This Master thesis deals with modification of lead battery charger connection. In particular, changes are made to the control board. The theoretical part describes the principle of charging lead batteries and the description of the basic types of switching power supplies. Furthermore, the dimensioning of important components in the circuit together with the optimization of the switching frequency and the parameters of the high-frequency transformer are also presented. At the end of the thesis is the procedure of assembling the whole charger.

This thesis deals with a design, construciton and testing of a switch-mode power supply (SMPS) which is working as a LiFEPO4 battery charger with output current up to 100~A and output voltage up to 14,6~V. The output voltage and current can be regulated by the operator from zero to maximum value. For this SMPS Half-bridge asymmetrical forward converter with two transformers and common output inductor topology is chosen. The control circuits are run by the IC SG3525. Cascaded regulation of output voltage and current is implemented by two discrete operational amplifiers. Undervoltage protection of the control circuits and independent overcurrent protection on the primary side is also implemented.

The aim of this master's thesis is suggest and construct regulator for charge NiMH storage battery from photovoltaic (PV) panel. Function regulator is tracking maximum power point from PV panel (MPPT), control charge and evaluation full charge of battery.

In this thesis suggest the involvement of appropriate driver for mobile phone travel charger. The work is a treatise on the available accumulators, which can be used as a source for the proposed power converter.

El presente proyecto es un cargador solar ecológico que puede ser transportado en todo momento debido a su tamaño compacto y su poco peso de 150 gramos. Además, almacena la energía del sol y la luz led para luego cargar tu dispositivo en cualquier momento. Se desarrolla su viabilidad en base a una investigación realizada a hombres y mujeres de 18 a 39 años de los niveles socioeconómicos A, B y C. Por lo tanto, el análisis permite identificar a un grupo de personas que necesitan cargar su celular en momentos importantes durante el día pero que no encuentran lugar donde conectarlo o no tienen un cargador. Para validar la solución se utilizó un prototipo del producto el cual fue presentado al público y especialistas para que salga al mercado. Por último, se realizó un concierge para calcular la intención de compra del producto y proyectar sus estados financieros, los cuales, están respaldados por pertinentes desarrollos estratégicos que llevan a cabo un plan de negocio.

Εlectric vehicles are replacing the internal combustion engine vehicles rapidly and they will dominate the market completely in the next years. The amount of energy and power needed to support this new technology is huge. This will increase the already high electricity demand of our societies. The electric vehicles can provide a solution by using them to transfer energy to any other vehicles or infrastructure in combination with electricity management. This can be achieved by controlling the electric vehicle chargers and by knowing the exact consumption of the other vehicles or infrastructures. In Dansmästaren, Uppsala, there is a parking garage with 30 Charge Amps Aura charging stations. The same type of charger has been used in order to examine if it is possible to extract and update data through programming, as well as its functions regarding Vehicle-to-everything (V2X). This thesis presents two Python scriptswhere the first is used to update different functions of the charger and the secondto get high resolution electricity data and the energy consumption of the charger.The collected data is stored in two MySQL database every 30 seconds for future use. The data that can be updated by the user immediately, from anywhere and at any time. Similarly, the data collection has shown that different charging patterns exist and they can be observed by using the data that are generated and saved in the databases.

Rising fuel costs and concerns about air pollution have significantly increased interest in electric vehicles (EVs). EVs are equipped with rechargeable batteries that can be fully recharged by connecting to an external electrical source. However, the wider adoption of EVs is hindered by the need for an on-board charger system that is both lightweight and efficient. EVs utilize two main charging methods: on-board chargers (OBC) for regular charging and off-board (fast) chargers for quick refills of battery pack. Most EVs currently use 400V battery packs paired with 6.6kW or 11kW OBCs, while larger vehicles with over 100 kWh battery packs employ 16.5kW or 19.2kW OBCs, constrained by household voltage and current limits. Some manufacturers are transitioning to 800V battery packs to lower costs and enhance fast charging capabilities, necessitating the development of 800V OBCs with high efficiency and power density. For household use, EVs can charge via OBC in a grid-to-vehicle transfer and can supply energy back to the home or grid (vehicle-to-grid) for emergency use or to support smart grid functionalities, requiring bidirectional OBCs. Advanced power semiconductor devices have been instrumental in advancing power conversion technology. The introduction of power semiconductor devices based on wide bandgap (WBG) materials marks a revolutionary shift, offering potential improvements over silicon-based devices. These WBG devices are capable of achieving higher efficiency, and higher power density in power conversion at higher operation frequency. Elevating the switching frequency diminishes the voltage-second across the transformer, facilitating the utilization of printed-circuit-board (PCB) technology for the windings as opposed to Litz wire implementations. Compared to traditional Litz wire-based transformers, the manufacturing process is significantly streamlined, and the management of parasitic is considerably more straightforward. Furthermore, the integration of resonant inductors with PCB-based transformer results in a reduction in the overall number of magnetic components and improved power density. This dissertation focuses on the DC/DC conversion stage of a bi-directional battery charger. It aims to achieve high power density and high efficiency using a PCB-based integrated transformer, enhancing manufacturing processes. The dissertation details the specific accomplishments in this area: Firstly, a two-stage on-board charger structure for 800 V battery EVs is proposed. The first stage is a four-phase bridgeless totem pole AC/DC converter working at critical conduction mode (CRM) so that soft switching can be achieved for all the fast switches. The second stage is single phase CLLC (1PCLLC) converter which is attractive due to its less component counts of devices and driver circuits. A novel matrix integrated transformer with controllable built-in leakage inductance for bi-directional 1PCLLC converter was proposed. Integrating three UI-core-based (1UI-based) elemental transformers with non-perfectly interleaved winding structures into one 3UI-based integrated transformer can reduce the core loss significantly with a smaller footprint compared with three EI-core-based integrated transformers. The proposed integrated magnetics can be scalable for higher voltage and higher power converters by assembling more 1UI-based elemental transformers. A SiC-based 1PCLLC converter prototype operating at 250-kHz switching frequency for 11-kW OBC applications was built with the proposed integrated transformer, and it can achieve a power density of 250 W/in3 with maximum efficiency of 98.4%. Secondly, the challenge of increased common mode (CM) noise after adopting PCB-based windings in the design was discussed. The inter-winding capacitors between the primary and secondary windings act as a conduction path for high dv/dt CM noise, which can lead to electromagnetic interference (EMI) issues. To address this, a winding cancellation method for an integrated matrix transformer in a 1PCLLC converter was proposed and validated. This approach was tested in an 11-kW 1PCLLC converter. The EMI measurement results align with the analysis, confirming the effectiveness of the proposed method, which achieved a reduction in CM noise by 17dB. Furthermore, the 1PCLLC converter, incorporating the proposed planar matrix integrated transformer and winding cancellation technique, attained a power density of 420 W/in³ and a peak efficiency of 98.5%. Thirdly, to enhance efficiency further, the 1PCLLC converter is substituted with the proposed three-phase CLLC (3PCLLC) resonant converter equipped with three-phase rectifiers. The 3PCLLC converter becomes more promising for high power applications as its lower RMS current stress and automatic current sharing capabilities. It can achieve soft switching under all conditions. In addition, due to the symmetrical resonant tank, it is more suitable for bi-directional operation. Variable DC-link voltage is adopted so that the DC/DC stage can always work at its optimized point, providing best efficiency for the entire battery voltage. An improved core structure for the three-phase integrated transformer was proposed to reduce the core loss and simplify the magnetic components by integrating three primary resonant inductors, three secondary resonant inductors and three transformers into one magnetic component. A systematic method of converter design which includes the design of integrated transformer, converter loss optimization was adopted to design an 11kW 3PCLLC resonant converter. A SiC-based 3PCLLC converter prototype operating at 250-kHz switching frequency for 11-kW OBC applications was built with the proposed integrated transformer, and it can achieve a power density of 330 W/in3 with peak efficiency of 98.7%. Fourthly, the power level of OBC continues to increase to make up the large capacitance battery pack inside the EVs to relief the concern of mileage range. To address this challenge of higher power, a scalable matrix integrated transformer for multi-phase CLLC converter was proposed. A universal method of integrating magnetizing inductance with built-in leakage inductance based on multiple perfectly coupled transformers (PCTs). The integration of built-in leakage inductance can be achieved by connecting several PCTs using a standardized core type for cost considerations or can be further integrated into a customized core with interleaved magnetomotive force polarities across transformer legs to achieve better flux distribution and smaller core loss. The proposed concept can be applied to single-input single-output, and multiple-inputs multiple-outputs integrated transformer applications. A 3x3 PCTs-based integrated transformer built with PCB windings was designed for a 3PCLLC resonant converter, which integrates three primary resonant inductors, three secondary resonant inductors, and three transformers into one magnetic core to simplify the complexity of the converter. The effectiveness of the proposed concept was demonstrated through a high-efficiency, high-power density 3PCLLC DC/DC converter for an 800V 16.5kW OBC. The designed converter can achieve a power density of 500 W/in3 and a peak efficiency of 98.8%. / Doctor of Philosophy / Rising fuel costs and concerns about air pollution have significantly increased interest in electric vehicles (EVs). EVs are equipped with rechargeable batteries that can be fully recharged by connecting to an external electrical source. However, the wider adoption of EVs is hindered by the need for an on-board charger system that is both lightweight and efficient. The dissertation presents advances in OBC technology to address these challenges, focusing on the development of efficient, high-power density OBCs suitable for various EV applications. EVs utilize two main charging methods: on-board chargers (OBC) for regular charging and off-board (fast) chargers for quick refills of battery pack. Most EVs currently use 400V battery packs paired with 6.6kW or 11kW OBCs, while larger vehicles with over 100 kWh battery packs employ 16.5kW or 19.2kW OBCs, constrained by household voltage and current limits. Some manufacturers are transitioning to 800V battery packs to lower costs and enhance fast charging capabilities, necessitating the development of 800V OBCs with high efficiency and power density. For household use, EVs can charge via OBC in a grid-to-vehicle transfer and can supply energy back to the home or grid (vehicle-to-grid) for emergency use or to support smart grid functionalities, requiring bidirectional OBCs. Advanced power semiconductor devices have been instrumental in advancing power conversion technology. The introduction of power semiconductor devices based on wide bandgap (WBG) materials marks a revolutionary shift, offering potential improvements over silicon-based devices. These WBG devices are capable of achieving higher efficiency, and higher power density in power conversion at higher operation frequency. Elevating the switching frequency diminishes the voltage-second across the transformer, facilitating the utilization of printed circuit board (PCB) technology for the windings as opposed to Litz wire implementations. Compared to traditional Litz wire-based transformers, the manufacturing process is significantly streamlined, and the management of parasitic is considerably more straightforward. Furthermore, the integration of resonant inductors with PCB-based transformer results in a reduction in the overall number of magnetic components and improved power density. Addressing cost concerns, a novel, cost-effective single-phase converter design was proposed, achieving high efficiency with integrated magnetics. Additionally, the research tackled the challenge of electromagnetic interference (EMI) through a winding cancellation technique, significantly reducing common-mode noise and further improving the converter's performance. The research introduces an improved core structure for a three-phase integrated transformer, significantly reducing core loss and simplifying the design by combining multiple components into a single unit. This approach facilitated the creation of a high-efficiency, SiC-based converter prototype, demonstrating remarkable power density and peak efficiency compared with state-of-the-art solutions. To accommodate the increasing power requirements of OBCs, a scalable, matrix integrated transformer design was developed for multi-phase converters, optimizing cost and performance. This design simplifies the converter architecture, enhancing efficiency and power density, and is adaptable to both single and multiple output applications. These advancements offer promising solutions to the challenges hindering the wider adoption of EVs. The dissertation underscores the potential of advanced power conversion technologies, including the application of WBG devices, integrated magnetics to streamline converter design and enhance both the efficiency and power density of battery chargers.

The generic concept of quasi-single-stage (QSS) power conversion topology for ac-dc rectification and dc-ac inversion is proposed. The topology is reached by direct cascading and synchronized switching of two variety of buck or two variety of boost switching networks. The family of QSS power converters feature single-stage power processing without a dc-link low-pass filter, a unidirectional pulsating dc-link voltage, soft-switching capability with minimal extra commutation circuitry, simple PWM control, and high efficiency and reliability. A new soft-switched single-phase QSS bi-directional inverter/rectifier (charger) topology is derived based on the QSS power conversion concept. A simple active voltage clamp branch is used to clamp the otherwise high transient voltage on the current-fed ac side, and at the same time, to achieve zero-voltage-switching (ZVS) for the switches in the output side bridge. Seamless four-quadrant operation in the inverter mode, and rectifier operation with unity power factor in the charger (rectifier) mode are realized with the proposed uni-polar center-aligned PWM scheme. Single-stage power conversion, standard half-bridge connection of devices, soft-switching for all the power devices, low conduction loss, simple center-aligned PWM control, and high reliability and efficiency are among its salient features. Experimental results on a 3 kVA bi-directional inverter/rectifier prototype validate the reliable operation of the circuit. Other single-phase and three-phase QSS bi-directional inverters/rectifiers can be easily derived as topological extensions of the basic QSS bi-directional inverter/rectifier. A new QSS isolated three-phase zero-voltage/zero-current-switching (ZVZCS) buck PWM rectifier for high-power off-line applications is also proposed. It consists of a three-phase buck bridge switching under zero current and a phase-shift-controlled full-bridge with ZVZCS, while no intermediate dc-link is involved. Input power and displacement factor control, input current shaping, tight output voltage regulation, high-frequency transformer isolation, and soft-switching for all the power devices are realized in a unified single stage. Because of ZVZCS and single-stage power conversion, it can operate at high switching frequency while maintaining reliable operation and achieving higher efficiency than standard two-stage approaches. A family of isolated ZVZCS buck rectifiers are obtained by incorporating various ZVZCS schemes for full-bridge dc-dc converters into the basic QSS isolated buck rectifier topology. Experimental and simulation results substantiate the reliable operation and high efficiency of selected topologies. The concept of charge control (or instantaneous average current control) of three-phase buck PWM rectifiers is introduced. It controls precisely the average input phase currents to track the input phase voltages by sensing and integrating only the dc rail current, realizes six-step PWM, and features simple implementation, fast dynamic response, excellent noise immunity, and is easy to realize with analog circuitry or to integrate. One particular merit of the scheme is its capability to correct any duty-cycle distortion incurred on only one of the two active duty-cycles which often happens in the soft-switched buck rectifiers, another merit is the smooth transition of the input currents between the 60o sectors. Simulation and preliminary experimental results show that smooth operations and high quality sinusoidal input currents in the full line cycle are achieved with the control scheme. / Ph. D.

This work explores how GaN devices and advanced control can improve the power density of battery chargers for the plug-in hybrid electric vehicle. Gallium nitride (GaN) devices are used to increase switching frequency and shrink passive components. An innovative DC link reduction technique is proposed and several practical design issues are solved. A multi-chip-module (MCM) approach is used to integrate multiple GaN transistors into a package that enables fast, reliable, and efficient switching. The on-resistance and output charge are characterized. In a double pulse test, GaN devices show fast switching speed. The loss estimation based on the characterization results shows a good match with the measurement results of a 500 kHz GaN-based boost converter. Topology selection is conducted to identify candidates for the PHEV charger application. Popular topologies are reviewed, including non-isolated and isolated solutions, and single-stage and two-stage solutions. Since the isolated two-stage solution is more promising, the topologies consisting of an AC/DC front-end converter and an isolated DC/DC converters are reviewed. The identified candidate topologies are evaluated quantitatively. Finally, the topology of a full bridge AC/DC plus dual active bridge DC/DC is selected to build the battery charger prototype for fixed switching-frequency, low loss, and low realization complexity. The DC link capacitor is one of the major power density barriers of the charger, as its size cannot be reduced by increasing the switching frequency. This work proposed a charging scheme to reduce the DC link capacitance by balancing the ripple power from input and output given that the double-line-frequency current causes minor impact to the battery pack in terms of capacity and temperature rise. An in-depth analysis of ripple power balance, with converter loss considered, unveils the conditions of eliminating the low-frequency DC link capacitors. PWM-zero-off charging where the battery is charged by a current at double-line-frequency and DC/DC stage is turned off at the zero level of the waveform, is also proposed to achieve a better tradeoff between the DC link capacitor size and the charger efficiency. The practical design issues are outlined and the solutions are given at different levels of implementations, including the full bridge building block, the AC/DC stage, and the DC/DC stage. The full bridge section focuses on the solution of a reliable driving and sensing circuitry design. The AC/DC stage portion stresses the modulator improvement, which solves the often-reported issues of the current spike at the zero-crossing of the line voltage for the high frequency totem-pole bridgeless converter. In the DAB section, analytical expressions are given to model the converter operation at various operating conditions, which match well with the measurement results. The overall charging-system operation including the seamless transition of bi-directional power flow and the charging-profile control is verified on a laboratory GaN charger prototype at 500 kHz and 1.8 kW with an efficiency of 92.4%. To push the power density, some bulky components including the control board, the cooling system, and the chassis are redesigned. Together with other already-verified building blocks including full bridges, magnetics, and capacitors, a high-density mock-up prototype with 125 W/in3 power density is assembled. / Ph. D.

The battery charger plays an important role in the development of electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs).This thesis focuses on the DC-DC converter for high voltage battery charger and is divided into four chapters. The background related to EV battery charger is introduced, and the topologies of isolated DC-DC converter possibly applied in battery charge are sketched in Chapter 1. Since the EV battery charger is high voltage high power, the phase-shifted full bridge and LLC converters, which are popularly used in high power applications, are discussed in detail in Chapter 2. They are generally considered as high efficiency, high power density and high reliability, but their prominent features are also limited in certain range of operation. To make full use of the advantages and to avoid the limitation of the phase-shifted full bridge and LLC converters, a novel hybrid resonant and PWM converter combining resonant LLC half-bridge and phase shifted full-bridge topology is proposed and is described in Chapter 3. The converter achieves high efficiency and true soft switching for the entire operation range, which is very important for high voltage EV battery charger application. A 3.4 kW hardware prototype has been designed, implemented and tested to verify that the proposed hybrid converter truly avoids the disadvantages of LLC and phase-shifted full bridge converters while maintaining their advantages. In this proposed hybrid converter, the utilization efficiency of the auxiliary transformer is not that ideal. When the duty cycle is large, LLC converter charges one of the capacitors but the energy stored in the capacitor has no chance to be transferred to the output, resulting in the low utilization efficiency of the auxiliary transformer. To utilize the auxiliary transformer fully while keeping all the prominent features of the previous hybrid converter in Chapter 3, an improved hybrid resonant and PWM converter is proposed in Chapter 4. The idea has been verified with simulations. The last chapter is the conclusion which summaries the key features and findings of the two proposed hybrid converters. / Master of Science