HEV-System Li-Ion Batteries Charger

1. Siam Bee Technologies
Tsuyoshi Horigome
HEV-System Li-Ion
Batteries Charger
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 1

2. Index
• Block Diagram
• How to use concept kit
• About Motor Generator Model
• About Control Signal
• About Buck Converter
• About Li-Ion Battery
• Simulation Result
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 2

3. Block Diagram
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 3
MG 3-phase rectifier Buck Li-Ion Battery
ChargeIGBT:300A/600V Step-down voltage
Maximum Voltage=4.2[V]
Capacity(CAh)=50[Ah]
Amount of Batteries(N)=85Cells
Vin=480[Vrms]
Vout=630[V]5
Vin=630[V] 5
Vout=200-360[V]
Frequency=50[Hz]
VMAX=400[V]

4. GND
GND
GND
Charge Current Limit
GND
GND_SW
Riso
100MEG
0
DMOD
D7
GND
Vrectif ier
VD
Cout
880uF
WD
U
SPWM
CTL1
CTL2
CTL3
Vref 1
Vref 2
Vref 3
VP
WP
A
-
+
+
-
E7
E
-1
0
DMOD
D1
DMOD
D3
D8
DCT300DJH060
DMOD
D5
-
+
+
-
E8
E
-1
0
DMOD
D2
UP
DMOD
D4
UD
R2
15k
VP WP
U1
CT300DJH060
-
+
+
-
E1
E
3
-
+
+
-
E3
E
3
-
+
+
-
E5
E
3
DMOD
D6
00 0
UP
U2
CT300DJH060
U3
CT300DJH060
R3
15k
R4
15k
VDUD WD
-
+
+
-
E2
E
3
-
+
+
-
E4
E
3
-
+
+
-
E6
E
3
00 0
U4
CT300DJH060
-
+
+
-
E9
E
-1
0
U5
CT300DJH060
U6
CT300DJH060
R5
15k
R6
15k
R7
15k
0
C
V1
FREQ = 50
VAMPL = {Vrms*sqrt(2)}
VOFF = 0
PHASE = 0
V2
FREQ = 50
VAMPL = {Vrms*sqrt(2)}
VOFF = 0
PHASE = -120
V3
FREQ = 50
VAMPL = {Vrms*sqrt(2)}
VOFF = 0
PHASE = -240
B
PARAMETERS:
Vrms = 280
GND_SW
VG2
TD = 0
TF = 100n
PW = {Duty _buck*(1/Freq_buck)}
PER = {1/Freq_buck}
V1 = 0
TR = 100n
V2 = 0
D_disch
D9
R9
15k
V101
{(4.2*N)-(8.2m)}U8
CT300DJH060
-
+
+
-
E11
E
1
IBATT
0Vdc
PARAMETERS:
N = 85
CAh = 50
rate = 1
HI
G2
R10
1u
PARAMETERS:
Voch = {(4.2*N)-(8.2m)}
Capacity = 1
VG1
TD = 0
TF = 100n
PW = {Duty _buck*(1/Freq_buck)}
PER = {1/Freq_buck}
V1 = 0
TR = 100n
V2 = 15
+ -
U9
LI-ION_BATTERY
SOC = 0
NS = {N}
TSCALE = {3600*4}
C = {CAh}
C2
10n
L1
225uH
1 2
C1
315uF
VBATT
PARAMETERS:
Freq_buck = 10k
Duty _buck = 0.44
rl1
10m
n1
rc1
0.05m
G1
R8
15k
U7
CT300DJH060
-
+
+
-
E10
E
1
Simulation Circuit and Setting
- Generator, 3 phase rectifier, Buck converter and Li-Ion Battery
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 4
3-phase rectifier
Motor
Generator
Buck converter
Li-Ion Battery
Vrms=280V Freq_buck=10k
Duty_buck=0.44
N=85
CAh=50
SOC : 0%
http://www.ae.pwr.wroc.pl/filez/20110606092430_HEV_Toyota.pdf

5. About Motor Generator Model
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 5
Phase angle between V1 and V2, V2 and V3, V3 and V1 are equaled 120 degree ()
0
V1
FREQ = 50
VAMPL = {Vrms*sqrt(2)}
VOFF = 0
PHASE = 0
V2
FREQ = 50
VAMPL = {Vrms*sqrt(2)}
VOFF = 0
PHASE = -120
V3
FREQ = 50
VAMPL = {Vrms*sqrt(2)}
VOFF = 0
PHASE = -240
PARAMETERS:
Vrms = 280

6. About Control Signal (1/3)
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 6
VD
WD
U
SPWM
CTL1
CTL2
CTL3
Vref 1
Vref 2
Vref 3
VP
WP
-
+
+
-
E7
E
-1
0
-
+
+
-
E8
E
-1
0
UP
UD
-
+
+
-
E9
E
-1
0
Double click
Output voltage (3-phase motor generator) feed to Vref1, Vref2 and Vref3
Control Signal of
Switching IGBT
To Connected to Motor
Generator

7. About Control Signal (2/3)
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 7
V4TD = 0
TF = {(0.5/Freq)}
PW = 1n
PER = {1/Freq}
V1 = {Vsawh}
TR = {(0.5/Freq)}
V2 = {Vsawl}
0
PARAMETERS:
Freq = 500
m1 = {Vsawh-Vsawl}
m2 = {Vsawl-Vsawh}
PARAMETERS:
Vsawh = 3
Vsawl = -3
IN+
IN-
OUT+
OUT-
E1
IF(V(%IN+)>V(%IN-),1,-1)
EVALUE
0
IN+
IN-
OUT+
OUT-
E2
IF(V(%IN+)>V(%IN-),1,-1)
EVALUE
0
IN+
IN-
OUT+
OUT-
E3
IF(V(%IN+)>V(%IN-),1,-1)
EVALUE
0
saw
CTL3
CTL2
CTL1
-
+
+
-
E4
E
0.01
00
Vref 1
-
+
+
-
E5
E
0.01
0 0
Vref 2
-
+
+
-
E6
E
0.01
0 0
Vref 3
SPWM
Reference voltage compared with sawtooth signal
Sawtooth Signal

8. About Control Signal (3/3)
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 8
Vref1
Vref2
Vref3
CTL1
CTL2
CTL3

9. About Buck Converter (1/2)
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 9
GND
GND_SW
Riso
100MEG
0
D8
DCT300DJH060
DMOD
D7
Vrectif ier
Cout
880uF
GND_SW
VG2
TD = 0
TF = 100n
PW = {Duty _buck*(1/Freq_buck)}
PER = {1/Freq_buck}
V1 = 0
TR = 100n
V2 = 0
R9
15k
U8
CT300DJH060
-
+
+
-
E11
E
1
G2
VG1
TD = 0
TF = 100n
PW = {Duty _buck*(1/Freq_buck)}
PER = {1/Freq_buck}
V1 = 0
TR = 100n
V2 = 15
L1
225uH
1 2
C1
315uF
VBATT
PARAMETERS:
Freq_buck = 10k
Duty _buck = 0.44
rl1
10m
n1
rc1
0.05m
G1
R8
15k
U7
CT300DJH060
-
+
+
-
E10
E
1
No Use
Voltage and Current are controlled
by adjust “Duty_buck” parameter of
Upper IGBT (U7)

10. About Buck Converter (2/2)
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 10
UPPER IGBT:VDS
UPPER IGBT:VGS
LOWER IGBT:VGS

11. About Li-Ion Battery
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 11
GND
GNDGND
D_disch
D9
V101
{(4.2*N)-8.2m}
IBATT
0Vdc
PARAMETERS:
N = 85
CAh = 50
rate = 1
PARAMETERS:
Voch = {(4.2*N)-8.2m}
Capacity = 1
HI
+ -
U9
LI-ION_BATTERY
SOC = 0
NS = {N}
TSCALE = {3600*4}
C = {CAh}
C2
10n
“N” is Amount
of Battery Cell
“TSCALE={3600*4}” is meant
1second (simulation setting-runtime)
equal 4 hours
“CAh” is Capacity of Battery
(ampere-hour capacity)

12. Simulation Result (parametric sweep)
All Rights Reserved Copyright (C) Bee Technologies Corporation 2015 12
Duty_buck=0.44 Duty_buck=0.34 Duty_buck=0.24
Battery Voltage
Battery Charging Current
Buck: Output Voltage
Buck: Gate Drive Voltage
3-phase rectifier: Output Voltage
3-phase Generator: Output Voltage
6 Hours
Simulation time for 1 condition is about 15 minute