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PCIM 2012 PRESENTATION
1. 9kW Isolated DC-DC
Converter for Hybrid Bus.
Alexander Isurin and Alexander Cook
PCIM2012 ISO 9001:2000 / TS-16949:2002 Registered Company 1
2. Components Eliminated with a
DC to DC Converter
Regulator
Alternator
Bracket Pulley
Cast
Tensioner Bracket
Inlet Air
Idler Piping
Belt
ISO 9001:2000 / TS-16949:2002 Registered Company
3. Introduction
24VLoad
up
300-500A
Engine Alternator 12V Load up 100A
Simplified block diagram of 24V system of the bus
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4. FIELD
CURRENT
1.0x
Simplified curve of 0.1x
transient response DC
VOLTAGE
~100mS ~100mS
of an alternator 2.0x
1.0x
PCIM2012 ISO 9001:2000 / TS-16949:2002 Registered Company 4
5. Path of Electrical Flow
Flow
Allison Hybrid Drive
Allison DPIM
Unit
24 Volts DC
Vanner DC-DC Converter
ISO 9001:2000 / TS-16949:2002 Registered Company
6. 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
7. Main Battery
500-800VDC 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
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14. Soft-Switch Commutation
t5 to t6
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15. Next half cycle power conversion
t6 to t7
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16. Ch.1- gate signal of S2
Ch.2-voltage cross of S2
ZCS and ZVS 1750V/uS
Ch.3-voltage cross of D6
ZVS 1000V/uS
Ch.4-current via transformer TR1 Vin=700VDC Pout=9kw
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17. Discharge Energy of the Inductor
t3 to t4
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18. Phase-shift Topologies
Standard topology
Improved topology
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19. Comparisons
PARAMETERS STANDARD IMPROVED NEW
Max. com. freq. 1x 1.2x 2x
Load range Limited Unlimited
Commutation ZVS ZVS ZCS ZVS ZCS
Rectifier recovery Recovery losses More complex Simple and soft
Paralleling of stages Requires additional control Simple
Transformer Not optimal Optimal
Control Standard Special
Efficiency Approximately the same for all three
Idle losses 1.5% 0.15%
Bi-directional Additional constraints Readily
COST Basis Basis plus Basis minus
>10%
PCIM201 ISO 9001:2000 / TS-16949:2002 Registered Company 19
20. Low voltage side power stage with integrated power transformer
Presented without
the clamping frame
Patent US 7,123,123
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21. Comparisons
Cost and efficiency of the low-voltage side
power 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 280A
PCIM2012 ISO 9001:2000 / TS-16949:2002 Registered Company 21
22. Comparisons
650VDC
24V 24V
Load DC- Load
Engine DC
Engine Alternator 12V Load Direct Drive Main Generator 12V Load
The alternator’s system efficiency The DC-DC system efficiency
65% with 9kW output power 82% with 9kW output power
The difference is 17% meaning 2.8 kW
Saving average 0.1mpg or 370gal. per year per bus
PCIM2012 ISO 9001:2000 / TS-16949:2002 Registered Company 22
23. Conclusion
The DC to DC converter has some notable advantages
1. Significant increase in reliability of the 24VDC system
2. Cost of maintenance of 24VDC system significantly reduced
3. Fuel economy improvement
4. 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
24. Conclusion
Finally all the advantages of
the DC-DC converter
can help to save MONEY
and make life better
PCIM2012 ISO 9001:2000 / TS-16949:2002 Registered Company 24
25. Thank You for Your
Attention.
PCIM2012 ISO 9001:2000 / TS-16949:2002 Registered Company 25
