General analysis and design guideline for a battery buffer system with dcdc converter and edlc for electric vehicles and its influence on efficiency

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General Analysis and Design Guideline for a
Battery Buffer System with DC/DC Converter
and EDLC for Electric Vehicles and its Influence
on Efficiency
Abstract
Introduction:
In an electric driven vehicle, the battery has a major
influence on the costs and the volume. Thus, a high lifetime of
the battery, connected with a high operation range of the vehicle
and low volume is required. In a common electric propulsion
system, the battery is connected to a voltage source inverter via
a dc/ac converter, which feeds an electric machine that is mostly
an induction machine (IM) or a permanent magnet synchronous
machine. The battery has to deliver or accept all the power
which is demanded or recuperated by the propulsion system at
all operating points. Loaded with high currents, the battery
temperature rises and, thus, the reaction rate of the undesired
chemical processes, such as corrosion, increases. Hence, a
higher temperature causes a reduction of the battery lifetime.
Further, during charging of the battery with high currents that
occur during regenerative braking, the efficiency is not
satisfying because a part of the recuperated energy is lost in the

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chemical processes. Another problem of high charging currents
is the reduction of active mass.
Existing system:
The energy system implemented in the EV, with the main
source composed by the batteries already mentioned, and the
auxiliary source implemented with the buck-boost converter and
the ultracapacitor bank. The buck-boost converter allows the
energy flow from the ultracapacitors to the batteries or to the
traction motor in both directions. During regenerative braking,
the ultracapacitors store energy, and during acceleration they
provide energy to the vehicle. Nevertheless, the control system
must predict some driving conditions to be able to minimize de
energy consumption. Some variables needed for this process are
the speed of the vehicle, the load current and the SOC of the
ultracapacitors. Considering the batteries to be a passive
element, the current across them is controlled by monitoring the
load current and by managing the current across the Buck-Boost
converter. The ultracapacitor charge is controlled by a second
current control loop.

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Proposed system:
In this paper, a general design guideline about the design of
an optimized BBS including an n-phase inductor is presented.
The benefits of the application of multiphase converters with
nonideal coupled inductors (CIs) in interleaved operation are
analyzed as well as a method to realize current sharing with a
reduced sensor number in those converters. In contrast to former
contributions, this paper gives universally valid guidelines for
the whole BBS which can be applied to a system with arbitrary
phase numbers and miscellaneous parts of the converter, or the
BBS respectively, and not only for a particular case or a selected
part of the converter. The duty cycle operation limits for a single
sensor current-sharing method including the guideline to choose
the suitable method is presented as well as the comparison of the
current characteristics between coupled and discrete inductors
(DIs) at the same resulting current ripple. The benefits of the
additional buffer system in comparison to the operation without
this system are verified at a test bench for an electric lift truck’s
propulsion system.

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Applications:
 Hybrid electric vehicles.
 Fuel cell vehicles.
 Pure electric vehicles.
Block diagram:

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Gate driver
circuit
PIC controller
circuit
Battery Load
BUFFER
circuit
5VDC
12 V
DC
Inverter
Battery
storage
Interleaved
boost
converter
Control
switch

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Tools and software used:
 MPLAB – microcontroller programming.
 ORCAD – circuit layout.
 MATLAB/Simulink – Simulation.

General analysis and design guideline for a battery buffer system with dcdc converter and edlc for electric vehicles and its influence on efficiency

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General analysis and design guideline for a battery buffer system with dcdc converter and edlc for electric vehicles and its influence on efficiency