The move toward electric vehicles (EVs) has a significant impact to reduce greenhouse
gas (GHG) emissions and make transportation more eco-friendly. Fast-charging stations
play a crucial role in this transition, making EVs more convenient for adoption
specifically when driving in long distance. However, the challenge is to create a fast-charging
system that can work with the different types of EVs and their varying power
needs while still being efficient and effective. In this context, this thesis embarks on
this journey by introducing an innovative solution for efficient universal fast charging,
spanning both low voltage and high voltage battery systems.
A novel, configurable dual secondary resonant converter is proposed, which empowers
the charging module to extend its output range without imposing additional
demands on the resonant tank components. This solution addresses the pressing
need for a wide output voltage range in fast-charging standard in the growing EV
landscape.
To ensure optimal performance across a broad voltage and power range, the thesis
employs an analytical model for LLC resonant converters to optimize the resonant
components. This strategic component selection aims to achieve the desired output
voltage and power range while minimizing conduction losses. The proposed topology
and design methodology are rigorously validated through the development of a 10 kW prototype. Furthermore, the study introduces a two degrees of freedom (2DoF) control scheme for the proposed LLC resonant converter with the configurable dual secondary LLC
converter topology. An analytical model is formulated to guide the selection of control
parameters, ensuring coverage of the desired output voltage and power range
without compromising system efficiency. The steady-state analytical model is utilized
for determining optimized control parameters at each operating point within
the converter's output range.
To enhance the charging module's power density and efficiency, a high-frequency
litz-wire transformer design methodology is introduced. The transformer's core size
is optimized to achieve high power density and efficiency, while the winding configuration is chosen to minimize conduction losses. Finite Element Analysis (FEA) simulations validate transformer losses and operating temperatures.
The culmination of this research is the development of a 30 kW charging module
prototype. This prototype features an LLC resonant converter with a configurable
dual secondary and two degrees of freedom control for output voltage control. The
component ratings, estimated losses, and power board design are carefully considered
to create a compact and efficient charging module. Experimental testing across a
universal output voltage and power range con rms the effectiveness of the proposed
solution.
In summary, this thesis presents a comprehensive approach to design of a module
for EV fast charging application addressing voltage range, efficiency, and component
optimization, resulting in the successful development of a high-performance charging
module prototype. / Thesis / Doctor of Engineering (DEng)
| Identifer | oai:union.ndltd.org:mcmaster.ca/oai:macsphere.mcmaster.ca:11375/29442 |
| Date | January 2023 |
| Creators | Elezab, Ahmed |
| Contributors | Narimani, Mehdi, Electrical and Computer Engineering |
| Source Sets | McMaster University |
| Language | English |
| Detected Language | English |
| Type | Thesis |
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