Hardware-in-the-loop implementation of single- and dual-phase shift control for dual active bridge converters in EV applications

Isolated DC-DC converters play a significant role in fast charging and maintaining the variable output voltage for EV applications. This study aims to investigate the different Isolated DC-DC converters for onboard and offboard chargers, then, once the topology is selected, study the control techniques and, finally, achieve a real-time converter model to accomplish Hardware-In-The-Loop (HIL) results. Among the different isolated DC-DC topologies, the Dual Active Bridge (DAB) converter has the advantage of allowing bidirectional power flow, which enables operating in both Grid to Vehicle (G2V) and Vehicle to Grid (V2G) modalities. Recently, DAB has been used in the offboard chargers for high voltage applications due to SiC and GaN MOSFETs; this new technology also allows the utilization of higher switching frequencies. By empowering soft switching techniques to reduce switching losses, higher switching frequency operation is possible in DAB. There are four phase shift control techniques for the DAB converter. They are Single Phase shift, Extended Phase shift, Dual Phase shift, Triple Phase shift controls. This thesis considers two control strategies; Single-Phase, and Dual-Phase shifts, to understand the circulating currents, power losses, and output capacitor size reduction in the DAB. Hardware-In-The-Loop (HIL) experiments are carried out on both controls with high switching frequencies using the PLECS software tool and the RT box supporting the PLECS. Root Mean Square Error is also calculated for steady-state values of output voltage with different sampling frequencies in both the controls to identify the achievable sampling frequency in real-time. DSP implementation is also executed to emulate the optimized DAB converter design, and final real-time simulation results are discussed for both the Single-Phase and Dual-Phase shift controls.

Analysis of the impact of stationary energy storage systems in trolleybus grids using Simulink-based modelling

The voltage profile of the catenary between traction substations (TSSs) is affected by the trolleybus current intake and by its position with respect to the TSSs: the higher the current requested by the bus and the further the bus from the TSSs, the deeper the voltage drop. When the voltage drops below 500V, the trolleybus is forced to decrease its consumption by reducing its input current. This thesis deals with the analysis of the improvements that the installation of an BESS produces in the operation of a particularly loaded FS of the DC trolleybus network of the city of Bologna. The stationary BESS is charged by the TSSs during off-peak times and delivers the stored energy when the catenary is overloaded alleviating the load on the TSSs and reducing the voltage drops. Only IMC buses are considered in the prospect of a future disposal of all internal combustion engine vehicles. These trolleybuses cause deeper voltage drops because they absorb enough current to power their traction motor and recharge the on board battery. The control of the BESS aims to keep the catenary voltage within the admissible voltage range and makes sure that all physical limitations are met. A model of FS Marconi Trento Trieste is implemented in Simulink environment to simulate its daily operation and compare the behavior of the trolleybus network with and without BESS. From the simulation without BESS, the best location of the energy storage system is deduced, and the battery control is tuned. Furthermore, from the knowledge of the load curve and the battery control trans-characteristic, it is formulated a prediction of the voltage distribution at BESS connection point. The prediction is then compared with the simulation results to validate the Simulink model. The BESS allows to decrease the voltage drops along the catenary, the Joule losses and the current delivered by the TSSs, indicating that the BESS can be a solution to improve the operation of the trolleybus network.

Nanostructured piezoelectric materials for the design and development of self-sensing composite materials and energy harvesting devices

The work activities reported in this PhD thesis regard the functionalization of composite materials and the realization of energy harvesting devices by using nanostructured piezoelectric materials, which can be integrated in the composite without affecting its mechanical properties. The self-sensing composite materials were fabricated by interleaving between the plies of the laminate the piezoelectric elements. The problem of negatively impacting on the mechanical properties of the hosting structure was addressed by shaping the piezoelectric materials in appropriate ways. In the case of polymeric piezoelectric materials, the electrospinning technique allowed to produce highly-porous nanofibrous membranes which can be immerged in the hosting matrix without inducing delamination risk. The flexibility of the polymers was exploited also for the production of flexible tactile sensors. The sensing performances of the specimens were evaluated also in terms of lifetime with fatigue tests. In the case of ceramic piezo-materials, the production and the interleaving of nanometric piezoelectric powder limitedly affected the impact resistance of the laminate, which showed enhanced sensing properties. In addition to this, a model was proposed to predict the piezoelectric response of the self-sensing composite materials as function of the amount of the piezo-phase within the laminate and to adapt its sensing functionalities also for quasi-static loads. Indeed, one final application of the work was to integrate the piezoelectric nanofibers in the sole of a prosthetic foot in order to detect the walking cycle, which has a period in the order of 1 second. In the end, the energy harvesting capabilities of the piezoelectric materials were investigated, with the aim to design wearable devices able to collect energy from the environment and from the body movements. The research activities focused both on the power transfer capability to an external load and the charging of an energy storage unit, like, e.g., a supercapacitor.

Analysis and improvements of four-wire power converters for electric vehicle chargers

A robust and well-distributed backbone charging network is the priority to ensure widespread electrification of road transport, providing a driving experience similar to that of internal combustion engine vehicles. International standards set multiple technical targets for on-board and off-board electric vehicle chargers; output voltage levels, harmonic emissions, and isolation requirements strongly influence the design of power converters. Additionally, smart-grid services such as vehicle-to-grid and vehicle-to-vehicle require the implementation of bi-directional stages that inevitably increase system complexity and component count. To face these design challenges, the present thesis provides a rigorous analysis of four-leg and split-capacitor three-phase four-wire active front-end topologies focusing on the harmonic description under different modulation techniques and conditions. The resulting analytical formulation paves the way for converter performance improvements while maintaining regulatory constraints and technical requirements under control. Specifically, split-capacitor inverter current ripple was characterized as providing closed-form formulations valid for every sub-case ranging from synchronous to interleaved PWM. Outcomes are the base for a novel variable switching PWM technique capable of mediating harmonic content limitation and switching loss reduction. A similar analysis is proposed for four-leg inverters with a broad range of continuous and discontinuous PWM modulations. The general superiority of discontinuous PWM modulation in reducing switching losses and limiting harmonic emission was demonstrated. Developments are realized through a parametric description of the neutral wire inductor. Finally, a novel class of integrated isolated converter topologies is proposed aiming at the neutral wire delivery without employing extra switching components rather than the one already available in typical three-phase inverter and dual-active-bridge back-to-back configurations. The fourth leg was integrated inside the dual-active-bridge input bridge providing relevant component count savings. A novel modified single-phase-shift modulation technique was developed to ensure a seamless transition between working conditions like voltage level and power factor. Several simulations and experiments validate the outcomes.