. CONCLUSION Frequency 3 Phase Transformer for Solid State Transformer
A new high power rectifier topology was introduced in this Application, in Electrical Engineering2010, North Carolina State
University: Raleigh, North Carolina.
paper for electric transit bus battery charging. The theoretical
17. Kheraluwala, M.N., et aI., Performance characterization of a high
analysis, calculations and simulation results were discussed in power dual active bridge. Industry Applications, IEEE Transactions
detail, along with the advantages of the system. It is seen that on, 1992.28(6): p. 1294-1301.
the proposed converter has the potential to enhance the
performance and efficiency of power conversion in high power
electric bus battery charging and V2G power conversion. The
topology reduces the overall system size and increases the
power density, making it suitable for on-board battery
charging. This is achievable due to the HF transformer and
elimination of electrolytic capacitors from the primary side
2871