Taewon Kang

Bi-directional power flow rapid charging system using coupled inductor for electric vehicle

This paper presents a simple and cost-effective stand-alone rapid battery charging system of 30kW for electric vehicles. The proposed system mainly consists of active front-end rectifier of neutral point clamped 3-level type and non-isolated bi-directional dc-dc converter of multi-phase interleaved half-bridge topology. The charging system is designed to operate for both lithium-polymer and lithium-ion batteries. The complete charging sequence is made up of three sub-interval operating modes; pre-charge mode, constant-current mode, and constant-voltage mode. The pre-charge mode employs the stair-case shaped current profile to accomplish shorter charging time while maintaining the reliable operation of the battery. The proposed system is able to reach the full-charge state within less than 16min for the battery capacity of 8kWh by supplying the charging current of 78A. Owing to the simple and compact power conversion scheme, the proposed solution has superior module-friendly mechanical structure which is absolutely required to realize flexible power expansion capability in a very high-current rapid charging system.

A design and control of bi-directional non-isolated DC-DC converter for rapid electric vehicle charging system

This paper presents a simple and cost-effective stand-alone rapid battery charging system of 30kW for electric vehicles. The proposed system mainly consists of active front-end rectifier of neutral point clamped 3-level type and non-isolated bi-directional dc-dc converter of multiphase interleaved half-bridge topology. The charging system is designed to operate for both lithium-polymer and lithium-ion batteries. The complete charging sequence is made up of three sub-interval operating modes; pre-charge mode, constant-current mode, and constant-voltage mode. The pre-charge mode employs the stair-case shaped current profile to accomplish shorter charging time while maintaining the reliable operation of the battery. The proposed system is able to reach the full-charge state within less than 16min for the battery capacity of 8kWh by supplying the charging current of 78A. The optimal discharging algorithm for Vehicle to the Grid (V2G) operation has been adopted to maintain the discharging current of 1C. Owing to the simple and compact power conversion scheme, the proposed solution has superior module-friendly mechanical structure which is absolutely required to realize flexible power expansion capability in a very high-current rapid charging system.

Comparison of voltage source and current source based Converter in 5MW PMSG wind turbine systems

This paper provides a comparison of power converter loss and thermal description for voltage source and current source type 5MW-class medium voltage topologies of wind turbines. Neutral-point clamped three-level converter is adopted for voltage source type topology while two-level converter is employed for current source type topology considering the popularity in the industry. In order to match the required voltage level of 4160V with the same switching device of IGCT as in voltage source converter, two active switches are connected in series for the case of current source converter. Transient thermal modeling of a four-layer Foster network for heat transfer is done to better estimate the transient junction and case temperature of power semiconductors during various operating conditions in wind turbines. The loss analysis is confirmed through PLECS simulations. The comparison result shows that VSC-based wind turbine system has a higher efficiency than that of CSC under the rated operating conditions.

A Design and Control of Rapid Electric Vehicle Charging System for Lithium-Ion Battery

This paper presents a simple and cost-effective stand-alone rapid battery charging system of 30kW for electric vehicles. The proposed system mainly consists of active front-end rectifier of neutral point clamped 3-level type and non-isolated bi-directional dc-dc converter of multi-phase interleaved half-bridge topology. The charging system is designed to operate for both lithium-polymer and lithium-ion batteries. The complete charging sequence is made up of three sub-interval operating modes; pre-charge mode, constant-current mode, and constant-voltage mode. The pre-charge mode employs the stair-case shaped current profile to accomplish shorter charging time while maintaining the reliable operation of the battery. The proposed system is specified to reach the full-charge state within less than 16min for the battery capacity of 8kWh by supplying the charging current of 78A. Owing to the simple and compact power conversion scheme, the proposed solution has superior module-friendly mechanical structure which is absolutely required to realize flexible power expansion capability in a very high-current rapid charging system.

Design of optimized coupling factor for minimum inductor current ripple in rapid EV charger systems using multi-winding coupled inductor

This paper investigates the design of 3-winding coupled inductor for minimum inductor current ripple in rapid traction battery charger systems. Based on the general circuit model of 3-winding coupled inductor together with the operating principles of dc-dc converter, the relationship between the ripple size of inductor current and the coupling factor for a 3-winding coupled inductor is derived under the different duty ratio. The optimal coupling factor which corresponds to a minimum inductor ripple current becomes -0.5, i.e. a complete inverse coupling without leakage inductance, as the steady-state duty ratio operating point approaches 1/3 or 2/3. In an opposite manner, the optimal coupling factor value of zero, i.e. zero mutual inductance, is required when the steady-state duty ratio operating point approaches either zero or one. Coupled inductors having optimal coupling factor can minimize the ripple current of inductor and battery ripple current resulting in a reliable and efficient operation of battery chargers.

Comparison of Efficiency for Voltage Source and Current Source Based Converters in 5MW PMSG Wind Turbine Systems

This paper provides a comparison of power converter loss and thermal description for voltage source and current source type 5 MW-class medium-voltage topologies of wind turbines. Neutral-point clamped three-level converter is adopted for a voltage source type topology, whereas a two-level converter is employed for current source type topology, considering the popularity in the industry. To match the required voltage level of 4160 V with the same switching device of IGCT as in the voltage source converter, two active switches are connected in series for the case of current source converter. Transient thermal modeling of a four-layer Foster network for heat transfer is done to better estimate the transient junction and case temperature of power semiconductors during various operating conditions in wind turbines. The loss analysis is confirmed through PLECS simulations. Comparison result shows that the VSC-based wind turbine system has higher efficiency than the CSC under the rated operating conditions.

Optimized coupling factor design of multiple-phase coupled inductor for minimum inductor current ripple operation in EV charger systems

The magnetic coupling of filter inductors is widely utilized in various power electronics application fields including dc-dc converters in EV charger system in order to enhance the filtering performance while maintaining the minimal filter size. The optimal distribution of self and mutual inductance of coupled inductor is regarded to be one of important design tasks with respect to the coupled inductor. This paper proposes a novel method to design the optimal coupling factor for a generalized n-winding coupled inductor which generates the least size of inductor current ripple in phase-staggered multi-paralleled dc-dc converters. The explicit mathematical form of optimal coupling factor for a generalized n-winding coupled inductor in n-phase staggered multi-paralleled dc-dc converters is presented. Experimental result based on the HILS setup has successfully confirmed the newly proposed method of obtaining the optimal coupling factor.

Optimized coupling factor of multi-winding coupled inductor for minimum inductor current ripple in rapid traction battery charger system

This paper investigates the design of 3-winding coupled inductor for minimum inductor current ripple in rapid traction battery charger systems. Based on the general circuit model of 3-winding coupled inductor together with the operating principles of dc-dc converter, the relationship between the ripple size of inductor current and the coupling factor for a 3-winding coupled inductor is derived under the different duty ratio. The optimal coupling factor which corresponds to a minimum inductor ripple current becomes -0.5, i.e. a complete inverse coupling without leakage inductance, as the steady-state duty ratio operating point approaches 1/3 or 2/3. In an opposite manner, the optimal coupling factor value of zero, i.e. zero mutual inductance, is required when the steady-state duty ratio operating point approaches either zero or one. Coupled inductors having optimal coupling factor can minimize the ripple current of inductor and battery ripple current resulting in a reliable and efficient operation of battery chargers.

Carrier based PWM for three-phase three-switch buck-type rectifier in EV rapid charging system

This paper investigates an economic and highly efficient power converter topology and its modulation scheme for 60kW rapid EV charger system. The target system consists of three-phase three-switch buck-type rectifier topology. A new Carrier Based PWM scheme along with its simple implementation using logic gates is introduced in this paper. This PWM scheme replaces the diode rectifier equivalent switching state with an active switching state producing the effectively same current flowing path. As a result, the distortion of input current during the polarity reversal of capacitor line voltage can be mitigated. The proposed modulation technique is confirmed through simulation verification. The proposed modulation technique and its implementation scheme can expand the operation range of the three-phase three-switch buck-type rectifier having ac input and capacitor ripple current of high quality.

Reduced Current Distortion of Three-Phase Three-Switch Buck-Type Rectifier using Carrier Based PWM in EV Traction Battery Charging Systems

This study investigates an economic and highly efficient power-converter topology and its modulation scheme for 60 kW rapid EV charger system. The target system is a three-phase three-switch buck-type rectifier topology. A new carrier-based PWM scheme, which is characterized by simple implementation using logic gates, is introduced in this paper. This PWM scheme replaces the diode rectifier equivalent switching state with an active switching state to produce the same effective current flowing path. As a result, the distortion of input current during the polarity reversal of capacitor line voltage can be mitigated. The proposed modulation technique is confirmed through simulation verification. The proposed modulation technique and its implementation scheme can expand the operation range of the three-phase three-switch buck-type rectifier with high-quality AC input and capacitor ripple current.