Development of the power flow controller
New Year 2021 arrives 🎆, so we are accelerating the work in MoReSiC – Project! Now we would give you a little taste of the task which include development of the power flow controller.
The main objective of this task is to analyze all possible operation modes and develop the power flow control algorithm taking into account requested power from connected vehicles, state of the energy storage and performance of the power converters (estimated power losses), and finally design the digital control system and implement the algorithm.
📶 To effectively manage the power flow appropriate #communication interface, ensuring low latency and high reliability, will be analyzed and implemented. External communication for remote monitoring and control will also be provided.
🔄 Another important task is to elaborate #controlalgorithm to stabilize voltages in three wire DC distribution bus in different operating modes, especially in transient states.
☑ Furthermore, after full capability of the controller in all power modes will be achieved the #digitalcontrolsystem will be designed.
✅ Finally, the last part will consider implementing the developed algorithm into the designed control system so it is ready for #hardwaretesting.
SiC-based power electronics submodules
2️⃣ The second task is named “SiC-based #powerelectronics submodules”. This will be a key component for the realization of the entire MoReSiC – Project. This basic unit will provide the opportunity to implement the main assumptions of the system: #modular construction and easy #reconfigurability.
❗ The main objective of this task is to conduct research aiming in development of a highly-optimized multilevel submodule with 1.2kV rated SiC power devices. The submodule will contain four switches with #SiCMOSFET and #Schottkydiodes, DC capacitors, gate drivers and air-forced cooling system.
📑 The developed unit should work up to maximum DC side voltage of 800 V and RMS currents up to 30 A. All junction temperatures will be kept below 100 °C by suitable cooling and control system. Gate drivers are expected to provide typical protection functions: overcurrent & overtemperature protection as well as gate supply monitoring and the generation of dead-times. Finally, isolation between the submodule and control system above 3.4 kV (50Hz, 1 minute test).
The task will be conducted by Markel team supported by Politechnika Warszawska PhD student. The task will be managed by Radosław Sobieski, who is head of Markel’s R&D department.
Reconfigurable, multiport isolated DC-DC converter
3️⃣ The third task main objective is to deliver a #reconfigurable and #multiport isolated DC/DC converter employing #SiCMOSFETs and exhibiting an #efficiency at nominal power higher than 9️⃣7️⃣%. 🔝
Following secondary objectives shall be accomplished:
✔ To identify the fundamental #design of an isolated DC/DC converter topology that enables multiple configurations in terms of input and output stages.
✔ To #validate theoretically and experimentally various configurations of the isolated DC/DC converters for supplying charging power in the range of 10-20 kW.
✔ To identify design and operating electrical and #thermal parameters in terms of voltage, current and temperature.
✔ To design and experimentally #test the multilevel circuit with 1.2 kV SiC MOSFETs along with the necessary auxiliary sub-circuits of the isolated DC/DC converter
✔ To #deliver design and operating guidelines for integration of the isolated DC/DC converters with the charging infrastructure.
✔ To offer high-quality #research training to one PhD student at Norges teknisk-naturvitenskapelige universitet (NTNU).
Bidirectional multilevel AC-DC converter rated at 20 kVA
4️⃣ The main objective of the task named “Bidirectional multilevel AC-DC converter rated at 20 kVA” is to perform #research towards a highly efficient multilevel AC-DC #converter designed with SiC power devices including multilevel submodule structure. The investigated converter will be an input stage of the charging infrastructure connecting the three-phase grid with three-wire DC link. As the system is expected to be fully active in different modes, the bidirectional operation up to nominal power (20 kVA) is anticipated. Moreover, the task aims to obtain high efficiency operation (>98% at rated power) without sacrificing the high quality of the input current (THD < 5%).
Secondary objectives: 🧾
👁🗨 To #identify the topology of a multilevel AC/DC converter that enables bidirectional power flow between grid and DC link
✍ To identify #design and operating electrical and thermal parameters in terms of voltage, current and temperature.
🦾 To design and experimentally #test the prototype of the 20 kVA AC-DC converter
📫 To #deliver design and operating guidelines for integration of the multilevel AC-DC converter with the charging infrastructure.
📚 To offer career enhancement for the post-doc researchers and high-quality research training to PhD students at Politechnika Warszawska
Non-isolated DC-DC converter for the energy storage
5️⃣ The main objective of the task named “Non-isolated DC-DC converter for the energy storage” is to deliver a 20 kW #bidirectional non-isolated DC/DC converter employing #SiCMOSFETs interfacing a DC-link (+750/0/-750V) and #energystorage, capable of achieving #efficiency at rated power as high as 9️⃣8️⃣% and providing an additional function of balancing the voltage levels of the DC bus capacitors.
At the completion of this task, the following secondary objectives shall be accomplished:
📐 To select a non-isolated DC/DC converter #topology and design the model that enables operation in between three-wire DC link and the battery storage
🌡 To identify design and operating #electrical and #thermal parameters in terms of voltage, current and temperature.
⚖ To develop a control strategy that offers voltage #balancing and operation at maximum efficiency in all operation modes of the EV charging system
🔧 To design and experimentally #test the 20 kW rated three-level DC/DC converter
👨🏫 To offer the opportunity to strengthen co-operation between industry professionals from Markel and researchers from Politechnika Warszawska, especially gain in experiences of #PhDstudents will be significant
Integration & experiments on the complete EV charging system
6️⃣ The main objective of the task named “Integration & experiments on the complete EV charging system“ is to integrate and perform complete series #experiments on the developed charging system up to the nominal power of 40 kW, as well as to #test and #verify the assumed efficiency and power quality factors (grid current THD).
As a final stage of the project, this task will be conducted together by Markel and Politechnika Warszawska teams using facilities of the university and, when necessary, the company resources. The #PhDstudent from Norges teknisk-naturvitenskapelige universitet (NTNU) is also expected to be involved in this research moving to Warsaw for 9 months to support performed tasks and gain experience from direct co-operation with researchers from Politechnika Warszawska and #industry professionals from Markel.