In this thesis analysis and design of a wide input range DC-DC converter is proposed along with a robust power control scheme. The proposed converter and its control is designed to be compatible to a fuel cell power source, which exhibits 2:1 voltage variation as well as a slow transient response. The proposed approach consists of two stages: a primary three-level boost converter stage cascaded with a high frequency, isolated boost converter topology, which provides a higher voltage gain and isolation from the input source. The function of the first boost converter stage is to maintain a constant voltage at the input of the cascaded DC-DC converter to ensure optimal performance characteristics with high efficiency. At the output of the first boost converter a battery or ultracapacitor energy storage is connected to take care of the fuel cell slow transient response (200 watts/min). The robust features of the proposed control system ensure a constant output DC voltage for a variety of load fluctuations, thus limiting the power being delivered by the fuel cell during a load transient. Moreover, the proposed configuration simplifies the power control management and can interact with the fuel cell controller. The simulation results and the experimental results confirm the feasibility of the proposed system.

The core of any electric vehicle (EV) is the electric drive train, intended as the energy conversion chain from the energy tank (typically some kind of rechargeable battery) to the electric motor that converts the electrical energy into the mechanical energy needed for the vehicle motion. The need for on-board electrical energy storage is the factor that has so far prevented pure electric vehicles from conquering significant market share. In fact electrochemical batteries, which are currently the most suitable device for electrical energy storage, have serious limitations in terms of energy and/or power density, cost and safety. All those characteristics reflect in pure electric vehicles being outperformed by standard internal combustion engine (ICE) based vehicles in terms of driving range, time needed to refuel and purchase cost. Electric vehicles do have their distinctive advantages, being intrinsically much more efficient, operating at zero emissions at the pipe, and offering a higher degree of controllability that can potentially enhance driving safety. No wonder then, that electric energy storage technology has attracted considerable R&D investments, resulting in new traction battery packs that are getting closer and closer to the industrial targets. In this scenario of EV technology gaining momentum, power electronics engineers have to come up with newer solutions allowing for more efficient and more reliable utilization of the precious on-board energy that comes in a form that cannot be directly utilized by the motor. At present, most of the research in the area of power electronics for automotive is focused in volume and cost reduction techniques. The increase in power density is pursued by developing components that can be operated at higher temperature, thus relieving the requirements on cooling. In this thesis, the focus is on the development of alternative topologies for the power electronics converters that make use of some peculiarities of the energy storage components and of the electrical drive train in general, rather than being a mere component-level optimization of well established topologies. A novel converter topology is proposed for hybridization of the energy source with a supercapacitor-based power buffer being used to assist the main traction battery. From the functional point of view, the topology implements a bidirectional DC/DC converter. Making use of the fact that the battery terminal voltage is close to constant, an arrangement for the supercapacitors is devised allowing for bidirectional power flow by using power electronics devices of lower ratings than the ones needed in conventional DC/DC converters. At the same time, much smaller magnetic components are needed. Theoretical analysis of the operation of the proposed converter is given, allowing for optimized design. A full-scale experimental prototype rated at 30 kW, intended for use in a pure EV, has been built and tested. Results validate the theory and show that no particular impediment exist to the deployment of the concept in practical applications. Another concept introduced in the thesis is an architecture where the traction inverter is embedded in the energy storage device. The latter is constituted by several modules, as in the case of modern Li-ion battery systems, and each module is equipped with a local power electronics interface, making it functionally equivalent to a controllable voltage source. The result is a modular, distributed system that can be engineered to have very high reliability and also to exhibit self-healing properties. A prototype with a minimum number of modules has been built and tested. Results confirm the effectiveness of the system, and make it a good candidate for deployment in applications where reliability is the most important requirement.

To support the increasingly demanding requirements for power conversion units, a digitally controlled dual output stage buck converter is designed. The system consists of a dual output stage, which includes an auxiliary buck output stage connected in parallel with a main output stage. The auxiliary output stage is only active during load transient to suppress the output voltage variation. A digital controller is designed to control both stages with a linear/nonlinear control scheme. Nonlinear control is applied during load transient based on the capacitor charge balance principle; whereas linear PID control governs the steady state operation. The design is verified with simulation and experimentally with discrete components. The controller is realized with a FPGA with preset output stage parameters. The experimental result shows a 60% reduction of output voltage variation for a heavy-to-light load transient.

A digital adaptive slope control (DASC) technique is presented to improve the dynamic response and efficiency of a current programmed mode (CPM) buck converter employing a low-cost auxiliary phase. Compared to the existing nonlinear control techniques, the advantages of the proposed control scheme include superior voltage droop and settling time, and on-line calibration to compensate for tolerance in the inductance. The proposed technique is experimentally verified on a 500 kHz, 10 V to 2.5 V CPM buck converter prototype. Charge balancing and optimal transient response are achieved for a range of positive and negative load steps. In addition, compared to a representative single phase converter, the proposed system not only has better dynamic response but also achieves 2 % heavy-load and 10 % light-load steady-state efficiency improvement. The impact of the auxiliary phase operation on the converter’s dynamic efficiency is also evaluated at different load step amplitudes and frequencies.

To support the increasingly demanding requirements for power conversion units, a digitally controlled dual output stage buck converter is designed. The system consists of a dual output stage, which includes an auxiliary buck output stage connected in parallel with a main output stage. The auxiliary output stage is only active during load transient to suppress the output voltage variation. A digital controller is designed to control both stages with a linear/nonlinear control scheme. Nonlinear control is applied during load transient based on the capacitor charge balance principle; whereas linear PID control governs the steady state operation. The design is verified with simulation and experimentally with discrete components. The controller is realized with a FPGA with preset output stage parameters. The experimental result shows a 60% reduction of output voltage variation for a heavy-to-light load transient.

A digital adaptive slope control (DASC) technique is presented to improve the dynamic response and efficiency of a current programmed mode (CPM) buck converter employing a low-cost auxiliary phase. Compared to the existing nonlinear control techniques, the advantages of the proposed control scheme include superior voltage droop and settling time, and on-line calibration to compensate for tolerance in the inductance. The proposed technique is experimentally verified on a 500 kHz, 10 V to 2.5 V CPM buck converter prototype. Charge balancing and optimal transient response are achieved for a range of positive and negative load steps. In addition, compared to a representative single phase converter, the proposed system not only has better dynamic response but also achieves 2 % heavy-load and 10 % light-load steady-state efficiency improvement. The impact of the auxiliary phase operation on the converter’s dynamic efficiency is also evaluated at different load step amplitudes and frequencies.

La generación de nuevas estructuras convertidoras y su modelado matemático son las dos temáticas principales estudiadas en esta tesis. El seguimiento de una metodología que modifica la estructura del circuito, realizando una ruptura de la simetría con base en los resultados de simulación, permitió generar la familia de convertidores en "interleaving" asimétrico compuesta por el AIDB, el AIDBB y el grupo-AIDF. En el apartado de modelado se ha desarrollado una nueva aproximación conceptual inspirada en las ideas de trabajos previos que se estudian en el estado del arte. El nombre dado a esta nueva aproximación es: Promediado Modificado Usando Métodos Gráficos. Este nuevo enfoque ha sido utilizado para obtener el modelo promediado de la nueva familia de convertidores en el espacio de estados. Las mediciones experimentales de la respuesta en frecuencia del convertidor AIDB y el diseño del controlador LQR permitieron verificar la aproximación del modelo en pequeña señal obtenido. / The two main topics presented in this thesis are the generation and mathematical modelling of new converter structures. The fundamental idea behind the methodology used to generate the new converter structures was to break the symmetry. This involved modifying the circuit structure on the basis of the simulation results. This methodology allowed the generation of the family of asymmetrical interleaved converters, which consists of the AIDB, the AIDBB and the AIDFgroup. A new conceptual modelling approach was developed on the basis of ideas taken from previous research which is reviewed in the state of the art. This approach was called Modified Averaging Using Graphical Methods. Because of its features, this new method can be used to model the state space average of the new converter family presented here. The accuracy of the AIDB converter small signal model was verified by measuring the frequency response and by designing an LQR controller.

Factors such as global warming, dwindling fossil fuel reserves, and energy security concerns combine to indicate that a replacement for the internal combustion engine (ICE) vehicle is needed. Fuel cell vehicles have the potential to address the problems surrounding the ICE vehicle without imposing any significant restrictions on vehicle performance, driving range, or refuelling time. Though there are currently some obstacles to overcome before attaining the widespread commercialization of fuel cell vehicles, such as improvements in fuel cell and battery durability, development of a hydrogen infrastructure, and reduction of high costs, the fundamental concept of the fuel cell vehicle is strong: it is efficient, emits zero harmful emissions, and the hydrogen fuel can be produced from various renewable sources. Therefore, research on fuel cell vehicle design is imperative in order to improve vehicle performance and durability, increase efficiency, and reduce costs. This thesis makes a number of key contributions to the advancement of fuel cell vehicle design within two main research areas: powertrain design and DC/DC converters. With regards to powertrain design, this research presents a novel fuel cell-battery-ultracapacitor topology which shows reduced mass and cost, and increased efficiency, over other promising topologies found in the literature. A detailed vehicle simulator created in MATLAB/Simulink is used to perform a comprehensive parametric study on different fuel cell vehicle types, resulting in general conclusions for optimal topologies, as well as component types and sizes, for fuel cell vehicles. Next, a general analytical method to optimize the novel battery-ultracapacitor energy storage system based on maximizing efficiency, and minimizing cost and mass, is developed. With regards to DC/DC converters, it is important to design efficient and light-weight converters for use in fuel cell and other electric vehicles to improve overall vehicle fuel economy. Thus, this research presents a novel soft-switching method, the capacitor-switched regenerative snubber, for the high-power DC/DC boost converters commonly used in fuel cell vehicles. This circuit is shown to increase the efficiency and reduce the overall mass of the DC/DC boost converter.

This work describes the implementation of DC to DC converter for Smart Dust in 65 nm CMOS technology. The purpose of a DC to DC converter is to convert a battery voltage of 1 Vto a lower voltage of 0.5 V used by the processor. The topology used in this DC to DC converteris of Buck type which converts a higher voltage to lower voltage with the advantage of givinghigh efficiency about 75%. The system uses PWM (Pulse width modulation) technique. It usesnon-overlapping clock generation technique for reducing the power consumption. The systemprovides up to 5 mA load current and has power consumption of 2.5 mW.

Factors such as global warming, dwindling fossil fuel reserves, and energy security concerns combine to indicate that a replacement for the internal combustion engine (ICE) vehicle is needed. Fuel cell vehicles have the potential to address the problems surrounding the ICE vehicle without imposing any significant restrictions on vehicle performance, driving range, or refuelling time. Though there are currently some obstacles to overcome before attaining the widespread commercialization of fuel cell vehicles, such as improvements in fuel cell and battery durability, development of a hydrogen infrastructure, and reduction of high costs, the fundamental concept of the fuel cell vehicle is strong: it is efficient, emits zero harmful emissions, and the hydrogen fuel can be produced from various renewable sources. Therefore, research on fuel cell vehicle design is imperative in order to improve vehicle performance and durability, increase efficiency, and reduce costs. This thesis makes a number of key contributions to the advancement of fuel cell vehicle design within two main research areas: powertrain design and DC/DC converters. With regards to powertrain design, this research presents a novel fuel cell-battery-ultracapacitor topology which shows reduced mass and cost, and increased efficiency, over other promising topologies found in the literature. A detailed vehicle simulator created in MATLAB/Simulink is used to perform a comprehensive parametric study on different fuel cell vehicle types, resulting in general conclusions for optimal topologies, as well as component types and sizes, for fuel cell vehicles. Next, a general analytical method to optimize the novel battery-ultracapacitor energy storage system based on maximizing efficiency, and minimizing cost and mass, is developed. With regards to DC/DC converters, it is important to design efficient and light-weight converters for use in fuel cell and other electric vehicles to improve overall vehicle fuel economy. Thus, this research presents a novel soft-switching method, the capacitor-switched regenerative snubber, for the high-power DC/DC boost converters commonly used in fuel cell vehicles. This circuit is shown to increase the efficiency and reduce the overall mass of the DC/DC boost converter.