1 1 Electric Vehicle Power Converters Sam Emrie Jacob Anderson Advisor: Dr. W. Na

2 2 Outline Project Summary Project Summary Project Goals Project Goals Background Background Detailed Description Detailed Description Functional Description and Requirements Functional Description and Requirements Equipment and Parts List Equipment and Parts List Preliminary Lab Work Preliminary Lab Work Schedule of Spring Tasks Schedule of Spring Tasks

3 3 Figure 1: Block Diagram of Power Converter Project Summary

4 4 Project Goals Being able to charge the battery throughout the wall power outlet, 120 Vrms, 60Hz. Being able to charge the battery throughout the wall power outlet, 120 Vrms, 60Hz. Having the DC able to charge a battery by making the signal approximately 52V. Having the DC able to charge a battery by making the signal approximately 52V. Analyzing charging and discharging voltage current characteristics of 400W, 52 V Li-Ion battery. Analyzing charging and discharging voltage current characteristics of 400W, 52 V Li-Ion battery. Developing a more safe and efficient charging and discharging control algorithm of the battery Developing a more safe and efficient charging and discharging control algorithm of the battery

5 5 Background Previous work done by Matt Daly, Peter Burrmann, and Renee Kohl Previous work done by Matt Daly, Peter Burrmann, and Renee Kohl Completed Small Scale System Completed Small Scale System Simulated and Designed Large Scale System Simulated and Designed Large Scale System Found Internal Resistance of Battery Found Internal Resistance of Battery

6 6 Detailed Description Power Factor Correction Circuit Power Factor Correction Circuit Bidirectional Converter Circuit Bidirectional Converter Circuit Gate Driver Circuit Gate Driver Circuit DSP Protection Circuit DSP Protection Circuit Battery Testing Circuit Battery Testing Circuit Digital Signal Processor Digital Signal Processor

7 7 Figure 2: Power Factor Correction Output Power Factor Correction

8 8 Figure 3: Diagram of Power Factor Correction Circuit Power Factor Correction

9 9 Figure 4: Diagram of Bidirectional Circuit Bidirectional Converter

10 Figure 5: Diagram of Gate Driver Circuit Gate Driver Circuit (IR2110)

11 Figure 6: Diagram of the A/D Sensing Circuit DSP A/D Sensing Circuit

12 Figure 7: Diagram of the Saft-Battery Model Battery Testing National Renewable Energy Laboratory Saft- Battery Model

13 Figure 8: Diagram of the Battery Test Circuit in Simulink Battery Test Circuit in Simulink

14 Figure 9 and Figure 10: Battery Simulation Results Simulation Result

15 DSP Using TMS320F2812 DSP board to control the PWM duty cycle Using TMS320F2812 DSP board to control the PWM duty cycle Switching frequency between 10-50kHz Switching frequency between 10-50kHz Sensing frequency between 10-50kHz Sensing frequency between 10-50kHz A/D inputs 0-3V A/D inputs 0-3V PWM output 0-3V PWM output 0-3V

16 Digital Signal Processor TMS320F2812 DSP TMS320F2812 DSP 32-Bit CPU 32-Bit CPU 150 MHz Board 150 MHz Board 16 Channel ADC = 3V input 16 Channel ADC = 3V input 16 PWM Channels 16 PWM Channels Programmable via Simulink and Code Composer Programmable via Simulink and Code Composer

17 Figure 11: Picture of MOSFET (IRFP460A) MOSFET and Heat Sink IRFP460A N-Type V_DS = 500V I_D = 20A Low Voltage High Freq. 55ns Rise Time SK 145 Heat Sink Thermal Resistance 13.2K/W

18 MOSFET Gate Driver HCPL E HCPL E 2.5 A maximum peak output current 2.5 A maximum peak output current Power Supply VCC-VEE 10Vmin 20Vmax Power Supply VCC-VEE 10Vmin 20Vmax 250 kHz maximum switching speed PWM input 250 kHz maximum switching speed PWM input

19 Figure 12: Picture of Diode Rectifier (NTE5328) Diode Rectifier NTE5328 – Bridge Rectifier NTE5328 – Bridge Rectifier Maximum RMS Bridge Input Voltage = 700V Maximum RMS Bridge Input Voltage = 700V Surge Overload Rating: 400A (Peak) Surge Overload Rating: 400A (Peak) Average Forward Current (TC = +75°C), IF (AV) = 25A Average Forward Current (TC = +75°C), IF (AV) = 25A

20 Figure 13 and Figure 14: Picture of Diode and Diode Circuit Diode VS-HFA50PA60CPBF VS-HFA50PA60CPBF VR = 600 V VR = 600 V Maximum continuous forward current 25A per leg 50A per device Maximum continuous forward current 25A per leg 50A per device

21 Figure 15: Picture of Current Transducer 21 Current Transducer L08P050D15 Current Transducer L08P050D15 Current Transducer Power Supply VCC ±15V±5% Power Supply VCC ±15V±5% Nominal Primary DC current Nominal Primary DC current I_f = 50AT (wrapping) I_f = 50AT (wrapping) Maximum Current I_fmax = ±150AT Maximum Current I_fmax = ±150AT Output Voltage V_OUT = ±I_f Output Voltage V_OUT = ±I_f Uses hall effect via cable winded through opening to sense current Uses hall effect via cable winded through opening to sense current

22 Figure 16: Chip Layout of Op-Amp Op-Amp OP484FPZ Op-Amp OP484FPZ Op-Amp Supply Voltage Range VS = 3V - 36V Supply Voltage Range VS = 3V - 36V Output Voltage High = 2.8Vmin Output Voltage High = 2.8Vmin Output Voltage Low = 125mVmax Output Voltage Low = 125mVmax Overvoltage protection Overvoltage protection

23Figure 17: Chip Layout of Hex Inverter 23 Hex Inverter NXP - 74HC04N NXP - 74HC04N Inverts input Inverts input VCC supply voltage = 5.0V VCC supply voltage = 5.0V

24 Capacitors and Inductors Aluminum Electrolytic Capacitor Aluminum Electrolytic Capacitor Capacitance = 1500UF Capacitance = 1500UF Voltage = 400V Voltage = 400V Inductance =500UH, Inductance =500UH, Current = 35A Current = 35A

25 Figure 18 and Figure 19: Picture of Voltage Regulator 25 Voltage Regulators LD1117V33C LD1117V33C Vin = 15V Vin = 15V Vo = 3.3V Vo = 3.3V LM1117T-5.0/NOPB LM1117T-5.0/NOPB Vin = 15V Vin = 15V Vo = 5V Vo = 5V

26 Future Work Small Scale Test Battery Small Scale Test Battery Large Scale Test Battery Large Scale Test Battery PCB Design PCB Design DSP Design DSP Design

27 Spring Schedule Week 1 Any Extra Battery Research Week 1 Any Extra Battery Research Weeks 2-3 Small Scale Battery Testing Weeks 2-3 Small Scale Battery Testing Weeks 4-6 PCB Design Weeks 4-6 PCB Design Weeks 7-9 DSP Design Weeks 7-9 DSP Design Weeks Large Scale Battery Testing Weeks Large Scale Battery Testing Week 12 Implementation Week 12 Implementation

28 References Daly, Matt, Renee Kohl, and Peter Burrmann. "Electric Vehicle Charger for Plug-In Hybrid Electric Vehicles." PHEV: Plug in Hybrid Electric Vehicle Charger. 26 Sept Web. 24 Sept Daly, Matt, Renee Kohl, and Peter Burrmann. "Electric Vehicle Charger for Plug-In Hybrid Electric Vehicles." PHEV: Plug in Hybrid Electric Vehicle Charger. 26 Sept Web. 24 Sept N. Mohan, First Course on Power Electronics. Minneapolis: MNPERE, N. Mohan, First Course on Power Electronics. Minneapolis: MNPERE, 2009.

29 Questions?