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This paper describes the design and performance of a 6-kW, full-bridge, bidirectional isolated dc-dc converter using a 20-kHz transformer for a 53.2-V, 2-kWh lithium-ion (Li-ion) battery energy storage system. The dc voltage at the high-voltage side is controlled from 305 to 355 V, as the battery voltage at the low-voltage side (LVS) varies from 50 to 59 V. The maximal efficiency of the dc-dc converter is measured to be 96.0% during battery charging, and 96.9% during battery discharging. Moreover, this paper analyzes the effect of unavoidable dc-bias currents on the magnetic-flux saturation of the transformer. Finally, it provides the dc-dc converter loss breakdown with more focus on the LVS converter. [ABSTRACT FROM AUTHOR]

In this paper, the general design of a battery buffer system (BBS) consisting of a dc/dc converter and electric double layer capacitors for an electric vehicle is presented. This is intended to save the regenerative braking energy and to support the battery during acceleration. The design of a multiphase converter in interleaved operation with nonideal coupled inductors is stated to minimize volume and power losses while maintaining given current ripple limitations. A reduced sensor current-sharing control method is developed and its correct choice of the sensor position is explained. The peak efficiency of the designed and built converter can be measured to nearly 99%. The corresponding BBS is implemented in a lead-acid battery powered electric lift truck propulsion system. The system operation with and without the BBS is compared to examine the behavior and the overall efficiency. It can be shown that the traction battery stress can be strictly reduced as well as the temperature rise in the battery. Furthermore, the efficiency can be increased in the range of 5-6%. The battery's lifetime improvement is estimated by means of the difference in the temperature rise to approximately 20%. [ABSTRACT FROM AUTHOR]

The first stage of a battery charger in electric vehicles is a power factor correction (PFC) circuit, which creates a second harmonic in the dc link. This harmonic is typically filtered through a bulky dc-link capacitor. In the conventional battery chargers, another dc/dc stage is utilized to regulate the battery current. In this paper, the second harmonic in the dc link is analyzed in detail and a new load current compensation technique is proposed. The proposed technique replaces the second stage dc/dc converter with a bidirectional dc/dc converter connected in parallel with the load, and requires a secondary energy source, i.e., a small-size capacitor. The capacitor injects 180° phase-shifted second harmonic current to the dc link. Thus, the dc-link capacitor can be reduced significantly as it is only sized for high-frequency ripples rather than being sized for low-frequency content. The proposed method is generalized for resistive and battery loads with voltage- and current-source PFC circuits. A 360 W prototype is developed to experimentally verify the proposed technique. A 72 V/10 A·h battery module is charged by filtering an oscillating power of 360 W using a two-quadrant bidirectional dc/dc converter and an UC module, demonstrating a peak charging current of 16 A. [ABSTRACT FROM AUTHOR]

This paper presents an alternative to the traditional dc-dc converter interfacing the battery with the inverter dc bus in plug-in hybrid electric vehicle (HEV) traction drives. The boost converter used in commercial HEVs meets with obstacles when it comes to upgrading the power rating and achieving high efficiency while downsizing the converter. A four-level flying-capacitor dc-dc converter is explored that can overcome these drawbacks by dramatically reducing the inductance requirement. A special case of the four-level converter, the 3X dc-dc converter, operates at three discrete output/input voltage ratios, thus further reducing the inductance requirement to a minimal value (almost zero). When further compared to its switched-capacitor dc-dc converter counterparts, the 3X dc-dc converter can be operated at variable output/input voltage ratios without sacrificing efficiency, and it lowers the capacitance requirement by utilizing the parasitic inductance. The operating principle, current ripple analysis, the transient control to limit the inrush current, and power loss analysis are introduced. Experimental results of a 55-kW prototype are provided to demonstrate the principle and analysis of this topology. [ABSTRACT FROM AUTHOR]