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Prof. Omar Hegazy, MOBI at University of Brussels

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Professor Omar Hegazy, MOBI at VUB's talk at the EV Momentum Summit Berlin, 19 June 2018

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Prof. Omar Hegazy, MOBI at University of Brussels

  1. 1. Advances in Power Electronics Converters for Efficient Drivetrains 1 By Prof. Dr. Omar Hegazy ü Professor and Team leader of Power Electronics and Electrical Machines
  2. 2. Outline q Introduction of Power Electronics Systems q Integrated converter design and performances qNew switching technologies: WBG q Conclusions and Future trend 2
  3. 3. Outline q Introduction of Power Electronics Systems q Integrated converter design and performances qNew switching technologies: WBG q Conclusions and Future trend 3
  4. 4. 4 How to change the way we Design technologies? Thinking in full systems & large scale 1) Material/component development (power electronics, chargers Battery, motor efficiency, material criticality) 2) Co-design of powertrain systems (sizing, modularity) 3) Integration and thermal management 4) Charging strategy optimization (grid integration, V2X) 5) Designing the full technosphere (supply chain mgt, circular economy) Systemlevel Technology Integration Large scale
  5. 5. Powertrain Topologies: BEVs (/SC) 5 Advantages of Battery (High Energy) /SC or High Power Battery ü Improve the battery lifetime ü More energy efficiency ü High dynamic performance ü Advanced DC/DC converter (i.e. MPC) with high efficiency (up to 96% thanks to WBG technology) o More compactness o High reliability - + Inverter DC/AC Electric motor DC Link Uni/Bi-directional dc-dc converter Battery SC - + Bi-directional dc-dc converter HE - + Inverter DC/AC Electric motorBi-directional dc-dc converter BatterySC - + HE - + Inverter DC/AC Electric motor DC Link Multiple-input Bidirectional dc-dc converter Battery SC - + HE - + Inverter DC/AC Electric motor DC Link Uni/Bi-directional dc-dc converter Battery SC - + Bi-directional dc-dc converter HP HE: High Energy ; HP: High power: WBG: Wide-Bandgap semiconductors
  6. 6. Advances in Charging Systems 6 Charging Systems Conductive On-Board Off-Board Inductive (Wireless) On-board (Secondary Coil) & Off-Board (Primary Coil) OLEV WPT Up to 100 kW Up to 600 kWUp to 100 kW Up to 22 kW
  7. 7. Outline q Introduction of Power Electronics Systems q Integrated converter design and performances qNew switching technologies: WBG q Conclusions and Future trend 7
  8. 8. 8 New Switching technologies: Wide Bandgap (WBG) à SiC & GaN Source: a Fairchild Sem iconductor presentation by Alex AVRON, founder of PntPower.comSource: status of Power Electronics Industry report, Yole Développem ent, 2017
  9. 9. 9 New Switching technologies: WBG Source: a Fairchild Sem iconductor presentation by Alex AVRON, founder of PntPower.comSource: status of Power Electronics Industry report, Yole Développem ent, 2017
  10. 10. Outline q Introduction of Power Electronics Systems q Integrated converter design and performances qNew switching technologies: WBG q Conclusions and Future trend 10
  11. 11. 11 Integrated Power Electronics Converters: MPC for multi-source Battery + - Q2 L1 L2 L3 Q4 Q6 Cf Electric motor Inverter DC/AC Q1 Q3 Q5 Q2 L1 L2 L3 Q4 Q6 Q1 Q3 Q5 SC + - EMTECHNO project
  12. 12. 12 g d Core database IGBT database Multiobjective Optimization Genetic Algorithm Pareto-front & Ranking method SOLIDWORKS Matlab Computer-Aided Design FEM Inventor Optimization Problem Formulation Litz wire database Converter Analysis & Control design Prototype Design DatabaseOptimized Design Solver Specification (Pmax, Vin, Vout, Iripple) Integrated Power Electronics Converters: MPC Optimization Objective functions of Optimization ü Input current ripples ü Weight of inductor ü Power loss of converter EMTECHNO project
  13. 13. 13 Integrated Power Electronics Converters: MPC control system Battery + - Q2 L1 L2 L3 Q4 Q6 Cf Electric motor Inverter DC/AC Q1 Q3 Q5 Q2 L1 L2 L3 Q4 Q6 Q1 Q3 Q5 SC + - EMTECHNO project
  14. 14. 14 Integrated Power Electronics Converters: MPC Optimization IGBT modules/Heatsink thermal equivalent model Battery + - Q2 L1 L2 L3 Q4 Q6 Cf Q1 Q3 Q5 Q2 L1 L2 L3 Q4 Q6 Q1 Q3 Q5 SC + - Loss Model Heat sink Thermal Model Tsink EMTECHNO project
  15. 15. 15 Impact of WBG switches on MPC performance 0 0.5 1 1.5 2 2.5 3 3.5 MPC with Si @ 20KHz MPC with SiC @ 60KHz PowerLosses(kW) P_IGBT P_d P_core P_cond Reduce 57% Source: E. Gurpinar and A. Castellazzi, "Single-Phase T-Type Inverter Performance Benchmark Using Si IGBTs, SiC MOSFETs, and GaN HEMTs," in IEEE Transactions on Power Electronics, vol. 31, no. 10, pp. 7148-7160, Oct. 2016. Source: VUB EMTECHNO project
  16. 16. 16 On-board Charger based on GaN Technology Objectives 1. Architecture Optimization 2. Cost/Size Optimization 3. Advanced topologies 4. V2G Or G2V MODES Bidirectional AC-DC Isolated- Bidirectional DC-DC DC-link Battery Grid Si Device <100kHz 3-12W/in3 92-94%Efficiency Uni-directional Manuf.?? GaN Device >250kHz >20W/in3 95-96%Efficiency Bidirectional Target
  17. 17. 17 On-board Charger: Architecture Optimization and Integration DC/AC 3-Phase Inverter H V D C B U S Bidirectional DC/DC Converter Propulsion Battery EM Super Capacitor Bidirectional DC/DC Converter LDC Converters Auxiliary Battery Off-Board charger On-Board Charger Integration
  18. 18. 18 On-board Charger: Architecture Optimization and Integration DC/AC 3-Phase Inverter H V D C B U S Bidirectional DC/DC Converter Propulsion Battery EM Super Capacitor Bidirectional DC/DC Converter LDC Converters Auxiliary Battery Off-Board charger On-Board Charger Integration
  19. 19. 19 ? Integration Conventional OBC Conventional LDC Problems of Individual Power-Elec Converter in EVs • Large number of components • Less compactness • Low power density Advantages • Compactness • High power density • Cost reduction Challenges: • Performances of the LDC converter OBC LDC MOBC On-board Charger: Architecture Optimization and Integration
  20. 20. On-board Charger: Architecture Optimization and Integration The proposed Multi-Functional OBC ü 40% size reduction of the LV DC/DC ü Around 60 % reduction in the cost of LV DC/DC converter üHigh compactness ü97% efficiency
  21. 21. Outline q Introduction of Power Electronics Systems q Integrated converter design and performances qNew switching technologies: WBG q Conclusions and Future trend 21
  22. 22. Conclusions 22 ü Wide bandgap (WBG) technology has a high potential to improve the converters’ performance towards: ü High efficiency ü More compactness ü High reduction in the cooling system üPower Electronics: design optimization framework is an enabler tool toward minimum TCO and minimized development time. üV2G mode towards smart mobile storage system
  23. 23. 23 Contacts Prof. Omar Hegazy Omar.hegazy@vub.be +32 2 629 29 92 Thank you for your attention Mobi.vub.ac.be/home/

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