Magnetic materials and soft-switched topologies for high-current DC-DC converters

The thesis is focused on the magnetic materials comparison and selection for high-power non-isolated dc-dc converters for industrial applications or electric, hybrid and fuel cell vehicles. The application of high-frequency bi-directional soft-switched dc-dc converters is also investigated. The thesis initially outlines the motivation for an energy-efficient transportation system with minimum environmental impact and reduced dependence on exhaustible resources. This is followed by a general overview of the power system architectures for electric, hybrid and fuel cell vehicles. The vehicle power sources and general dc-dc converter topologies are discussed. The dc-dc converter components are discussed with emphasis on recent semiconductor advances. A novel bi-directional soft-switched dc-dc converter with an auxiliary cell is introduced in this thesis. The soft-switching cell allows for the MOSFET's intrinsic body diode to operate in a half-bridge without reduced efficiency. The converter's mode-by-mode operation is analysed and closed-form expressions are presented for the average current gain of the converter. The design issues are presented and circuit limitations are discussed. Magnetic materials for the main dc-dc converter inductor are compared and contrasted. Novel magnetic material comparisons are introduced, which include the material dc bias capability and thermal conductivity. An inductor design algorithm is developed and used to compare the various magnetic materials for the application. The area-product analysis is presented for the minimum inductor size and highlights the optimum magnetic materials. Finally, the high-flux magnetic materials are experimentally compared. The practical effects of frequency, dc-bias, and converters duty-cycle effect for arbitrary shapes of flux density, air gap effects on core and winding, the winding shielding effect, and thermal configuration are investigated. The thesis results have been documented at IEEE EPE conference in 2007 and 2008, IEEE APEC in 2009 and 2010, and IEEE VPPC in 2010. A 2011 journal has been approved by IEEE Transactions on Power Electronics.

High-current inductors for high-power automotive DC-DC converters

This thesis is focused on the investigation of magnetic materials for high-power dcdc converters in hybrid and fuel cell vehicles and the development of an optimized high-power inductor for a multi-phase converter. The thesis introduces the power system architectures for hybrid and fuel cell vehicles. The requirements for power electronic converters are established and the dc-dc converter topologies of interest are introduced. A compact and efficient inductor is critical to reduce the overall cost, weight and volume of the dc-dc converter and optimize vehicle driving range and traction power. Firstly, materials suitable for a gapped CC-core inductor are analyzed and investigated. A novel inductor-design algorithm is developed and automated in order to compare and contrast the various magnetic materials over a range of frequencies and ripple ratios. The algorithm is developed for foil-wound inductors with gapped CC-cores in the low (10 kHz) to medium (30 kHz) frequency range and investigates the materials in a natural-convection-cooled environment. The practical effects of frequency, ripple, air-gap fringing, and thermal configuration are investigated next for the iron-based amorphous metal and 6.5 % silicon steel materials. A 2.5 kW converter is built to verify the optimum material selection and thermal configuration over the frequency range and ripple ratios of interest. Inductor size can increase in both of these laminated materials due to increased airgap fringing losses. Distributing the airgap is demonstrated to reduce the inductor losses and size but has practical limitations for iron-based amorphous metal cores. The effects of the manufacturing process are shown to degrade the iron-based amorphous metal multi-cut core loss. The experimental results also suggest that gap loss is not a significant consideration in these experiments. The predicted losses by the equation developed by Reuben Lee and cited by Colonel McLyman are significantly higher than the experimental results suggest. Iron-based amorphous metal has better preformance than 6.5 % silicon steel when a single cut core and natural-convection-cooling are used. Conduction cooling, rather than natural convection, can result in the highest power density inductor. The cooling for these laminated materials is very dependent on the direction of the lamination and the component mounting. Experimental results are produced showing the effects of lamination direction on the cooling path. A significant temperature reduction is demonstrated for conduction cooling versus natural-convection cooling. Iron-based amorphous metal and 6.5% silicon steel are competitive materials when conduction cooled. A novel inductor design algorithm is developed for foil-wound inductors with gapped CC-cores for conduction cooling of core and copper. Again, conduction cooling, rather than natural convection, is shown to reduce the size and weight of the inductor. The weight of the 6.5 % silicon steel inductor is reduced by around a factor of ten compared to natural-convection cooling due to the high thermal conductivity of the material. The conduction cooling algorithm is used to develop high-power custom inductors for use in a high power multi-phase boost converter. Finally, a high power digitally-controlled multi-phase boost converter system is designed and constructed to test the high-power inductors. The performance of the inductors is compared to the predictions used in the design process and very good correlation is achieved. The thesis results have been documented at IEEE APEC, PESC and IAS conferences in 2007 and at the IEEE EPE conference in 2008.

Efficient building management with IP-based wireless sensor network

Existing Building/Energy Management Systems (BMS/EMS) fail to convey holistic performance to the building manager. A 20% reduction in energy consumption can be achieved by efficiently operated buildings compared with current practice. However, in the majority of buildings, occupant comfort and energy consumption analysis is primarily restricted by available sensor and meter data. Installation of a continuous monitoring process can significantly improve the building systems’ performance. We present WSN-BMDS, an IP-based wireless sensor network building monitoring and diagnostic system. The main focus of WSN-BMDS is to obtain much higher degree of information about the building operation then current BMSs are able to provide. Our system integrates a heterogeneous set of wireless sensor nodes with IEEE 802.11 backbone routers and the Global Sensor Network (GSN) web server. Sensing data is stored in a database at the back office via UDP protocol and can be access over the Internet using GSN. Through this demonstration, we show that WSN-BMDS provides accurate measurements of air-temperature, air-humidity, light, and energy consumption for particular rooms in our target building. Our interactive graphical user interface provides a user-friendly environment showing live network topology, monitor network statistics, and run-time management actions on the network. We also demonstrate actuation by changing the artificial light level in one of the rooms.

Artificial neural network application in short-term prediction in an oscillating water column

Oscillating Water Column (OWC) is one type of promising wave energy devices due to its obvious advantage over many other wave energy converters: no moving component in sea water. Two types of OWCs (bottom-fixed and floating) have been widely investigated, and the bottom-fixed OWCs have been very successful in several practical applications. Recently, the proposal of massive wave energy production and the availability of wave energy have pushed OWC applications from near-shore to deeper water regions where floating OWCs are a better choice. For an OWC under sea waves, the air flow driving air turbine to generate electricity is a random process. In such a working condition, single design/operation point is nonexistent. To improve energy extraction, and to optimise the performance of the device, a system capable of controlling the air turbine rotation speed is desirable. To achieve that, this paper presents a short-term prediction of the random, process by an artificial neural network (ANN), which can provide near-future information for the control system. In this research, ANN is explored and tuned for a better prediction of the airflow (as well as the device motions for a wide application). It is found that, by carefully constructing ANN platform and optimizing the relevant parameters, ANN is capable of predicting the random process a few steps ahead of the real, time with a good accuracy. More importantly, the tuned ANN works for a large range of different types of random, process.