Resonant Converter Dc-Dc Buck Technique for Battery Charger to Yield Efficient Performance in Charging Shaping

7/28/2019 Resonant Converter Dc-Dc Buck Technique for Battery Charger to Yield Efficient Performance in Charging Shaping

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Electrical and Electronics Engineering: An International Journal (ELELIJ) Vol 2, No 2, May 2013

15

ABATTERYCHARGING SYSTEM &APPENDED ZCS

(PWM)RESONANT CONVERTERDC-DC BUCK:

TECHNIQUE FORBATTERYCHARGER TOYIELDEFFICIENT PERFORMANCE IN CHARGING SHAPING

IrfanJamil*1, Zhao Jinquan

2, Rehan Jamil

3, Rizwan Jamil

4and Abdus Samee

5

1,2Department of Energy & Electrical Engineering, Hohai University, Nanjing, China

[email protected]

3School of Physics & Electronic Information, Yunnan Normal University, China

[email protected]

4Heavy Mechanical Complex (HMC-3) Taxila, Rawalpindi, Pakistan

[email protected]

5Chashma Centre of Nuclear Training, PAEC, [email protected]

ABSTRACT

This paper presents technique for battery charger to achieve efficient performance in charging shaping,

minimum low switching losses and reduction in circuit volume .The operation of circuit charger is switched

with the technique of zero-current-switching, resonant components and append the topology of dc-dc buck.

The proposed novel dc-dc battery charger has advantages with the simplicity, low cost, high efficiency and

with the behaviour of easy control under the ZCS condition accordingly reducing the switching losses. The

detailed study of operating principle and design consideration is performed. A short survey of battery

charging system, capacity demand & its topologies is also presented. In order to compute LC resonant pair

values in conventional converter, the method of characteristic curve is used and electric function equations

are derived from the prototype configuration. The efficient performance of charging shaping is confirmedthrough the practical examines and verification of the results is revealed by the MATLAB simulation. The

efficiency is ensured about 89% which is substantially considered being satisfactory performance as

achieved in this paper.

KEYWORDS

ZCS, PWM Resonant Converter, dc-dc Buck, Battery Charger

1. INTRODUCTIONIn recent years, with the enhancement of power electronics technology and control strategies in

power electronics devices coupled with the increasing demand of high efficiency in batterycharger system has invoked enormous attention from the research scholars around the world.

Battery charger system technology is currently being incorporated in urban industrial areas tomaintain with these demands lot of work is on towards. Therefore, many battery chargers with

different ratings and functionalities are being developed for high output efficiency since few


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16

years. The battery charger usually works to globalize the energy saving and to serve in fast

transportation systems. The use of battery charger brings convince life solution during the

traveling from urban to rural areas. Many techniques were fetched out by the scientists since

battery charger device was developed for renewable energy generation, electronic communication

power supplies, electric vehicles, UPS or an uninterruptible power supplies, PV systems andportable electronics products. Many charging methods have been developed to improve thebattery charger efficiency in the last few decades. In order to achieving high efficiency in battery

charger, append the traditional battery charger with the technique of ZCS ( Zero-Current-

Switching) resonant buck topology which delivered the efficient performance in charging

shaping[11-12-13-14].

This work looks at the issues which associates ZCS PWM (Zero-Current-Switching Pulse width

Modulation) converter, buck topology with the battery charger. This paper develops a novel high-

efficiency battery charger with ZCS PWM buck topology which has simple circuit structure, low

switching losses, easy control and high charging efficiencies [1-3]. Zero Current Switching

resonant buck converter is analyzed and mode of operation is also studied. Various waveforms &

charging curve period were noted down during the piratical examine using MATLAB software.The curve of charging efficiency during the charging period shows 89% charging output

efficiency of novel proposed prototype.

Fig.1 Block Diagram for the Proposed Novel Battery Charger

2. BATTERY CHARGERING SYSTEM & CAPACITY DEMANDTodays most modern electrical appliances receive their power directly right away the utility grid.Many devices are being developed everyday which requires electrical power from the batteries in

order to achieve large mobility and greater convenience.

The battery charger system utilizes the battery by working to recharge the battery when its energy

has been drained. The uses rechargeable batteries include everything from low-power cell phones

to high-power industrial fork lifts, and other construction equipment. Many of these products are

used everyday around-the-clock commonly in offices, schools, and universities, urban and


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civilian areas [8-9]. In fig. 2 shows that the Battery Capacities of Various Battery-Powered

Devices which are used in different rate of watt per hours level in cell phones, laptops, power

tools, forklifts and golf crafts etc.[10].

Fig.2 Battery Capacities of Various Battery-Powered Devices

A battery charger system is a system which uses energy drawn from the grid, stores it in an

electric battery, and releases it to power device. While engineers are used modern techniques to

usually design the battery charger systems, which maximize the energy efficiency of their devices

to make certain long functioning & operation time between charging; however they often neglecthow much energy is used in the conversion process of ac electrical power into dc electrical power

stored in the battery from the utility grid.

Apparently, energy savings can be possible if the conversion losses are reduced which associated

with the charging batteries in battery-powered products & output voltage can be controlled via

switching frequency. We can achieve these savings using different techniques includingbattery charger topology that is readily available today and is being employed in existing

products. The same technique and topology is discussed in this paper which increases the

efficient performance in charging shaping of novel battery charger.


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Fig.3Structure of a multi- piece battery charger system. The efficiency calculation is made over a

24 hour charge and maintenance period and a 0.2C discharge for the battery. (Prepared for

California Energy Commission Contract by EPRI Solution Ltd.,) [10].

3. METHODS OF BATTERY CHARGING SYSTEM & ITSTOPOLOGIES

Methods of efficiency improvements in battery charger systems in use today have substantially

lower possibilities due to a lack of cognitive skills in the charger and battery which commonly

consume more electricity than the product they power. The energy savings are achieved in

millions of battery charger systems that are presently in operation worldwide by reducing

inefficiencies in charger and battery. Battery charger systems work in three modes of operation.

In charge mode of operation, the battery is accumulating the charge while the maintenance mode

of operation occurs when battery is fully charged and charger is only started to supply energy to

undermine the natural discharge. No-battery mode of operation shows that the battery has beenphysically disconnected from the charger [8-9].

Fig.4SwitchModeBatteryChargerPowerVisibility


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There are lots of methods which are recognized to achieve the higher efficiency in battery charger

systems, including:

Higher voltage systems

Switch mode power supplies

Synchronous rectification

Improved semiconductor switches

Lithium-ion batteries

Charge and discharge at lower current rate

Off-grid charger when no battery is present.

Topologies NormalEfficiency

Range(%)

Estimated

Improved

Efficiency

Range (%)

Switch Mode 40%- 60% 50%- 70%

SCR 30%- 55% 45%- 60%

Ferro resonant 25%-50% 45%-55%

Linear 2%- 30% 20%- 40%

TABLE: 1 Efficiency improvements in charger topologies

Table.1 show that the efficiencies of normal and improved range are measured less than 15%,

comparable systems with overall efficiencies of 65% or greater are technically feasible in charger

topologies for battery charger system. The linear and switch mode chargers are analogous to

linear and switch mode power supplies with the exception that the charger topologies also

incorporate charge control circuitry on their outputs. Most multi- or single-piece chargers are

either linear or switch mode chargers. These two categories are found commonly in consumer

applications, particularly in the residential public sector. Ferro-resonant and SCR(siliconcontrolled rectifier) battery chargers form a large percentage of the chargers utilized in developedindustrial applications [10]. This paper provides basic idea about the method of use of switch

mode power supplies such as dc-dc converters are considered as they can achieve higher

efficiency in battery charger scheme.


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Electrical and Electronics Engi

4. CIRCUIT ANAL

CHARGER

The circuit analysis describesconverter and the circuit is

Modulationconverter dc-dc buc

said circuit are analyzed. As wvoltage gain are also obtained.

4.1. ZCS Resonant Buck C

Buck ZCSresonant converters

reducing the circuit volume and

output voltage via switching

converters turn ON &OFF at zer

resonant capacitor Cthat the rswitch S, resonant components i

The resonant converters are usu

and capacitors to enable the sw

Voltage Switching)went under

effective switching losses, switc

6-7-8]. The advantages of ZCS

the EMI (Electromagnetic Inter

over the switching elements MO

Fig.5

This paper develops a novel bat

novel circuit contains auxiliarycapacitor rC and forward diode Ds

[1-3-5]. In general way, battery

available. Without energy sourc

neering: An International Journal (ELELIJ) Vol 2, No 2,

SIS DESCRIPTION FOR NOVEL B

the study of ZCS (Zero Current Switching) Rproposed as Novel Zero Current Switching

for battery charger [5]. The various Modes of ope

ll as output voltage of the battery charger and th

nverter

are used for resolving the high-switching freq

controlling the switches with ease. Therefore, th

frequency. The switches of Zero-Current Switc

o current due to the current produced by resonant i

sonance flows across the switch. The resonant ciductor L and capacitorC.

lly which contains the serial or parallel connection

itch to achieve the ZCS (Zero Current Switching)

resonance conditions. The produces the occurr

hing stress and EMI (Electromagnetic Interference

onverters are that they have low switching losses,

ference) problems, easy control of the switches a

SFETs.

raditional ZCS Resonant Buck Converter

tery charger append with ZCS PWM converter dc-

switch 1S

which is connected in the serious withis placed as parallel to the auxiliary switch 1S as sh

is disabled to work for recharging if the energy

e battery cant recharge and charging method is re

May 2013

20

TTERY

sonant buckPulse width

rations of the

e normalized

ency losses,

y control the

ing resonant

ductorL and

rcuit holds a

s of inductors

ZVS (Zero

ing result of

problems[4-

can eliminate

d low stress

dc buck. The

the resonantown in fig. 6

source is not

plenished the


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energy, to ensure that battery o

to load. This study keeps the id

Fig.6 Proposed a No

4.2. Mode of Operation

The operation of novel battery

equivalent circuit of novel charg

respectively as shown in fig. 8 [

Fig.7 Equiv

Mode


erates continuously; enabling it provides a normal

a to develop a ZCS PWM battery charger [15-16].

vel ZCS PWM Converter dc-dc Buck for Battery Charge

harger circuit is divided into various modes of o

er is shown in fig. 7 and modes are fatherly divided

].

alent Circuit of ZCS PWM Converter dc-dc Buck

1 Mode 2

May 2013

21

power supply

erations. The

into 5 modes


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Mode 4

Fig.8 Modes

Mode 1:

0

1 1

r

tdc

L I

t E = =

Mode 2: 2 2 1 1( ) tt t t = =

Mode3:3 3 2

0

1( ) sit t t

= =

Mode4: ( ) {4 4 30

1r rC V

t t tI

= =

Mode5: 5 1 2St T t t =

The output Voltage gain of

throughout the freewheeling di

( ) (0 1 2 1 31

2dc s

E tt t t t

E T

= + +


Mode 3

Mode 5

of operation of ZCS PWM Converter dc-dc Buck

1 0 0

dc

I Z

E

+

D

( ) }3 2cos o t t

3 4t t

ovel charger can be determined from the volt

de as is given by

) ( )4 3t t

+

May 2013

22

(1)

(2)

(3)

(4)

(5)

ge Dmv

(6)


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23

4.3. Normalized Voltage Gain

The normalized voltage gain is derived by the substituting the operating modes of proposed

novel Zero Current Switching resonant buck converter battery charger into output voltage of

novel charger.

The normalized voltage equation is gained by substituting number the equations (1), (2), (3)

and (4) into (6)

1 10 0

0 0

3 1sin 1 cos sin

2 2

rrS

dc

E C RL M M Mf

E R f Q M Q

= + + + +

D DD

(7)

[ ]0

0 0

3 11 cos

2 2

rrS

C QZL MM f

QZ f M

= + +

D

(8)

[ ]32 1 cos2

nsM QM fQ M

= + +

D

(9)

The efficiency of novel battery charger is given by

( ) ( )0

0 0

1 .sT

s s r

t

E I

V T iL t dt

=

(10)

5. DESIGN CONSIDERATION

A lead-acid battery rated @ 12 V, 48 A h with an internal resistance of 0.1 ohm is used as a load

under investigates of practical examine. The battery first discharges to 13 V, and then charge to

16 V. The circuit charger components values are fixed as follows: input voltage 21VSV = , output

voltage 0 16VV = , output current 0 7AI = , switching frequency 84Sf kHz= , 0.7nsf = chosen

from the fig. 9 based on the normalized voltage gain 0 16 21 0.76dcM E E= = = . Normalized

load characteristic curve of novel ZCS resonant buck converter for battery charger is obtained by

using MATLAB. The values of 0f and rC can be calculated fatherly by determining the resonant

frequency 0f and obtaining for fixed switching frequency choosing the power quality factor Qfrom the fig.9 as well.


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Fig.9 Normalized Load Ch

The output impedance can be calgiven as

00

0

16 / 7 2.285E

RI

= = =

The characteristic impedance is

0 2.285R = , 1Q =

0 0 2.285 1 2.285Z R Q= = =

The resonant frequency is calcul

and set is based on normalized v

0 /s nsf f f= 84 / 0.7 1kHz= =

(14)

The LC-resonant pair will be derdesign parameters.

The resonant inductor rL is give

0

0

r

ZL

=


aracteristics curve (Versus M and fns) for novel battery c

culated from the output voltage 0E and the output c

omputed as given

ated from switching frequency and nsf chosen fro

ltage gain.

0kHz

ived for which fatherly computing the LC-filter pai

by

May 2013

24

harger

rrent 0I is

(11)

(12)

(13)

the Fig. 9

s of novel


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25

0

3

0

2.2853.00

2 *120*10r

ZL H

= = =

(15)

The resonant capacitance rC is given by

3

0 0

1 10.58

2.285*2 *120*10rC F

Z

= = =

(16)

LC- filter pairs of ZCS battery charger are set as follows

0 100 300rL L H= = (17)

0 100 58rC C F= = (18)

Table.2 presents the experimental circuit parameters& values for the developed novel high-

efficiency battery charger with a buck ZCS PWM converter. A deign circuit parameters are

considered & listed below in Table. 2 for practical examine [3].

Table.2 ZCS buck novel charger

The duty cycle is determined by using the parameters from above Table. 2

PARAMETER VALUES

Input Voltage dcE 21V

Output Charging Voltage 0E 16V

Resonant Inductor rL 3.0H

Resonant Capacitor rC 0.58F

Switching Frequency sf 84kHz

Resonant Frequency 0f 120kHz

Filter Inductor 0L 300 H

Filter Capacitor 0C 58 F

Output Charging Current 0I 7A


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26

1

6

01

2.285*10 *70.760

21

rt

dc

L It s

E

= = = =

(19)

2 10.760t t s = =

(20)

22 11.52

tt t s= + = (21)

1

3 3 2 3

1 7*2.285( ) sin 5.497

2 *120*10 21t

t t s

= = + =

DD

(22)

3 3 2 5.497 1.52 7.017tt t s s s = + = + = (Disruption time for switches S and S1) (23)

Total time period is computed as given

( )31 1 84*10 11.904s sT f s= = = (24)

Duty Cycle 5.497 11.904 0.461ON SD t f s s = = = (25)

The discharging time interval of capacitor is calculated as

( ) { }6

3 6

4 4 3

0.58*10 *211 cos 2 *120*10 *7.017*10 0.819

7t t t s

= = = D

(26)

44 30.819 7.017 7.84tt t s s s = + = + =

(27)

The design has reasonable range since 4 st T<

5.1. Practical Calculations of Novel Charger

As for the practical examine to calculate the ideal values of novel design, resonant inductor is

3.0uH and resonant capacitor 0.58uF were chosen.


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Fig.10 Prac

The resonant frequency 0f is co

(( 60

0

1 3.0*10 *0.5

2 2f

= =D D

Output Impedance 0Z of actual

6

0 6

3.0*102.

0.58*10r

r

LZ

C

= = =

5.2. Duty Cycle of Novel C

01 1 1.01

r

dc

L It t s

E = = =

2 2 1 1( ) 1.01t t t t s = = =

2 2 1 2.02t t t s= + = (32)

( )3 3 2 31

2 *120*10t t t = =

D

3 3 2 5.315 2.02t t t s= + = +

Total time period of novel desig


ical Circuit Prototype of Novel Battery Charger

puted as given by

) )68*10120.1kHz

=

ractical value is given by

274

arger

1 7*2.274sin 5.31521

s

+ =

D

7.335s s=

is

May 2013

27

(28)

(29)

(30)

(31)

(33)

(34)


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( )31 1 84*10 11.904S ST f s= = = (35)

The duty cycle D of switch S is determined as

3 7.335 0.61611.904

ON

S S

t t sD

T T s

= = = =

(36)

The duty cycle sD of switch S1 is calculated as

3 2 7.335 2.02 0.44611.904

s

S

t t s sD

T s

= = =

(37)

The discharging time of the capacitor is determined as

( ) { }6

3 6

4 4 3

0.58*10 *211 cos 2 *120*10 *5.315*10 1.65

7t t t s

= + = = D

(38)

4 4 3 2.87 7.335 10.205t t t s s s = + = + = (39)

After practical application, the design still can work within a reasonable range since

410.205 11.904

ss s t T < = <

6. SIMULATION & EXPERIMENT RESULTS

A prototype ZCS PWM converter dc-dc buck for battery charger is established [14]. Theexperiment results were confirmed through MATLAB software as simulation tool is used in this

paper. Fig. 11 shows that the waveforms of switch signalG

V & iLr

. The current iLr

is declined to

zero when the switch is cut off. As a consequence, the switch can be cut off and turned on

without retaining current meanwhile achieving zero current switching with low switching losses.

Fig. 12 shows that the trigger signal on the switchesS&S1,G

V denotes the trigger signal on switch

S whereas Gs1

V denotes the trigger signal on switch S1 as well. To increase the charging current,

trigger signal will be delayed by 0.088s.

In Fig.13 shows that the signal on the switch S1, Gs1V denotes the trigger signal on switch S1 and

resonant capacitor voltage VCron the switch S1. The resonant capacitor voltage VCrcan be chargedonce the switch is triggered. Fig. 14 shows that the waveforms ofi

Lr, V

Cr, i

Cr.The inductor current

iLr

is increased from 0A to 8A during 0-0.9995s, and maintained a constant value during

0.0995s-0.999 s. The resonance then began when the auxiliary switch is turned on after


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0.999s. The current iLr

is decli

current-switching. Fig. 15 show

waveform ofidm went down fro

is being charged. The diode Dm

current remained at zero after 0.

currentidm goes from 0A to 7A

Voltage Curve during the Charg

showing that charging the batte

simulation results Charging Cur

maximum charging current appr

Fig.11 Waveforms ofG

V

Fig.13 Waveforms ofV


ed to zero when the switch is cut off, thus it has a

s that the waveform of diode currentidm & diode vo

15A to zero during the 0-0.0995s when the indu

was cut off when iLr

=0

I due to the reverse bias vo

.0995s. The diode Dm was then turned on again,

ntil 0.0997s when VCr

is finished the discharging.

ing Period. The variation curve of terminal voltage

ry from 15V to 16.5V takes about 0.1 hour. Fig.

rent during the charging period of proposed novel

ximately 7.5A and mean about 7.6A is founded.

iLr

Fig.12 Waveforms of Trigger

GV &

1

GsV

1s

& CrV Fig.14 Waveform ofi

Lr,

May 2013

29

hieving zero-

ltageVdm

. The

tor current iLr

ltage, and the

and the diode

ig. 16 shows

of the battery

17 shows the

charger. The

ignal on

Cr and iCr


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Fig.15 Waveforms of idm

&

Fig.17 C

Fig. 18shows the practical c

89.5%.Thechargingtimeintervalis3


dm Fig.16 Voltage Curve during the C

arging Current during the charging period

arging efficiency variationcurve ofthenovelchargera

60minutesandthemeanefficiencyis calculatedabout89%.

May 2013

30

argingPeriod

pproximatelyis


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Fig.15 C

7. CONCULSION

This paper addresses the tec

Modulation) resonant Convert

demonstrates the effectiveness

PWM converter for novel batt

volume, minimum switching lo

discussion is done in battery ch

of circuit descriptions, operating

summarized. The simulation res

period of proposed novel prototgives gratification fulfillment wi

ACKNOWLEDGEMENTS

The authors would like to ackn

& Electrical Engineering and Co

REFERENCES

[1] Y.C. Chuang, Y.-L. Ke,

pulse-width-modulated co[2] M.D Singh, K B Khanch

McGraw-Hill, 2008, pp.77

[3] Ying-Chun Chuang, Hig

Transactions on Industrial


arging Efficiency during the charging period

nique of ZCS PWM (Zero Current Switching

er dc-dc buck append with battery charger

of developed methodology. The research method

ry charger relates the idea to gain high efficienc

ses and satisfactory performance in charging shapi

rger system and on useable functional methods. T

modes, output voltage gain and normalized voltag

ults are cited for its 89% efficiency that occurs du

pe. The practical examine is accord high repetitiouth the theoretical predictions in this paper.

wledge financial support of this project from Coll

llege of International Education, Hohai University,

High Efficiency battery charger with a buck zero-cu

verterIET Power Electron., 2008, Vol. 1, No.4, pp. 43andani, Electrical & Electronics Engineering series, 2

5-778.

h-Efficiency ZCS Buck Converter for Rechargeable B

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.

Pulse width

ircuit which

logy of ZCS

, low circuit

ng. The brief

e short study

e gain is also

ring charging

s work which

ge of Energy

hina.

rent-switching

-444.rd ed., TATA

atteries IEEE


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32

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AUTHORS

IrfanJamil was born in Punjab province, City Multan, Pakistan on Feb 25, 1987. He

received his bachelor degree in Electrical Engineering and its Automation from

Harbin Engineering University, Harbin, China in 2011. Currently he is pursuing his

Master degree at Hohai University, Nanjing, China. During these days he is doing

master research as a Visiting Research Scholar at Tsinghua University, Beijing

China. His research interest involves in Power electronics and Power system

Automation.


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RehanJamil was also born in Pun

1987. He received his bachelor i

Federal Urdu University of Arts, Sc

Currently he is pursuing his MasteChina. His research interest inv

generation.

Engr. RizwanJamil was born in

August 21, 1976. He received h

from University of Engineering

received his Master degree in P

Engineering & Technology, Karach

Heavy Mechanical Complex-3 (H

involved in research & developmeAWS code/standards for power sect

Dr.Abdus Sameegraduated as Ph

Institute of Technology in 2009. C

Chashma Centre of Nuclear Trainin

of Pakistan Institute of Engineerin

include modeling and simulation o

insulation aging and degradation, s

power plasma application in biolog

Prof. JinquanZhao was born in

1972. He received his B.S. and P

Shanghai Jiao tong University, Sh

From 1993 to 1995, he was a

Guangzhou, China. From Dec 2000

Cornell University, Ithaca, New

Tsinghua University, Beijing, Chin

Energy &Electrical Engineering,

been published more than 28 p

research interests in the area of vol

applications.


jab province, City Multan, Pakistan on Feb 25,

n B.Sc. Electrical (Electronic) Engineering from

ience & Technology Islamabad Pakistan in 2009.

degree at Yunnan Normal University, Kunminglves in Electronics, Renewable energy power

Punjab province, City Multan, Pakistan on

is bachelor degree in Mechanical Engineering

Technology, Lahore, Pakistan in 2000 and

ower Engineering from NED University of

i, Pakistan in 2003. Currently, he is working in

C-3) as a Senior Engineer since 2003. He is

t of different equipments as per ASME, API,or.

.D. in electrical power engineering at Harbin

urrently he is working as Associate Professor at

g, Pakistan. He is also a visiting faculty member

g and Applied Sciences. His research interests

f electrical systems, non-linear dielectrics, cable

pace charge behavior in solid insulation, pulsed

, environment and water waste.

angquan, Shanxi province, China, on June 26

.D. degrees, all in electrical engineering, from

nghai, China, in 1993 and 2000, respectively.

n engineer in Guangzhou Power Company,

to Sept 2003, he was a postdoctoral associate in

York. He was also postdoctoral associate in

a. Currently he isPh.D.-professor in College of

ohai University, and Nanjing, China. He has

pers in many international conferences. His

tage stability analysis and control, OPF and its

May 2013

33

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