EPE Association: EPE 1999 - Topic 08d: Battery Charger, Battery Management, Test Bench

EPE 1999 - Topic 08d: Battery Charger, Battery Management, Test Bench
You are here: EPE Documents > 01 - EPE & EPE ECCE Conference Proceedings > EPE 1999 - Conference > EPE 1999 - Topic 08: ELECTRIC AND HYBRID VEHICLES > EPE 1999 - Topic 08d: Battery Charger, Battery Management, Test Bench

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   An Original Battery Charger for Embarked Systems
By A. De Bernardinis; F. Meibody-Tabar; B. Laporte [View]
[Download]

Abstract: In order to charge batteries used in embarked systems like Hybrid Electric Vehicles (HEV), a well adapted solution when the speed varies in a wide range, consists of using an assembly of 3 phases Permanent Magnet Generator (PMG) - controlled IGBT bridge rectifier connected to the battery. In order to control the generator phase currentsand battery voltage whatever are the working conditions, two current control methods are presented in this paper: the sinusoidal current control method and the 120° rectangular current control method. the the 120° rectangular current control method, a current observer using two Hall effect sensors placed on the generator phases is proposed for the current control loop. This observer authorizes all kinds of switching modes and allows the control of the generator phase currents even during phase commutation intervals. The behavior of both sinusoidal current control strategy and 120° rectangular current control strategy with classical and proposed current sensing modes are tested by several numerical simulations and their performances are compared.

   Battery Models for Use in Electric Vehicles and Battery Energy Storage
By D. Sutanto; H.L. Chan; C.C. Fok [View]
[Download]

Abstract: This paper will initially present a review of the several battery models used for Electric Vehicles and Battery Energy Storage System applications. A model will be discussed which takes into account the non-linear characteristics of the battery with respect to the battery’s state of charge. Comparisons between simulation and laboratory measurements will be presented. The effects of high frequency switching on the battery performance will also be discussed. A strategy to reduce the high frequency charging and discharging current will be proposed.

   Electric Vehicle Motor Drive Arrangement Used as On-Board Charger for Propulsion Batteries
By F. Caricchi; F. Crescimbini; F. Giulii Capponi; L. Solero [View]
[Download]

Abstract: Electric Vehicles (EV's) are needed in densely populated urban areas to reduce air pollution. Battery chargers are needed to supply dc voltage to charge the high energy battery packs used in EVs. This paper deals with an on-board battery charger arrangement which is fully based on the use of the power components of the EV motor drive. Desired features for EV battery chargers such as minimum volume, low cost, high efficiency and high reliability are fully matched by means of the proposed solution. No additional power components to the motor drive arrangement are required. EV motor drive power devices turn out to be oversized with respect to technical specifications of the charger design resulting in high efficiency of the battery charge system. Moreover, during both monitoring and charging mode of operation of the motor drive arrangement, a small size dc-dc power electronic converter provides the maintenance charge of an auxiliary battery from the propulsion battery. The proposed on-board charger arrangement has been installed on an electric scooter prototype being developed for the Far East markets. Design analysis and experimental results of the on-board charger prototype are presented.

   Integrated Traction and Charging Unit for Battery Fed Vehicles
By M. Krüger [View]
[Download]

Abstract: With new developments of high energy batteries a well known problem of electric vehicles becomes more evident: the problem of recharging the battery. The following paper proposes a combination of inverter fed traction drive and battery charging unit that eliminates the costs, weight and volume of a separated high power battery charger.

   Intelligent and Universal Fast-Charger for NI-CD and NI-MH Batteries in Portable Applications
By J.A. Martin; A. M. Pernia; F. F. Linera; F. Nuno; J. Diaz [View]
[Download]

Abstract: Ni-Cd and Ni-MH batteries are the most frequently used in portable applications. In this papaer, a new fast charger, able to perform a full-protected charge mode, is presented for this kind of devices. In it, the control and supervision of the whole process has been entrusted to a microcontroller, which simplifies the requested circuitry, reduced to the microcontroller itself and a few additional components, and provides powerfull and intelligent tool to undertake, through the programmed algorithm, complex tasks. In fact, the resulting charger is able to work out the initial battery state (detecting deteriorated devices), decide the fit way to charge it (ensuring a long cyclic life) and determine when the charge process must be finished. This way, the state of the battery is perfectly controlled at every moment, avoiding any damage on it; including those related to an incorrect user's operation. This paper summarises the design and construction of the referred charger, as well as the experimental results obtained in the prototype tests.

   Novel Microprocessor-based Ferroresonant Battery Charger for Electric Vehicles
By C. R. Mersman; M. M. Morcos; N. G. Dillman [View]
[Download]

Abstract: An electric vehicle battery charger was designed, built and evaluated. Test results show that the use of a ferroresonant transformer in a battery charging application yields many benefits due to the transformer characteristics. The ferroresonant transformer exploits the saturation of magnetic materials through its capacitor winding to produce a well regulated output that resembles a square wave. The design of the ferroresonant transformer and the control circuitry, as well as the microprocessor software utilization, are presented. The efficiency of the battery charger was measured at an average of 86.5 percent through a charge cycle, with a range of 79 to 89 percent.

   Power Converter Arrangements with Ultracapacitor Tank for EVs
By A. Di Napoli; F. Giulii Capponi; L. Solero [View]
[Download]

Abstract: In EV motor drives, battery load leveling by means of ultracapacitors is one attractive approach to improve the battery life as well as vehicle driving range. Ultracapacitors have high power density and, in order to reduce the peak power requirement for the battery, they can be used to manage the bi-directional power flow due to vehicle acceleration and deceleration. The ultracapacitor tank is sized on the base of the load leveling requirement, which is dependent on the driving cycle by which the vehicle is expected to operate. In this paper three power converter arrangements which use an ultracapacitor tank for battery load leveling in EV motor drives are briefly reviewed. In the paper these converter arrangements are referred to as series connection, cascade connection and parallel connection. The parallel connection is the converter arrangement this paper is primarily concerned with. This configuration is accomplished by using a bidirectional step-up/step-down converter to connect an ultracapacitor tank in parallel with the battery pack and the motor drive dc link. Simulations and test results achieved from a test campaign carried out by using an ultracapacitor tank rated 34.5 V and 31.3 F will be shown.

   Prediction of Remaining Battery Discharge Capacity by Neural Networks and its Display Circuit
By M. Yasuo; M. Teramura. [View]
[Download]

Abstract: Lead-acid batteries are used in telecommunications power systems that require strict conditions of power source to provide un-interrupted power for telephone and data transmission service. The information concerning the remaining battery discharge capacity is very important for the maintenance and the drive of power systems to provide satisfactory backup energy. Especially it has great effect on the delivery problem of the mobile power source in emergency states that are supplied just only by the battery. The battery is also used for the electric vehicle that has to take one charge at one run. So it is expected that we can predict the remaining battery discharge capacity easily and quickly. The battery discharge capacity is influenced by the discharge current, temperature, newness of the batteries and other nonlinear parameters. Various estimation methods for residual capacity of the sealed lead-acid battery have been proposed. However, no method can accurately predict the residual capacity. This paper describes a new method for predicting remaining battery discharge capacity by using the backpropagation algorithm for the neural network (NN). The input layer of NN has two input terminals corresponding to the battery terminal voltage and discharge current, respectively. The NNs learn the discharge characteristics after getting tuned synaptic weights. And the results of learning are worked into the display circuits of the residual capacity without calculating process. The temperature effect on capacity is not considered, but by getting the data of the dependency of capacity on temperature, it can be simulated easily by adding one input parameter to the NN. The results of the simulation can be implemented with hardware using standard circuit elements.

   Testbench for Electric Vehicle Drives
By B. Hauck; B. G. Hexamer [View]
[Download]

Abstract: A testbench for electric vehicle drives must be able to measure all significant parameters of these drives. For this the testbench must fulfill all requirements of the drive relative to power, speed and torque and also to thermal demands. The here presented testbench has the nominal values of a continuous power of 100 kW and a continuous torque of 238 Nm. The testbench motor runs up to a speed of 8,000 rpm. With gearboxes the speed or the torque can be increased. The testbench is equipped with a measurement system for d.c. power, three phase a.c. power, speed, torque and temperature. Also a special cooling and heating device for the testing of liquid -cooled systems is available.

   Zero-Voltage-Switching Boost Converter for On-Board EV Charger
By H. Shigemoto; K. Harada; Y. Ishihara; T. Todaka; K. Ueda; H. Nakamura [View]
[Download]

Abstract: A Zero-Voltage-Switching Boost Converter for On-Board EV Charger is presented. The principal circuit employs only single power conversion stage for PFC and realizes Zero-Voltage- Switching by a simple auxiliary circuit. The characteristics of the circuit are investigated by analysis and verified by experiments. From the analysis of circuit operation, ZVS condition and the voltage and the current stress of the switch are clarified. In the experiment, the employed circuit has obtained a high overall efficiency about 95%.

EPE 1999 - Topic 08d: Battery Charger, Battery Management, Test Bench
You are here: EPE Documents > 01 - EPE & EPE ECCE Conference Proceedings > EPE 1999 - Conference > EPE 1999 - Topic 08: ELECTRIC AND HYBRID VEHICLES > EPE 1999 - Topic 08d: Battery Charger, Battery Management, Test Bench
	[return to parent folder]

	An Original Battery Charger for Embarked Systems By A. De Bernardinis; F. Meibody-Tabar; B. Laporte	[View] [Download]
Abstract: In order to charge batteries used in embarked systems like Hybrid Electric Vehicles (HEV), a well adapted solution when the speed varies in a wide range, consists of using an assembly of 3 phases Permanent Magnet Generator (PMG) - controlled IGBT bridge rectifier connected to the battery. In order to control the generator phase currentsand battery voltage whatever are the working conditions, two current control methods are presented in this paper: the sinusoidal current control method and the 120° rectangular current control method. the the 120° rectangular current control method, a current observer using two Hall effect sensors placed on the generator phases is proposed for the current control loop. This observer authorizes all kinds of switching modes and allows the control of the generator phase currents even during phase commutation intervals. The behavior of both sinusoidal current control strategy and 120° rectangular current control strategy with classical and proposed current sensing modes are tested by several numerical simulations and their performances are compared.

	Battery Models for Use in Electric Vehicles and Battery Energy Storage By D. Sutanto; H.L. Chan; C.C. Fok	[View] [Download]
Abstract: This paper will initially present a review of the several battery models used for Electric Vehicles and Battery Energy Storage System applications. A model will be discussed which takes into account the non-linear characteristics of the battery with respect to the battery’s state of charge. Comparisons between simulation and laboratory measurements will be presented. The effects of high frequency switching on the battery performance will also be discussed. A strategy to reduce the high frequency charging and discharging current will be proposed.

	Electric Vehicle Motor Drive Arrangement Used as On-Board Charger for Propulsion Batteries By F. Caricchi; F. Crescimbini; F. Giulii Capponi; L. Solero	[View] [Download]
Abstract: Electric Vehicles (EV's) are needed in densely populated urban areas to reduce air pollution. Battery chargers are needed to supply dc voltage to charge the high energy battery packs used in EVs. This paper deals with an on-board battery charger arrangement which is fully based on the use of the power components of the EV motor drive. Desired features for EV battery chargers such as minimum volume, low cost, high efficiency and high reliability are fully matched by means of the proposed solution. No additional power components to the motor drive arrangement are required. EV motor drive power devices turn out to be oversized with respect to technical specifications of the charger design resulting in high efficiency of the battery charge system. Moreover, during both monitoring and charging mode of operation of the motor drive arrangement, a small size dc-dc power electronic converter provides the maintenance charge of an auxiliary battery from the propulsion battery. The proposed on-board charger arrangement has been installed on an electric scooter prototype being developed for the Far East markets. Design analysis and experimental results of the on-board charger prototype are presented.

	Integrated Traction and Charging Unit for Battery Fed Vehicles By M. Krüger	[View] [Download]
Abstract: With new developments of high energy batteries a well known problem of electric vehicles becomes more evident: the problem of recharging the battery. The following paper proposes a combination of inverter fed traction drive and battery charging unit that eliminates the costs, weight and volume of a separated high power battery charger.

	Intelligent and Universal Fast-Charger for NI-CD and NI-MH Batteries in Portable Applications By J.A. Martin; A. M. Pernia; F. F. Linera; F. Nuno; J. Diaz	[View] [Download]
Abstract: Ni-Cd and Ni-MH batteries are the most frequently used in portable applications. In this papaer, a new fast charger, able to perform a full-protected charge mode, is presented for this kind of devices. In it, the control and supervision of the whole process has been entrusted to a microcontroller, which simplifies the requested circuitry, reduced to the microcontroller itself and a few additional components, and provides powerfull and intelligent tool to undertake, through the programmed algorithm, complex tasks. In fact, the resulting charger is able to work out the initial battery state (detecting deteriorated devices), decide the fit way to charge it (ensuring a long cyclic life) and determine when the charge process must be finished. This way, the state of the battery is perfectly controlled at every moment, avoiding any damage on it; including those related to an incorrect user's operation. This paper summarises the design and construction of the referred charger, as well as the experimental results obtained in the prototype tests.

	Novel Microprocessor-based Ferroresonant Battery Charger for Electric Vehicles By C. R. Mersman; M. M. Morcos; N. G. Dillman	[View] [Download]
Abstract: An electric vehicle battery charger was designed, built and evaluated. Test results show that the use of a ferroresonant transformer in a battery charging application yields many benefits due to the transformer characteristics. The ferroresonant transformer exploits the saturation of magnetic materials through its capacitor winding to produce a well regulated output that resembles a square wave. The design of the ferroresonant transformer and the control circuitry, as well as the microprocessor software utilization, are presented. The efficiency of the battery charger was measured at an average of 86.5 percent through a charge cycle, with a range of 79 to 89 percent.

	Power Converter Arrangements with Ultracapacitor Tank for EVs By A. Di Napoli; F. Giulii Capponi; L. Solero	[View] [Download]
Abstract: In EV motor drives, battery load leveling by means of ultracapacitors is one attractive approach to improve the battery life as well as vehicle driving range. Ultracapacitors have high power density and, in order to reduce the peak power requirement for the battery, they can be used to manage the bi-directional power flow due to vehicle acceleration and deceleration. The ultracapacitor tank is sized on the base of the load leveling requirement, which is dependent on the driving cycle by which the vehicle is expected to operate. In this paper three power converter arrangements which use an ultracapacitor tank for battery load leveling in EV motor drives are briefly reviewed. In the paper these converter arrangements are referred to as series connection, cascade connection and parallel connection. The parallel connection is the converter arrangement this paper is primarily concerned with. This configuration is accomplished by using a bidirectional step-up/step-down converter to connect an ultracapacitor tank in parallel with the battery pack and the motor drive dc link. Simulations and test results achieved from a test campaign carried out by using an ultracapacitor tank rated 34.5 V and 31.3 F will be shown.

	Prediction of Remaining Battery Discharge Capacity by Neural Networks and its Display Circuit By M. Yasuo; M. Teramura.	[View] [Download]
Abstract: Lead-acid batteries are used in telecommunications power systems that require strict conditions of power source to provide un-interrupted power for telephone and data transmission service. The information concerning the remaining battery discharge capacity is very important for the maintenance and the drive of power systems to provide satisfactory backup energy. Especially it has great effect on the delivery problem of the mobile power source in emergency states that are supplied just only by the battery. The battery is also used for the electric vehicle that has to take one charge at one run. So it is expected that we can predict the remaining battery discharge capacity easily and quickly. The battery discharge capacity is influenced by the discharge current, temperature, newness of the batteries and other nonlinear parameters. Various estimation methods for residual capacity of the sealed lead-acid battery have been proposed. However, no method can accurately predict the residual capacity. This paper describes a new method for predicting remaining battery discharge capacity by using the backpropagation algorithm for the neural network (NN). The input layer of NN has two input terminals corresponding to the battery terminal voltage and discharge current, respectively. The NNs learn the discharge characteristics after getting tuned synaptic weights. And the results of learning are worked into the display circuits of the residual capacity without calculating process. The temperature effect on capacity is not considered, but by getting the data of the dependency of capacity on temperature, it can be simulated easily by adding one input parameter to the NN. The results of the simulation can be implemented with hardware using standard circuit elements.

	Testbench for Electric Vehicle Drives By B. Hauck; B. G. Hexamer	[View] [Download]
Abstract: A testbench for electric vehicle drives must be able to measure all significant parameters of these drives. For this the testbench must fulfill all requirements of the drive relative to power, speed and torque and also to thermal demands. The here presented testbench has the nominal values of a continuous power of 100 kW and a continuous torque of 238 Nm. The testbench motor runs up to a speed of 8,000 rpm. With gearboxes the speed or the torque can be increased. The testbench is equipped with a measurement system for d.c. power, three phase a.c. power, speed, torque and temperature. Also a special cooling and heating device for the testing of liquid -cooled systems is available.

	Zero-Voltage-Switching Boost Converter for On-Board EV Charger By H. Shigemoto; K. Harada; Y. Ishihara; T. Todaka; K. Ueda; H. Nakamura	[View] [Download]
Abstract: A Zero-Voltage-Switching Boost Converter for On-Board EV Charger is presented. The principal circuit employs only single power conversion stage for PFC and realizes Zero-Voltage- Switching by a simple auxiliary circuit. The characteristics of the circuit are investigated by analysis and verified by experiments. From the analysis of circuit operation, ZVS condition and the voltage and the current stress of the switch are clarified. In the experiment, the employed circuit has obtained a high overall efficiency about 95%.