Regular Extreme Fast Charging Station for E-buses with Low Current Harmonic Content

Brandao, Dener A. de L.; Parreiras, Thiago M.; Pires, Igor A.; Cardoso Filho, Braz de J.

doi:10.18618/REP.e202533

person Dener A. de L. Brandao *

Conceptualization · Data Curation · Formal Analysis · Investigation · Methodology · Software · Validation · Visualization · Writing – Original Draft · Writing – Review & Editing Dener A. de L. Brandao was born in Brazil in 1994. He received the Master's degree in Electrical Engineering in 2021 from the Universidade Federal de Minas Gerais, Belo Horizonte, Brazil, where he is currently a doctoral student. His current research interests include industry applications, transportation electrification and microgrid control.

schoolUniversidade Federal de Minas Gerais, Graduate Program in Electrical Engineering - Av. Anônio Carlos 6627, Belo Horizonte, MG, Brazil; e-mail: dalbrandao@ufmg.br

0000-0002-1840-2329

person Thiago M. Parreiras

Conceptualization · Data Curation · Formal Analysis · Investigation · Methodology · Software · Supervision · Validation · Visualization · Writing – Original Draft · Writing – Review & Editing Thiago M. Parreiras received the Doctorate degree in Electrical Engineering in 2020 from the Universidade Federal de Minas Gerais, Belo Horizonte, Brazil, where he has been with TESLA Power Engineering Laboratory since 2013. Since 2023, he has been a Faculty Member with the Departament of Electrical Engineering, Centro Federal de Educação Tecnológica de Minas Gerais, Belo Horizonte, Brazil, where he is currently an assistant professor. His current research interests include high-power converters and drives, power quality, renewable energy and transportation electrification.

schoolCentro Federal de Educação Tecnolo´gica de Minas Gerais, Department of Electrical Engineering, Belo Horizonte 30510-000, Brazil. e-mail: thiago.parreiras@cefetmg.br

0000-0003-2300-5667

person Igor A. Pires

Conceptualization · Funding Acquisition · Investigation · Methodology · Project Administration · Resources · Supervision · Visualization · Writing – Original Draft · Writing – Review & Editing Igor A. Pires was born in Brazil in 1980. He received the Doctorate in electrical engineering from Universidade Federal de Minas Gerais (UFMG), Belo Horizonte, Brazil, in 2011. Since 2011, he is an assistant professor in Electronics Engineering Department of UFMG. His research interests include metal industry applications, power electronics, power quality, and vehicle electrification.

schoolUniversidade Federal de Minas Gerais, Department of Electronic Engineering, Belo Horizonte, Brazil e-mail: iap@ufmg.br

0000-0002-8442-0074

person Braz de J. Cardoso Filho

Conceptualization · Funding Acquisition · Methodology · Project Administration · Resources · Supervision · Visualization · Writing – Original Draft · Writing – Review & Editing Braz de J. Cardoso F. received the Ph.D. degree in electrical engineering from the University of Wisconsin–Madison, Madison, WI, USA, in 1998. Since 1989, he has been a Faculty Member with the Department of Electrical Engineering, Universidade Federal de Minas Gerais, Belo Horizonte, Brazil, where he is currently a Full Professor, and the Founder and the Head of the TESLA Power Engineering Laboratory. He has authored/coauthored about 200 technical papers on the topics of power electronics and electrical drives and holds eight patents. His research interests include utility applications of power electronics, renewable energy sources, semiconductor power devices, electrical machines and drives, and vehicle electrification.

schoolUniversidade Federal de Minas Gerais, Department of Electrical Engineering, Belo Horizonte, Brazil. e-mail: braz.cardoso@ieee.org

0000-0002-3470-4570

person* Corresponding author. e-mail:
dalbrandao@ufmg.br

Associate Editor

Levy F. Costa https://orcid.org/0000-0001-7372-8041

Editor-in-Chief

Heverton A. Pereira https://orcid.org/0000-0003-0710-7815

Grid-connected converter	LC Filter?	Diodes/Switches	Switches Technology	f_sw (kHz)	Sim. Power (kW)	Exp. Power (kW)	THD_i (%)
Conventional 2-level [¹¹]	✓	0/6	SiC	100	50	✗	4.04a
Conventional NPC [¹²]	✗	6/12	Si	1.08	240	1.2	2.46a/✗
NPC 4-leg [¹³]	✓	8/16	Si	2.16	1200	3.6	5.39a/5.8b
Conventional Vienna [¹⁴]	✗	6/6	Si	12/50	60	1.865	3.27a/3.5b
Vienna 3-sw. [¹¹]	✓	18/3	SiC	100	50	✗	1.26a
Vienna 6-sw. [¹¹]	✓	12/6	SiC	100	50	✗	1.26a
Parallel Vienna [¹⁵]	✗	12/6	Si	15	30	6.0	0.847^a/7.11b
Swiss [¹⁷]	✓	8/8	SiC	90	✗	10	4.9b
5-level E-type [²²]	✗	12/36	Si	20	✗	25	4.7b
MMCC [²⁶]	✓	120/120	Si	1.0	600	✗	1.25a
Proposal: ZHD converter	✗	0/18	Si	1.14	280	280	0.54a/2.29b

Reference	Main area	Application	ZHD voltage control?	DC-DC converter control?	ZHD closed-loop experimental results?	Prototype power
[³⁰]a	Power systems	Not specified	✗	-	✗	No data
[²⁰]	Vehicular	Electric charger	✗	✗	✗	No data
[³¹]	Mining industry	Electric drive system	✓	-	✗	No data
[³²]	Power systems	Wind system	✓	-	✗	30 kW
[³³]	Metal industry	Electric drive system	✓	-	✓	30 kW
[³⁴]	Metal industry	Static compensator	✓	-	✓	280 kW
[³⁵]	Metal industry	Not specified	✓	-	✓	280 kW
[³⁶]	Power systems	Islanded microgrids	✗	-	✓	4 kW
[³⁷]	Power systems	Islanded microgrids	✓	-	✗	-
This paper	Vehicular	Electric charger	✓	✓	✓	280 kW

Parameter	Controller Values
Parameter	Current Controller		Voltage Controller
	d-axis	q-axis
Poles Frequency	72 Hz	{72, 7.2} Hz	{7.2, 0.72} Hz
Proportional Gains	0.18 Ω	0.18 Ω	0.5 S
Integral Gains	-	8.15 Ω· s^-1	2.2 S· s^-1

Parameter	Controller Values
Parameter	Current Controller	Voltage Controller
Poles Frequency	{500 Hz, 50 Hz}	{5, 0.5} Hz
Proportional Gains	1.88 Ω	3040 S
Integral Gains	592 Ω· s^-1	9551 S· s^-1

ZHD Converter
Element	Parameter	Value
Grid	Voltage [V]	440
Grid	Frequency [Hz]	60
Transformer	Nominal power [kVA]	305
	Primary voltage [V]	506
	Secundaries voltage [V]	440
	Connection	Dd0y1
ac reactors	Δ/Y inductance [μH]	590/506.8
dc link	Capacitance [mF]	10.5
dc link	dc link voltage [V]	700

DC/DC Converter
Parameter	Symbol	Value
Input voltage	V_i	700 V
Switching frequency	f_sw	5 kHz
Max power	P_charger	308 kW
Output voltage	V_o	250 to 500 V
Output current	I_o	570 A
Output current ripple	ΔI_o	3%
dc inductance per arm	L_dc	600 μH

Conversion	Power Losses		Efficiency
Stage	[W]	[%]	[%]
Diode bridges	922	7.77	99.63
DC link^a	2730.61	23.02	98.90
IGBTs converters	1836.00	15.48	99.25
Reactors	3070	25.89	98.74
Transformer	3301.39	27.84	98.62
TOTAL	11,860	100	95.23
ZHD converter (w/o diode bridges)	10,938	92.23	95.58
ZHD converter (w/o DC link)	8,207	69.21	96.65

[\begin{matrix} 1 - 2 cos (α_{1}) + \dots + 2 {(- 1)}^{M} • cos (α_{M}) \\ 1 - 2 cos (n_{2} • α_{1}) + \dots + 2 {(- 1)}^{M} • cos (n_{2} • α_{M}) \\ ⋮ \\ 1 - 2 cos (n_{i} • α_{1}) + \dots + 2 {(- 1)}^{M} • cos (n_{i} • α_{M}) \end{matrix}] = [\begin{matrix} m_{i} \\ 0 \\ ⋮ \\ 0 \end{matrix}]

[TFN01] ^a
Simulation results.

[TFN02] ^b
Experimental results.

Cell voltage	2.7 V
Cell capacitance	500 F
Cell series resistance	1.6 mΩ
Strings in parallel/series	36/186
Initial and final bank voltage	250-500 V
Bank capacitance (C_eq)	97 F
Bank series resistance	8.3 mΩ