Power Electronics Research for HEV and FCV

Dr. Jin Wang

The Ohio State University Department of Electric and Computer Engineering 1-614-688-4041 wang@ece.osu.edu

Oct. 24 2008

Outline of the Presentation

1. Power Electronics research group 2. Understanding the real problems in automotive power electronics 3. Research topics on Near term application Middle term application Long term application

Power Electronics Research Group

Ohio State University

Power Electronics Research Group

Established in Oct. 2007. 6 graduate students and 2 visiting scholars. One student defended master thesis in Aug. 2008.

Taming the electricity!

Research in HEV/FCV

Research in Renewable Energy

Actively working with CAR on both areas. Within EE, co-operate with Dr. Longya Xu and Dr. Vadim Utkin. The joint research group has more than 12 graduate students working on power electronics, motor design, and motor control. 2
Power Electronics Research Group Ohio State University

Research Topics: From Concept to Realization

Renewable Energy and High Voltage MVA inverter topology study for renewable energy Multilevel inverter switching angle calculation 150 kW universal inverter module Power electronics vs. high voltage testing and diagnostics

HEV

Traction Drive DC link capacitor current ripple minimization HEV battery characterization for power electronics design Thermoelectric cooling and generation for HEV Matrix converter based multilevel inverter for Fuel Cell PHEV charger related study 3
Power Electronics Research Group Ohio State University

Understanding of Manufacturer Needs

Cost reduction:
-------- Device and system level optimization, packaging, cooling, etc; Reliability and fail safe strategy: -------- Switching device and passive device reliability, failure mode analysis (FMEA) and limited operation strategies (LOS); Efficiency: -------- Device design and PWM strategies; EMI analysis and testing: --------- Practical system level EMI reduction methods to lower the filter and wiring cost Acoustic noise reduction: --------- Magnetic component design and PWM strategies Stability and control strategy studies: --------- Stability of inter-connected converters and inverters Circuit study for DC/DC converter, air conditioner drive: --------- DC/DC converter efficiency and transient power capability Energy storage devices --------- Battery impedance modeling and testing

Power Electronics Research Group Ohio State University

Near Term Applications

Optimization of passive components Interaction between battery and power electronics PHEV charger circuit optimization PHEV vs. Utility Transients

Example:
DC Link Capacitor Current Analysis for Hybrid Electric Vehicle

Power Electronics Research Group Ohio State University

Problem Statement
1. In the power electronics box of the hybrid electric vehicle, the film capacitor occupies of the total volume and share more than 1/5 of the total cost. 2. The sizing of the DC link capacitor is decided by the RMS value of the current ripple goes into the capacitor. 3. In hybrid electrical vehicle, a boost converter and two inverter are connected to the same DC link capacitor, thus minimized capacitor RMS current can be achieved by properly coordinate the control strategies of the converter and inverters.

Power Electronics Research Group Ohio State University

Film Capacitor in Toyota Camry

Toyota Camry
Name Plate: 2098 uF, 750 V Manufacture: Nichicon Size: 26*17*4.5 mm Weight: 3.52 kg
Power Electronics Research Group Ohio State University

Results

The resulted program can be used by drive design engineers to predicate the current into the DC link capacitor thus proper size the capacitor. Minimum current ripple can be achieved by coordination of the control of the two inverters and converter.

Immediate application in HEV power electronics design! Power Electronics Research Group
Ohio State University

Middle Term Applications

Advanced thermal management for power electronics Study on the interactions between different power electronics components on the dc bus Efficiency optimization based on smart gate drive technology

Example:

Thermoelectric in Power Electronics

Power Electronics Research Group Ohio State University

Introduction
Thermoelectric effect was discovered in 1821 Thermoelectric cooling (TEC) is more popular than thermoelectric generation (TEG) because of the capability limitation of the TEG material In recent history, thermoelectric is mostly used for non-coolant refrigerator and high end CPU cooling Currently, the predicated maximum efficiency from thermoelectric generation is less than 20% In automotive, unfortunately or fortunately, so far thermoelectric is only used for cup holders to keep beverages at desired temperature So, countless research opportunities in this area

Power Electronics Research Group Ohio State University

Thermoelectric Module
Pairs of P/N Pellets Connected: Thermally in parallel Electrically in series Max. size 2 x 2 Modules may be connected in series or parallel

Power Electronics Research Group Ohio State University

Incentive of Using Thermoelectric Cooling

Increasing power demand vs. decreasing package space Better efficiency at high load condition Positive temperature characteristics of high power semiconductor devices

Power Electronics Research Group Ohio State University

Long Term Applications

Traction drive inverter structure study. New HEV structure study (Ongoing preliminary study with Chongqing Changan Motor) PHEV vs. Utility, anther micro grid issue? Testing and validation service

Example:

Matrix Converter based Multilevel Inverter for Two Energy Sources

Power Electronics Research Group Ohio State University

Circuit Design
Designed for vehicles involves two dc sources, such as fuel cell and battery or battery and super capacitor. Connects two dc sources and the ac machine with one power electronics circuit Realize multilevel inverter function

Lower cost and better performance!

Power Electronics Research Group Ohio State University

Better Performance
Line-line voltage to the motor (proposed circuit)

Line-line voltage to the motor (traditional circuit)

Power Electronics Research Group Ohio State University

Thank you!

Power Electronics Research Group

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Ohio State University