The document outlines the design of a bi-directional isolated DC-DC converter for a 20 kW application, supervised by an industry expert at CSIR-CEERI. It details objectives such as safety enhancement, power loss reduction, and thermal considerations, alongside operational modes like boost and buck. The project timeline from August 2015 to April 2016 includes phases like literature review, simulation, transformer design, coding, and testing.

1. BIDIRECTIONAL ISOLATED DC-DC CONVERTER
FOR 20KW APPLICATION
BY
P.VASUDEVA GUPTHA
14MPE0044
INTERNAL
Prof. N. Arun
(Assistant Professor)
Power Electronics and Drives Dept.,
V.I.T UNIVERSITY, VELLORE .
EXTERNAL
Sh. Rahul Verma
(Scientist G)
IEG Group Head,
CSIR-CEERI,PILLANI.
Under the guidance of

2. COMPANY DETAILS
• INDUSTRY NAME – CSIR-Central Electronics Engineering Research Institute
• ADDRESS - CSIR-CEERI
• CEERI Road,
• Pilani,
• Jhunjhunu District,
• Rajasthan,
• 333031.
• GUIDE - Sh. Rahul Verma ( Scientist G)
• EMAIL - rv@ceeri.ernet.in
• WEBSITE - http://www.ceeri.res.in/
• INTERNSHIP - Not Through PAT
• STARTING DATE - 1-08-2015
• ENDING DATE - 30-04-2016
• DURATION - 9 Months
• STIPEND - NO

3. AIM/OBJECTIVES
 To design Bi-directional isolated DC-DC converter for 20KW Application
OBJECTIVES:
1. To Provide Safety
2. To reduce power loss
3. To reduce size, weight and cost
4. To achieve Thermal considerations
5. To reduce Electro-magnetic interference
6. To implement Soft Switching Techniques
AIM:

4. SPECIFICATIONS
1. Input voltage – 100V
2. Output voltage – 600V
3. Output power – 20KW
4. Switching frequency – 20KHz
ADDITIONAL REQUIREMENTS
1. Galvanic Isolation – For safety purpose
2. High Conversion Efficiency
3. Lower converter volume – obtained by high switching frequency

5. INTRODUCTION
1. Bidirectional convertor allows the power flow in both directions
2. Bidirectional convertor operates in two modes
 BOOST MODE
 BUCK MODE

6. BOOST MODE

7. OUTPUT VOLTAGE
OUTPUT CURRENT
OUTPUT VOLTAGE : 618.5 volts
OUTPUT CURRENT : 32.4 amps
OUTPUT POWER : 20,039.4 watts
OUTPUT RESISTANCE : 18.5 ohms
SWITCHING FREQUENCY:20KHZ
DUTY Ratio : 0.6

8. ZCS SOFT SWITCHING OF PRIMARY SWITCHES
V1: switch voltage
I1: switch current

9. BUCK MODE

10. INPUT VOLTAGE : 600
OUTPUT VOLTAGE : 102.9 volts
OUTPUT CURRENT : 202 amps
OUTPUT POWER : 20,785watts
OUTPUT RESISTANCE : 0.5 ohms
SWITCHING FREQUENCY:20KHZ
DUTY RATIO : 0.5
OUTPUT VOLTAGE
OUTPUT CURRENT

11. ZVS SOFT SWITCHING OF PRIMARY SWITCHES
V2: switch voltage
I2: switch current

12. TRANSFORMER DESIGN
REQUIREMENTS:
1. AMCC-400 CORE MATERIAL
2. PRIMARI TURNS: 11
3. SECONDARY TURNS:27
4. TURNS RATIO :2.4
5. CURRENT DENSITY :6 A/mm2
CALCULATION RESULTS
1. CORE LOSS : 40 WATTS
2. COPPER LOSS : 76 WATTS
3. TOTAL LOSS:116 WATTS
COPPER FOIL REQUIREMENT
1.PRIMARY: 10mm * 1.8mm
2. SECONDARY : 10mm * 0.8mm
Ip :96A
Is :41A
POWER: 10KWATTS

13. DSP – TMS320F28027
FEAUTERS:
1. Frequency : 60MHz (16.67-ns Cycle Time)
2. High-Efficiency 32-Bit CPU

14. August 2015 Literature review
September Topology Selection
October Simulation
November Transformer Design
December Coding
January Hardware Implementation
February Testing
March Documentation
WORK PLAN

15. 1. Martin Pavlovsky, Sjoerd Walter Hero de Haan, and Jan Abraham Ferreira, “Reaching High Power
Density in Multi kilowatt DC–DC Converters With Galvanic Isolation” I.E.E.E Power Electronics,2009
2. R. Y. Chen, R. L. Lin, T. J. Liang, J. F. Chen, and K. C. Tseng, ” Current-fed Full-bridge Boost
Converter with Zero Current Switching for High Voltage Applications ” I.E.E.E Power Electronics,2005
3. Pan Xuewei, Student Member IEEE, Akshay K. Rathore, Senior Member IEEE,” Novel Bidirectional
Snubberless Soft-switching Naturally Clamped Zero Current Commutated Current fed Dual Active
Bridge (CFDAB) Converter for Fuel Cell Vehicles ” I.E.E.E Power Electronics,2013
4. Pan Xuewei, Student Member and Akshay K Rathore, Senior Member, IEEE,” Comparison of Bi-
directional Voltage-fed and Current-fed Dual Active Bridge Isolated Dc/Dc Converters Low Voltage High
Current Applications” I.E.E.E Power Electronics,2014
REFERENCES:

16. 5. Manu Jain, M. Daniele, and Praveen K. Jain, “A Bidirectional DC–DC Converter Topology for Low Power
Application” I.E.E.E Power Electronics,2000
6. F. Krismer, S. Round, J. W. Kolar, ” Performance Optimization of a High Current Dual Active Bridge
with a Wide Operating Voltage Range” I.E.E.E Power Electronics,2006
7.Yao-Ching Hsieh, Yong-Nong Chang, Kun-Ying Lee Yu-Chun Chiu Wei-Ting Wu,” Bidirectional Softly
Switched DC-to-DC Converter with Galvanic Isolation” I.E.E.E Power Electronics,2015
8. M. A. Bahmani and T. Thiringer, M. Kharezy” Design Methodology and Optimization of a Medium
Frequency Transformer for High Power DC-DC Applications” I.E.E.E Power Electronics,2015
REFERENCES:

17. THANK YOU