Efficiency and dynamic characteristics of improved dual‐stage power converter setup with advanced model predictive controller for electric vehicle battery charging

Abstract

SummaryThis paper proposes an advanced power converter setup to charge an electric vehicle battery from a renewable energy source, such as solar photovoltaic. An improved Z‐source DC–DC boost converter (IZSBC) is utilized in the first stage. A synchronous rectifier (SR) of a phase‐shifted full‐bridge converter (PSFBC) with continuous conduction mode (CCM) is employed in the second stage using the zero voltage switching (ZVS) technique to provide isolation between the source and the load. To address the disadvantage of undesirable dynamic characteristics of the PSFBC‐SR, an advanced voltage control using the advanced model predictive controller (AMPC) is suggested to improve the dynamic characteristic of the PSFBC‐SR converter and prevent output voltage overshoot. An AMPC‐based new control method is preferred to eliminate body‐diode conduction for improved efficiency at any load conditions. Simulation and experimental designs of 0.5 kW with a 25 V DC input from the SPV, a boosted output of 100 V for a 60 V, 16 Ah battery bank and switching frequencies of 100 and 250 kHz for IZSBC and PSFBC‐SR, respectively, are produced and evaluated. Results show an efficiency of 93.7% with 31.44 W loss in simulations and 93.94% with 30.25 W loss in hardware tests. The preferred system has fast dynamics and is robust to sudden load impedance changes, thereby improving current tracking and reducing converter losses. The AMPC strategy proposed in this paper can increase conversion efficiency and control the output voltage without additional gain tuning.