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9kW Isolated DC-DCConverter for Hybrid Bus. Alexander Isurin
and Alexander CookPCIM2012 ISO 9001:2000 / TS-16949:2002 Registered
Company 1
Components Eliminated with a DC to DC Converter Regulator
Alternator Bracket Pulley CastTensioner Bracket Inlet Air Idler
Piping Belt ISO 9001:2000 / TS-16949:2002 Registered Company
Introduction 24VLoad up 300-500A Engine Alternator 12V Load up
100ASimplified block diagram of 24V system of the busPCIM2012 ISO
9001:2000 / TS-16949:2002 Registered Company 3
FIELD CURRENT 1.0xSimplified curve of 0.1xtransient response DC
VOLTAGE ~100mS ~100mS of an alternator 2.0x 1.0xPCIM2012 ISO
9001:2000 / TS-16949:2002 Registered Company 4
Path of Electrical Flow FlowAllison Hybrid Drive Allison DPIM
Unit 24 Volts DC Vanner DC-DC Converter ISO 9001:2000 /
TS-16949:2002 Registered Company
Main Data 9kW Bi-directional DC-DC converter High voltage side:
500VDC-800VDC Low voltage side: 20VDC-30VDC @300A Operational
temperature: -40C to +70C @ full power Efficiency 93-94% excluding
reverse polarity protection and pre-charge (92-93% with) Efficiency
82% @ 5% load Consumption @ idle 60W Life time minimum 7 years Cost
for customer equivalent to conventional alternator PCIM2012 ISO
9001:2000 / TS-16949:2002 Registered Company 6
Main Battery500-800VDC Option DC-DC Electric 24VDC CONVERTER
Equalizer Grid Load Battery Monitor 12VDC Load Charger Vehicle
CAN-bus Network Block diagram of the converter integrated into the
bus electric system PCIM2012 ISO 9001:2000 / TS-16949:2002
Registered Company 7
DC-DC Convertercurrently inProductionPCIM2011 ISO 9001:2000 /
TS-16949:2002 Registered Company 8
New Topology DC-DC Converter in Step-down ModePresented
APEC2006 Patent US 6,483,731 PCIM2012 ISO 9001:2000 / TS-16949:2002
Registered Company 9
Charge Resonant Tank t0 to t2PCIM2012 ISO 9001:2000 /
TS-16949:2002 Registered Company 10
Soft-Switch Commutation t2 to t3 PCIM2012 ISO 9001:2000 /
TS-16949:2002 Registered Company 11
Discharge Energy of the Inductor t3 to t4 PCIM2012 ISO
9001:2000 / TS-16949:2002 Registered Company 12
Discharge Magnetizing Inductor t4 to t5 PCIM2012 ISO 9001:2000
/ TS-16949:2002 Registered Company 13
Soft-Switch Commutation t5 to t6 PCIM2012 ISO 9001:2000 /
TS-16949:2002 Registered Company 14
Next half cycle power conversion t6 to t7 PCIM2012 ISO
9001:2000 / TS-16949:2002 Registered Company 15
Ch.1- gate signal of S2Ch.2-voltage cross of S2 ZCS and ZVS
1750V/uSCh.3-voltage cross of D6 ZVS 1000V/uSCh.4-current via
transformer TR1 Vin=700VDC Pout=9kw PCIM2012 ISO 9001:2000 /
TS-16949:2002 Registered Company 16
Discharge Energy of the Inductor t3 to t4 PCIM2012 ISO
9001:2000 / TS-16949:2002 Registered Company 17
Phase-shift Topologies Standard topology Improved
topologyPCIM2012 ISO 9001:2000 / TS-16949:2002 Registered Company
18
Comparisons PARAMETERS STANDARD IMPROVED NEWMax. com. freq. 1x
1.2x 2xLoad range Limited UnlimitedCommutation ZVS ZVS ZCS ZVS
ZCSRectifier recovery Recovery losses More complex Simple and
softParalleling of stages Requires additional control
SimpleTransformer Not optimal OptimalControl Standard
SpecialEfficiency Approximately the same for all threeIdle losses
1.5% 0.15%Bi-directional Additional constraints ReadilyCOST Basis
Basis plus Basis minus >10% PCIM201 ISO 9001:2000 /
TS-16949:2002 Registered Company 19
Low voltage side power stage with integrated power transformer
Presented without the clamping frame Patent US 7,123,123 PCIM2012
ISO 9001:2000 / TS-16949:2002 Registered Company 20
ComparisonsCost and efficiency of the low-voltage sidepower
stage with two types of transformers Power Stage Product System
Incorporating: Cost Efficiency Integrated 1 94% transformer Planar
transformer 1+20% 92% Commutation frequency 110kHz Low voltage side
rating 280APCIM2012 ISO 9001:2000 / TS-16949:2002 Registered
Company 21
Comparisons 650VDC 24V 24V Load DC- Load Engine DC Engine
Alternator 12V Load Direct Drive Main Generator 12V LoadThe
alternators system efficiency The DC-DC system efficiency65% with
9kW output power 82% with 9kW output power The difference is 17%
meaning 2.8 kWSaving average 0.1mpg or 370gal. per year per bus
PCIM2012 ISO 9001:2000 / TS-16949:2002 Registered Company 22
Conclusion The DC to DC converter has some notable advantages1.
Significant increase in reliability of the 24VDC system2. Cost of
maintenance of 24VDC system significantly reduced3. Fuel economy
improvement4. Higher performance lower overshoot voltage,5. CAN-bus
communication, ease of external control.6. It is easy to connect in
parallel.7. Reduction of copper for manufacturing PCIM2012 ISO
9001:2000 / TS-16949:2002 Registered Company 23
Conclusion Finally all the advantages of the DC-DC converter
can help to save MONEY and make life betterPCIM2012 ISO 9001:2000 /
TS-16949:2002 Registered Company 24
Thank You for Your Attention.PCIM2012 ISO 9001:2000 /
TS-16949:2002 Registered Company 25