Design and Implementation of an 18-kW 500-kHz 98.8% Efficiency High-Density Battery Charger With Partial Power Processing

Cao, Yuliang; Ngo, Minh; Yan, Ning; Dong, Dong; Burgos, Rolando; Ismail, Agirman

doi:10.1109/jestpe.2021.3108717

Title: Design and Implementation of an 18-kW 500-kHz 98.8% Efficiency High-Density Battery Charger With Partial Power Processing

Journal Article · 30 August 2021 · IEEE Journal of Emerging and Selected Topics in Power Electronics

DOI: https://doi.org/10.1109/jestpe.2021.3108717 · OSTI ID:2441273

^[1];

^[2];

^[3]

Virginia Polytechnic Institute and State University (Virginia Tech), Blacksburg, VA (United States); Virginia Polytechnic Institute and State University
Virginia Polytechnic Institute and State University (Virginia Tech), Blacksburg, VA (United States)
Carrier Power Electronics Group, Bloomfield, CT (United States)

The demand for high-density, high-efficiency bidirectional battery chargers is driven by the fast development of energy storage system in renewable energy system, microgrid, and transportation electrification. Isolated dc–dc converter that interfaces a battery with a variable voltage range is one of the critical components. Input-parallel output-series (IPOS) partial power (PP) converter is considered a promising high-efficiency, high-density solution because only a fraction of power is processed via multistage converters to regulate the output voltage. However, due to the tight coupling between two dc transformers (DCXs), the design of PP converter is complicated. To solve this issue, an overall design procedure for a bidirectional soft-switching resonant-type PP converter is proposed. In the parameters design part, a decoupled design method is proposed to simplify the DCXs design. With this method, two DCXs can be designed separately, and a typical optimization method can be easily applied. As for the hardware design part, to minimize the ac loop inductance and resistance, a two-direction (2-D) flux cancellation method and an “intraleaving” winding structure are proposed for circuit layout and high-frequency (HF) transformer to obtain high operation efficiency and power density. Finally, the whole design procedure is verified by an 18-kW-rated, 25-kW peak, prototype operating at 500 kHz. The realized PP converter features a peak efficiency of 98. 8% and a power density of 142 W/in3. Furthermore, this article is accompanied by two videos demonstrating the dynamic voltage regulation test and the efficiency measurement.

View Accepted Manuscript (DOE)

Cite

Export

Save

Research Organization:: North Carolina State University, Raleigh, NC (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: EE0006521

OSTI ID:: 2441273

Journal Information:: IEEE Journal of Emerging and Selected Topics in Power Electronics, Journal Name: IEEE Journal of Emerging and Selected Topics in Power Electronics Journal Issue: 6 Vol. 10; ISSN 2168-6777

Publisher:: IEEECopyright Statement

Country of Publication:: United States

Language:: English

References (34)

High‐efficiency battery charger with cascode output design Chiu, Huang‐Jen; Lo, Yu‐Kang; Tseng, Po‐Jung IET Power Electronics, Vol. 7, Issue 7 https://doi.org/10.1049/iet-pel.2013.0613	journal	July 2014
A novel approach for minimizing high-frequency transformer copper losses Vandelac, J. -P.; Ziogas, P. D. IEEE Transactions on Power Electronics, Vol. 3, Issue 3 https://doi.org/10.1109/63.17944	journal	July 1988
Computationally efficient winding loss calculation with multiple windings, arbitrary waveforms, and two-dimensional or three-dimensional field geometry Sullivan, C. R. IEEE Transactions on Power Electronics, Vol. 16, Issue 1 https://doi.org/10.1109/63.903999	journal	January 2001
Practical design considerations for a LLC multi-resonant DC-DC converter in battery charging applications Musavi, Fariborz; Craciun, Marian; Edington, Murray 2012 Twenty-Seventh Annual IEEE Applied Power Electronics Conference and Exposition (APEC) https://doi.org/10.1109/APEC.2012.6166189	conference	February 2012
Efficiency optimization of LLC resonant converters operating in wide input- and/or output-voltage range by on-the-fly topology-morphing control Jovanovic, Milan M.; Irving, Brian T. 2015 IEEE Applied Power Electronics Conference and Exposition (APEC) https://doi.org/10.1109/APEC.2015.7104534	conference	March 2015
Design and Analysis of a High-frequency CLLC Resonant Converter with Medium Voltage insulation for Solid-State-Transformer Zhao, Chunyang; Hsieh, Yi-Hsun; Lee, Fred C. 2021 IEEE Applied Power Electronics Conference and Exposition (APEC) https://doi.org/10.1109/APEC42165.2021.9487101	conference	June 2021
A High Efficiency High Density DC/DC Converter for Battery Charger Applications Jin, Feng; Nabih, Ahmed; Chen, Chen 2021 IEEE Applied Power Electronics Conference and Exposition (APEC) https://doi.org/10.1109/APEC42165.2021.9487108	conference	June 2021
Design of 500 kHz, 18 kW Low Leakage Inductance Intraleaved Litz Wire Transformer for Bi-directional Resonant DC-DC Converter Ngo, Minh; Cao, Yuliang; Dong, Dong 2021 IEEE Applied Power Electronics Conference and Exposition (APEC) https://doi.org/10.1109/APEC42165.2021.9487443	conference	June 2021
Design and Implementation of High-density Isolated Bi-directional Soft-switching Resonant DC-DC Converter with Partial Power Processing Cao, Yuliang; Ngo, Minh; Yan, Ning 2021 IEEE Applied Power Electronics Conference and Exposition (APEC) https://doi.org/10.1109/APEC42165.2021.9487457	conference	June 2021
A two-stage bidirectional DC/DC converter with SiC-MOSFET for vehicle-to-grid (V2G) application Park, Jin-Hyuk; Lee, Kyo-Beum 2017 IEEE Conference on Energy Conversion (CENCON) https://doi.org/10.1109/CENCON.2017.8262500	conference	October 2017
10 kW High Efficiency Compact GaN-Based DC/DC Converter Design Sun, Bingyao; Burgos, Rolando; Boroyevich, Dushan 2018 IEEE Energy Conversion Congress and Exposition (ECCE) https://doi.org/10.1109/ECCE.2018.8557541	conference	September 2018
High-Frequency Transformer Design with High-Voltage Insulation for Modular Power Conversion from Medium-Voltage AC to 400-V DC Li, Zheqing; Hsieh, Yi-Hsun; Li, Qiang 2020 IEEE Energy Conversion Congress and Exposition (ECCE) https://doi.org/10.1109/ECCE44975.2020.9236384	conference	October 2020
DC Distribution Converter with Partial Power Processing for LVDC/MVDC Systems Cao, Yuliang; Ngo, Minh; Yan, Ning 2021 IEEE Fourth International Conference on DC Microgrids (ICDCM) https://doi.org/10.1109/ICDCM50975.2021.9504626	conference	July 2021
Design, characteristics and application of pluggable low-inductance switching power cell of paralleled GaN HEMTs Sun, Bingyao; Burgos, Rolando; Haryani, Nidhi IECON 2017 - 43rd Annual Conference of the IEEE Industrial Electronics Society https://doi.org/10.1109/IECON.2017.8216185	conference	October 2017
A High-Efficiency High-Density Wide-Bandgap Device-Based Bidirectional On-Board Charger Li, Bin; Li, Qiang; Lee, Fred C. IEEE Journal of Emerging and Selected Topics in Power Electronics, Vol. 6, Issue 3 https://doi.org/10.1109/JESTPE.2018.2845846	journal	September 2018
A Modular SiC High-Frequency Solid-State Transformer for Medium-Voltage Applications: Design, Implementation, and Testing Dong, Dong; Agamy, Mohammed; Bebic, Jovan Z. IEEE Journal of Emerging and Selected Topics in Power Electronics, Vol. 7, Issue 2 https://doi.org/10.1109/JESTPE.2019.2896046	journal	June 2019
High-Frequency and High-Efficiency Isolated Two-Stage Bidirectional DC–DC Converter for Residential Energy Storage Systems Liu, Yu-Chen; Chen, Chen; Chen, Kai-De IEEE Journal of Emerging and Selected Topics in Power Electronics, Vol. 8, Issue 3 https://doi.org/10.1109/JESTPE.2019.2953117	journal	September 2020
High-Efficiency Isolated Boost DC–DC Converter for High-Power Low-Voltage Fuel-Cell Applications Nymand, M.; Andersen, M. A. E. IEEE Transactions on Industrial Electronics, Vol. 57, Issue 2 https://doi.org/10.1109/TIE.2009.2036024	journal	February 2010
Optimal Design and Tradeoff Analysis of Planar Transformer in High-Power DC–DC Converters Ouyang, Ziwei; Thomsen, Ole C.; Andersen, Michael A. E. IEEE Transactions on Industrial Electronics, Vol. 59, Issue 7 https://doi.org/10.1109/TIE.2010.2046005	journal	July 2012
A Novel Three-Level CLLC Resonant DC–DC Converter for Bidirectional EV Charger in DC Microgrids Xuan, Yang; Yang, Xu; Chen, Wenjie IEEE Transactions on Industrial Electronics, Vol. 68, Issue 3 https://doi.org/10.1109/TIE.2020.2972446	journal	March 2021
A New ZVS Bidirectional DC–DC Converter for Fuel Cell and Battery Application Peng, F. Z.; Li, H.; Su, G. -J. IEEE Transactions on Power Electronics, Vol. 19, Issue 1 https://doi.org/10.1109/TPEL.2003.820550	journal	January 2004
Analysis and Design of a Three-Level LLC Series Resonant Converter for High- and Wide-Input-Voltage Applications Lee, Il-Oun; Moon, Gun-Woo IEEE Transactions on Power Electronics, Vol. 27, Issue 6 https://doi.org/10.1109/TPEL.2011.2174381	journal	June 2012
Differential Power Processing for Increased Energy Production and Reliability of Photovoltaic Systems Shenoy, Pradeep S.; Kim, Katherine A.; Johnson, Brian B. IEEE Transactions on Power Electronics, Vol. 28, Issue 6 https://doi.org/10.1109/TPEL.2012.2211082	journal	June 2013
Design Methodology of Bidirectional CLLC Resonant Converter for High-Frequency Isolation of DC Distribution Systems Jung, Jee-Hoon; Kim, Ho-Sung; Ryu, Myung-Hyo IEEE Transactions on Power Electronics, Vol. 28, Issue 4 https://doi.org/10.1109/TPEL.2012.2213346	journal	April 2013
Review of the Impact of Vehicle-to-Grid Technologies on Distribution Systems and Utility Interfaces Yilmaz, Murat; Krein, Philip T. IEEE Transactions on Power Electronics, Vol. 28, Issue 12 https://doi.org/10.1109/TPEL.2012.2227500	journal	December 2013
An LLC Resonant DC–DC Converter for Wide Output Voltage Range Battery Charging Applications Musavi, Fariborz; Craciun, Marian; Gautam, Deepak S. IEEE Transactions on Power Electronics, Vol. 28, Issue 12 https://doi.org/10.1109/TPEL.2013.2241792	journal	December 2013
Classification and Comparative Evaluation of PV Panel-Integrated DC–DC Converter Concepts Kasper, Matthias; Bortis, Dominik; Kolar, Johann W. IEEE Transactions on Power Electronics, Vol. 29, Issue 5 https://doi.org/10.1109/TPEL.2013.2273399	journal	May 2014
Converter Rating Analysis for Photovoltaic Differential Power Processing Systems Kim, Katherine A.; Shenoy, Pradeep S.; Krein, Philip T. IEEE Transactions on Power Electronics, Vol. 30, Issue 4 https://doi.org/10.1109/TPEL.2014.2326045	journal	April 2015
High-Frequency Power Transformers With Foil Windings: Maximum Interleaving and Optimal Design Barrios, Ernesto L.; Urtasun, Andoni; Ursua, Alfredo IEEE Transactions on Power Electronics, Vol. 30, Issue 10 https://doi.org/10.1109/TPEL.2014.2368832	journal	October 2015
Optimal Design Methodology for LLC Resonant Converter in Battery Charging Applications Based on Time-Weighted Average Efficiency Fang, Zhijian; Cai, Tao; Duan, Shanxu IEEE Transactions on Power Electronics, Vol. 30, Issue 10 https://doi.org/10.1109/TPEL.2014.2379278	journal	October 2015
Calculation of Leakage Inductance for High-Frequency Transformers Ouyang, Ziwei; Zhang, Jun; Hurley, William Gerard IEEE Transactions on Power Electronics, Vol. 30, Issue 10 https://doi.org/10.1109/TPEL.2014.2382175	journal	October 2015
Series-Connected Partial-Power Converters Applied to PV Systems: A Design Approach Based on Step-Up/Down Voltage Regulation Range Zientarski, Jonatan Rafael Rakoski; Martins, Mario Lucio da Silva; Pinheiro, Jose Renes IEEE Transactions on Power Electronics, Vol. 33, Issue 9 https://doi.org/10.1109/TPEL.2017.2765928	journal	September 2018
High-Frequency PCB Winding Transformer With Integrated Inductors for a Bi-Directional Resonant Converter Li, Bin; Li, Qiang; Lee, Fred C. IEEE Transactions on Power Electronics, Vol. 34, Issue 7 https://doi.org/10.1109/TPEL.2018.2874806	journal	July 2019
Active Magnetizing Current Splitting ZVS Modulation of a 7 kV/400 V DC Transformer Guillod, Thomas; Rothmund, Daniel; Kolar, Johann Walter IEEE Transactions on Power Electronics, Vol. 35, Issue 2 https://doi.org/10.1109/TPEL.2019.2918622	journal	February 2020

Similar Records

Switching Transition Analysis and Optimization for Bidirectional CLLC Resonant DC Transformer

Journal Article · 2021 · IEEE Transactions on Power Electronics · OSTI ID:2441316

Cao, Yuliang; Ngo, Minh; Burgos, Rolando; +2 more

Battery charger and state of charge indicator. Final report

Technical Report · 1984 · OSTI ID:7029476

Latos, T. S.

A High-Density, High-Efficiency, Isolated On-Board Vehicle Battery Charger Utilizing Silicon Carbide Power Devices

Journal Article · 2014 · IEEE Transactions on Power Electronics · OSTI ID:1211436

Whitaker, B; Barkley, A; Cole, Z; +6 more

Related Subjects

25 ENERGY STORAGE
DC transformer (DCX)
decoupling design
intraleaving
partial power (PP) converter
resonant converter
two-direction (2-D) flux cancellation

Title: Design and Implementation of an 18-kW 500-kHz 98.8% Efficiency High-Density Battery Charger With Partial Power Processing

Citation Formats

References (34)

Similar Records

Related Subjects