BIDIRECTIONAL ISOLATED DC-DC CONVERTER FOR 20KW APPLICATIONBY

P.VASUDEVA GUPTHA14MPE0044

INTERNAL Prof. N. Arun

(Assistant Professor) Power Electronics and Drives Dept., V.I.T UNIVERSITY, VELLORE .

EXTERNALSh. Rahul Verma

(Scientist G)IEG Group Head,

CSIR-CEERI,PILLANI.

Under the guidance of

COMPANY DETAILS

• INDUSTRY NAME – CSIR-Central Electronics Engineering Research Institute• ADDRESS - CSIR-CEERI• CEERI Road,• Pilani,• Jhunjhunu District,• Rajasthan,• 333031.• GUIDE - Sh. Rahul Verma ( Scientist G)• EMAIL - rv@ceeri.ernet.in• WEBSITE - http://www.ceeri.res.in/• INTERNSHIP - Not Through PAT• STARTING DATE - 1-08-2015• ENDING DATE - 30-04-2016• DURATION - 9 Months• STIPEND - NO

AIM/OBJECTIVES

To design Bi-directional isolated DC-DC converter for 20KW Application

OBJECTIVES:

1. To Provide Safety

2. To reduce power loss

3. To reduce size, weight and cost

4. To achieve Thermal considerations

5. To reduce Electro-magnetic interference

6. To implement Soft Switching Techniques

AIM:

SPECIFICATIONS

1. Input voltage – 100V

2. Output voltage – 600V

3. Output power – 20KW

4. Switching frequency – 20KHz

ADDITIONAL REQUIREMENTS

1. Galvanic Isolation – For safety purpose

2. High Conversion Efficiency

3. Lower converter volume – obtained by high switching frequency

INTRODUCTION1. Bidirectional convertor allows the power flow in both directions

2. Bidirectional convertor operates in two modes BOOST MODE BUCK MODE

BOOST MODE

OUTPUT VOLTAGE

OUTPUT CURRENT

OUTPUT VOLTAGE : 618.5 voltsOUTPUT CURRENT : 32.4 ampsOUTPUT POWER : 20,039.4 wattsOUTPUT RESISTANCE : 18.5 ohmsSWITCHING FREQUENCY:20KHZDUTY Ratio : 0.6

ZCS SOFT SWITCHING OF PRIMARY SWITCHES

V1: switch voltageI1: switch current

BUCK MODE

INPUT VOLTAGE : 600OUTPUT VOLTAGE : 102.9 voltsOUTPUT CURRENT : 202 ampsOUTPUT POWER : 20,785wattsOUTPUT RESISTANCE : 0.5 ohmsSWITCHING FREQUENCY:20KHZDUTY RATIO : 0.5

OUTPUT VOLTAGE

OUTPUT CURRENT

ZVS SOFT SWITCHING OF PRIMARY SWITCHES

V2: switch voltageI2: switch current

TRANSFORMER DESIGN

REQUIREMENTS:

1. AMCC-400 CORE MATERIAL2. PRIMARI TURNS: 113. SECONDARY TURNS:274. TURNS RATIO :2.45. CURRENT DENSITY :6 A/mm2

CALCULATION RESULTS6. CORE LOSS : 40 WATTS7. COPPER LOSS : 76 WATTS8. TOTAL LOSS:116 WATTS

COPPER FOIL REQUIREMENT1.PRIMARY: 10mm * 1.8mm2. SECONDARY : 10mm * 0.8mm

Ip :96A

Is :41A

POWER: 10KWATTS

DSP – TMS320F28027

FEAUTERS:

1. Frequency : 60MHz (16.67-ns Cycle Time)2. High-Efficiency 32-Bit CPU

August 2015 Literature review

September Topology Selection

October Simulation

November Transformer Design

December Coding

January Hardware Implementation

February Testing

March Documentation

WORK PLAN

1. Martin Pavlovsky, Sjoerd Walter Hero de Haan, and Jan Abraham Ferreira, “Reaching High Power Density in Multi kilowatt DC–DC Converters With Galvanic Isolation” I.E.E.E Power Electronics,2009

2. R. Y. Chen, R. L. Lin, T. J. Liang, J. F. Chen, and K. C. Tseng, ” Current-fed Full-bridge Boost Converter with Zero Current Switching for High Voltage Applications ” I.E.E.E Power Electronics,2005

3. Pan Xuewei, Student Member IEEE, Akshay K. Rathore, Senior Member IEEE,” Novel Bidirectional Snubberless Soft-switching Naturally Clamped Zero Current Commutated Current fed Dual Active Bridge (CFDAB) Converter for Fuel Cell Vehicles ” I.E.E.E Power Electronics,2013

4. Pan Xuewei, Student Member and Akshay K Rathore, Senior Member, IEEE,” Comparison of Bi-directional Voltage-fed and Current-fed Dual Active Bridge Isolated Dc/Dc Converters Low Voltage High Current Applications” I.E.E.E Power Electronics,2014

REFERENCES:

5. Manu Jain, M. Daniele, and Praveen K. Jain, “A Bidirectional DC–DC Converter Topology for Low Power Application” I.E.E.E Power Electronics,2000

6. F. Krismer, S. Round, J. W. Kolar, ” Performance Optimization of a High Current Dual Active Bridgewith a Wide Operating Voltage Range” I.E.E.E Power Electronics,2006

7.Yao-Ching Hsieh, Yong-Nong Chang, Kun-Ying Lee Yu-Chun Chiu Wei-Ting Wu,” Bidirectional Softly Switched DC-to-DC Converter with Galvanic Isolation” I.E.E.E Power Electronics,2015

8. M. A. Bahmani and T. Thiringer, M. Kharezy” Design Methodology and Optimization of a Medium Frequency Transformer for High Power DC-DC Applications” I.E.E.E Power Electronics,2015

REFERENCES:

THANK YOU