02-Photovoltaic Energy Harvesting For Hybrid Electric Vehicles - Nikolic2012
02-Photovoltaic Energy Harvesting For Hybrid Electric Vehicles - Nikolic2012
02-Photovoltaic Energy Harvesting For Hybrid Electric Vehicles - Nikolic2012
Abstract—This paper presents a topology comparison of a hybrid integrated power stage, controlled by maximum power point
low-voltage step-up dc-dc converter in terms of European tracking algorithms implemented using a microcontroller, DSP,
Efficiency. Such converters are suited to be integrated with solar or done in a custom ASIC [2], [3], [4], [5]. For instance, [3]
cells, thus forming a photovoltaic energy harvesting architecture gives a design example of photovoltaic powered portable
dedicated for an integrated realisation of a solar range extender system performing image processing and wireless
for electric vehicles. Except of a discrete power stage realisation, communication tasks. Reference [2] discusses fully
the rest of a system, such as control, time and power autonomous converter with an input power range spanning
management, shall be monolithically integrated in the AMS from 5 μW up to 10 mW, fabricated in a commercial TSMC
0.35μm HV CMOS process. Developed efficiency model allows
0.25 μm CMOS process with 5 metal layers and using one
straightforward comparison of different converter topologies, as
compact SMD inductor of 1 mH. Another example of
shown on an example of the dc-dc converter which supplies the
electric vehicle auxiliary board net (12 V) with photovoltaic integrated energy harvesting architecure is [4], where an
power up to 40 W from a stack of 9-10 solar cells. Optimisation of inductor-less on-chip micro power management system for
the design variables: the external power switches, and the light energy harvesting applications was designed and
converter switching frequency is outlined on a given example. implemented using an AMS 0.35 μm CMOS process.
Opposite to the latter examples which dealt with extremely
Keywords: dc-dc converter; boost converter; synchronous
low power processing (up to mW range), in the cases when
rectifier; energy harvesting; European Efficiency; renewable
energy; photovoltaics.
much higher photovoltaic-obtained electric power (an order of
value: several tens of Watts) has to be processed it turns out to
be very expensive to integrate power switches. Since it is
certainly the case in the discussed application, this paper
I. INTRODUCTION investigates solutions with a discrete power stage. An overview
of the essential research results of photovoltaic (PV) power
Effective use of photovoltaic energy resources is limited by generators installations, both grid-connected and stand-alone
power capacity of the solar cells, their orientation and applications is given in [5]. As well as the latter reference, also
incliniation angle in respect to sun, as well as by geographic- commercially available products of photovoltaic panels [6], [7]
dependent weather conditions. In order to maintain effective concentrate primarily to photovoltaic inverter realisations, i.e.
utilisation of solar energy for a priori defined photovoltaic- dc-ac converters. On the other hand, this work discusses a dc-
area, and given type of solar cells, the design goal is to keep dc converter being part of a photovoltaic conversion chain.
power processing of photovoltaic-obtained electric energy
highly efficient. Therefore, contributing to the European targets Conventional solutions in processing solar energy are not
for reducing CO2 emission, fossil fuel liquids consumption and suited for vehicle integration as they encounter two common
the development of “green technologies”, novel on board problems: (1) cell-mismatch loss in series-connected solar cell
integrated solar power generators are proposed within the stack due to shadowing of any single cell, (2) an impedance
Energy Efficient Electrical Car (E3Car) project [1] to provide mismatch between solar panel on a micro-level and load, which
an auxiliary way of charging hybrid/electric vehicles, and to has as a consequence non-maximal energy transfer. In order to
improve energy efficiency providing optimum utilisation of overcome the first issue, state-of-the-art photovoltaic panels
photovoltaic energy. use output bypass diodes [6], which should guide available
current around “weaker” groups of cells (input photovoltage
Up to now much work has been done in the field of the per group: 15-40 V). In that way, energy of such cell-groups
photovoltaics. A wide variety of applications have been remains unused and the rest of the cells might run out of the
considered, such as powering wireless devices [2], or satellite maximum power point of operation. The second issue is only
systems, emergency telephones, remote sensors, sun-powered partially handled by module-level maximum power point
radios, and space vehicles, according to [3]. Different tracking [7], dividing the whole photovoltaic panel in several
implementations were proposed, with either a discrete or
On the one hand, conduction loss could be reduced if a diode They are shown in Table I alongside with the respective
is replaced by a synchronous rectifier, while on the other hand data points, i.e. the conversion efficiencies indexed by a
this increases the gate charge loss, since there is an additional percentage of the total rated power of the photovoltaic
active switch. Other differences are pronounced in terms of generator. These weighting factors reflect the statistical
the number of external devices. In a low-side driver, an input working time of each operating point [8]. If further the
low voltage CMOS logic signal is transformed in a logic constant input voltage VIN is assumed, then operating points
signal swinging from ground to the voltage VDDH are defined by input currents
( VDDH VIN ). Opposite of low-side drivers, which drive a P k
I IN k
IN . (3)
power MOSFET whose source is connected to ground (Fig. 2 VIN
and 3), high-side drivers (Fig. 3) have to make use of power
limited auxiliary voltage supplies for proper overdriving [9]. This is a reasonable assumption for photovoltaic applications
In any case, the two control signals should be pseudo- and will be used throughout the text. Averaging given by (1)
complementary to each other in order to eliminate shoot- could be applied to three different quantities: dc-dc converter
efficiency, static tracking efficiency of the MPPT tracker, and
through effect, i.e. some predefined time should elapse before
total efficiency, which is the product of the previous two.
turning on one of the two power devices after the turn off of
Here, only the dc-dc converter efficiency will be discussed.
the other power device in order to avoid cross-conduction
currents.
IV. EFFICIENCY MODELLING OF THE POWER STAGES
Hence, synchronous rectification is more complicated from A real converter contains a large number of dissipative
the converter control point of view. All solutions for elements. Inductor copper loss, and inductor core loss (due to
delivering a gate voltage adequately higher than the positive hysteresis and eddy current losses in the magnetic core) are
power supply rail, which is usually not available at board or just one type of losses that occur in the converter.
Semiconductor conduction losses (due to semiconductor
system level, and which is necessary for high-side drivers,
device forward voltage drops) and semiconductor switching
could be classified in two different categories [9]: (1)
losses (due to turn-on and turn-off transitions of
bootstrap techniques, and (2) charge pump techniques. semiconductor devices and charging/discharging of gate
However, for integrated/hybrid converters any of these capacitances) are further examples of converter losses [8]. The
solutions is already drawback since it requires use of power needed to operate the control circuitry is in milliwatt
additional external devices such as capacitors and diodes, range and hence negligible in this application. In the first
making boost topology with synchronous rectifier less approximation of the analysis to be presented, it will be
favourable. assumed that converters operate in the Continuous Conduction
Mode (CCM), and that stages are realised with use of external
devices – a discrete power stage. Also, inductor core loss,
III. EUROPEAN EFFICIENCY which is proportional to frequency, will be neglected.
In order to consider the deviation from the nominal
conditions in the solar system's efficiency characterisation, i.e. A. Conventional Boost DC-DC Converter Topology
for specific latitudes and variable weather conditions, in-plane (Topology 1)
sun irradiance, module temperature, a suitable figure of merit
The conduction loss in the case of the conventional boost
is the European Efficiency EURO which is based on annual converter topology is given by
statistical analysis of these conditions optimised for Central
Europe [1]. It is the weighted mean value of the converter Pres I IN
2
RON , ML D I INVF 1 D I IN
2
RL (4)
where D is the duty cycle, I IN the average input current of converter switching frequency. The transistor turn-on and
the converter, RL the inductor series resistance, VF the diode turn-off times are tON , ML and tOFF , ML , respectively.
forward voltage, and RON , ML the power MOSFET on-resistance. Therefore, the total loss in a particular operating point is
The diode forward voltage VF in principle depends on the expressed by
diode current. However, in datasheets it is usually provided for PLOSS Pdrv Poverlap Pres . (10)
one current value or it is characterised by its maximal value
[12], [13], [14]. Graphical current-voltage dependencies of the In order to calculate the European Efficiency, the dc-dc
diodes are also provided [12], [13], [14], but from them it is converter efficiency in different operating points given by
difficult to extract analytical models of these dependencies, Table I should be considered and finally averaged employing
especially to obtain the unified model. Hence, it is assumed (1). Thus, for the k -th, k 1,...,6 operating point holds
that the diode forward voltage VF remains roughly constant.
POUT k
PLOSS k
VIN I IN RL I IN RON , ML D
, (5) which after simplification, using (3), (4), and (7)-(10), yields
VIN I IN RL VF VOUT 1 D 0
I IN k
1 D fV
the duty cycle D could be obtained k
1 RL VF s DDH QG , ML
V I k
VIN VIN IN IN
VIN I IN RL RON , ML . (12)
D 1 , (6) f sVOUT DI IN k
VOUT VF I IN RON , ML tON ,ML tOFF , ML RON , ML
2VIN VIN
which, having neglected second-order terms1, simplifies to
The European Efficiency is then given by employing (1) to
V expression (12), using additionally (2), which brings
D
1 IN . (7)
VOUT
EURO 1 FHSSW FIND FLSSW
, (13)
The switching loss is, on the other hand, given through
transition-loss mechanisms in a power MOSFET and a diode. 1 D
FHSSW VF (14)
A diode recovery loss during turn-off transitions could be VIN
eliminated by using Schottky diodes which are majority-
6
carrier devices [8]. The energy provided by the gate driver to
charge and discharge the low-side MOSFET gate-to-source A k
I k
k 1
IN
I IN max
capacitance during turn-on and turn-off transitions in each FIND RL
0.5035 RL (15)
switching cycle represents the part of the converter switching VIN VIN
loss caused by a driver circuit. It is approximately given by f sVDDH QG , ML 6 A k
f sVOUT
Pdrv QG , MLVDDH f s . (8)
FLSSW
VIN
I k
2VIN
tON ,ML tOFF ,ML
k 1 IN
Pres I IN
2
RON , ML D I IN
2
RON , MH 1 D I IN
2
RL . (17) C. Topology Comparison for European Efficiency
f sVDDH fV DI k
1 D fV DI k
k
1 QG , MH s OUT tON , ML tOFF , ML IN RON , MH VF + s DDH QG , ML IN RON , ML ,
VIN I IN k
2VIN VIN VIN VIN I IN k
VIN
k 1,...,6 (21)
f sVDDH QG , MH 6 A k
DRON , MH 6
fV DI IN max
FHSSW
VIN
I k
k 1 VIN
A k
I k
3.3433 V I
k 1
IN
s DDH
QG , MH 0.5035
VIN
RON , MH (22)
IN IN IN max
TABLE II. INFLUENCE OF DIFFERENT INDUCTOR SERIES RESISTANCES ON determine the European efficiency for pre-selected discrete
THE EUROPEAN EFFICIENCY
transistors and Schottky diodes [12], [13], [14] listed in Tab.
RL [mΩ] 10 25 50 75 100 III and IV, respectively, and forming a discrete design space.
1 FIND [%]
In the first step, with a specific setup of the topology 1:
99.19 97.99 95.97 93.96 91.94
certain simple driver (without level shifting stage), diode–
“STPS5L25B”, L 10 μH , C 100 nF , esr 50 m˟ , and
iHSSW
neglecting inductor-based losses, efficiency simulations were
100% I IN max performed at different frequencies, so as to choose an
appropriate low-side switch. The best results were provided by
diode the part “IPD135N03L G”. Therefore, in the following step,
already selecting that transistor for both topologies (as they
synchronous should have the same optimal solution), further optimisation is
done in order to select an optimal high-side switch. Fig. 5
rectifier
C shows the results for the topology 1, and Fig. 6 for the
topology 2. Applied dead time amounts 1% of the switching
50% I IN max
period. Table V summarises the post-layout simulation results
obtained with the optimised low-side gate driver, designed in
the AMS 0.35μm HV CMOS process, and with the
30% I IN max
A B combination of external semiconductor switches which
20% I IN max provide the best European Efficiency at the specified
10% I IN max frequencies.
5% I IN max Not surprisingly, the two-MOSFET converter using the
VF HSSW largest MOSFETs gives the highest efficiency at 200 kHz. As
0
switching frequency becomes higher, switching losses
increase proportionally and advantage of synchronous
Figure 4. Comparison of high-side switch realisations. Arbitrary mutual rectification dissapears. So, there is a limitting switching
dependence is shown (illustration). Current values, i.e. operating points, used
in the definition of European Efficiency are highlighted.
frequency up to which synchronous rectification is a preferred
topology. Also, it is noticeable (Fig. 6) that the optimal
nting .lib models of commercially available external transistor at higher frequencies is not the same as the one at
semiconductor switches in readable form for the targeted 200 kHz. Although having more than two times larger on-
software. Specifications of the dc-dc converter are: nominal resistance (Tab. IV), it has a (slightly) smaller gate charge. It
input voltage 5 V, output voltage 12 V, and maximal input means that at higher frequencies the gate charge becomes
power 40 W. Circuit simulations were performed to obtain the more and more important factor.
converter efficiency graphs versus input current and to
TABLE III. DISCRETE N-CHANNEL MOSFET TRANSISTORS FOR EFFICIENCY COMPARISON (WORST-CASE VALUES)
Drain-Source On-resistance
Drain Current
Part Number Breakdown [mΩ]×Gate Package Manufacturer
(continuous) [A]
Voltage [V] Charge [nC]
BSO330N02K G 20 6.5 30×4.9 PG-DSO-8 Infineon
STP22NF03L 30 22 60×9 TO-220 ST Microelectronics
BSO300N03S 30 7.2 45×4.6 P-DSO-8 Infineon
BSO350N03 30 6 52×3.7 P-DSO-8 Infineon
STS15N4LLF3 40 15 7×28 SO-8 ST Microelectronics
STS6NF20V 20 6 40×11.5 SO-8 ST Microelectronics
IPD135N03L G 30 30 20.5×6.4 PG-TO252-3 Infineon
IPP147N03L G 30 20 21.7×4.8 PG-TO220-3-1 Infineon
ACKNOWLEDGEMENT
Financial funding from the Austrian BMVIT via FFG and the
ENIAC joint undertaking in the project E3Car is appreciated.
Figure 5. Comparison of high-side switches, 500 kHz (Topology 1). The authors especially thank to Mr. Paolo D’Abramo and Mr.
Harald Gall from austriamicrosystems AG for their support.
REFERENCES