Department of Engineering

1. Department of Engineering Design and Implementation of the Digital Controller for a Fuel Cell DC-DC Power Converter system O.A. Ahmed, J.A.M. Bleijs

2. 2 • presentation Outline • Introduction • Dynamic Performance of PEMFC • FC Converter Features • Controller Design • Simulation Results • Control Algorithm Implementation • Converter System Implementation • Conclusions

3. Introduction 3 DC Microgrid Power System

4. Introduction 4 • DC Microgrid may comprise of : • A dispatchable power generator, such as the fuel cell (FC) or a back-up diesel generator. • Non-dispatchable sources, such as solar PV • and wind turbines. • Energy storage, such as ultra-capacitor or battery. • The overall efficiency of the distributed system depends on efficiency of power electronic converters. • To obtain a cost-effective converter solution: • High efficiency. • Low cost. • Robust control system

5. objective 5 Dynamic Response Analysis and Modeling of a Ballard Nexa 1.2kW PEMFC Development of a Two-Loop Controller for a High Efficiency FBCFC for a FC generator Digital Controller Design Based on a TMS320F2812 DSP

6. Dynamic Performance of PEMFC 6 • Nexa data acquisition system is inadequate to show actual response. • Fast-acting switches and high speed transducers are used. • The gross stack current is 1.3 of the nominal current. Experimental Dynamic Response Set-up for PEMFC

7. Dynamic Performance of PEMFC 7 Data log file Accurate transient response using experimental set-up

8. Dynamic Performance of PEMFC 8 Fuel cell model of test with resistive load

9. Dynamic Performance of PEMFC 9 Simulated Transient Response of FC model

10. FC Converter Features 10 FBCFC for FC system • The clamp switch gives zero voltage switching (ZVS) for all switches at turn on and alleviates the usual voltage ringing across the bridge switches (S1~S4); • At turn off the voltage across all switching devices is clamped to the capacitor voltage. • The output rectifier diodes operate with zero current switching (ZCS). • Full bridge with voltage doubler technique results in reduced voltage across output capacitors and diode rectifier. • Minimizes the voltage rating of the semiconductor devices. • Reduces the turn ratio of high frequency transformer to half that of the conventional FBCFC. • Untapped secondary winding transformer simplifies the transformer construction, improves window utilization, and results in lower leakage inductance.

11. Controller Design 11 • Initially an analogue PI was designed for the FBCFC based on its small signal transfer functions . • Digital average current (DAC) mode control and predictive current control (PCC) techniques can be used for the system. • Since FC takes 0.24 second to respond after a sudden load application from no-load DAC is selected without need for a complex control algorithm. Two-loop PI digital controller

12. Controller Design 12 • The designed digital controller takes into account the sampling delay (Hsmp) and the computation delay (Hc). • Two PI controllers with anti-windup protection were designed and their optimal parameters obtained using the Control Design Toolbox in Matlab. • Based on the designed digital controller loop for the FBCFC, the transfer function for the current, voltage and overall open loop response of the system are obtained .

13. Controller Design 13 • The plot indicate that inner loop Cid(z) gain has a desired crossover frequency at 5kHz with a phase margin of 590. • Digital PI parameters for Cid(z) are: Kpc= 0.1147, and Kic= 506.66. Bode Plot of Current Controller Open Loop

14. Controller Design 14 • To accommodate the slow FC response, low bandwidth is used for voltage loop Cvi(z). • The voltage loop has a crossover frequency of 149Hz and a phase margin of 58.70. • Digital PI parameters for Cvi(z) are: Kpv = 1.08625, • Kiv = 100.748 Bode Plot of Voltage Controller Open Loop

15. Controller Design 15 • Due to the active clamp the resonance is absence. • The plots show that the bandwidth and phase margin of the controller system are designed as desired. Bode Plot of Overall Open Loop System

16. simulation results 16 • The simulated dynamic response of the converter at sudden load changes shows that the voltage recovers to its steady-state value within 15m sec. Output voltage waveform during load changes • Designed PI digital controller has been implemented in a DSP; the on-chip ADC converter, PWM “compare function” and other functions were emulated in Simulink.

17. control algorithm implementation 17 • IQ math library in CCS is used for the PI compensators, ADC results and ADC and PWM scaling factors. • The number of GP timers in a DSP is limited to four. The PWM signals for all switches are generated using only one GP timer with dead-band zone. Flow chart of the overlap PWM algorithm for FBCFC

18. control algorithm implementation 18 Fbk Software block diagram of 32-bit PI digital control for voltage and current loop

19. converter system implementation 19 • The sampling frequencies are chosen 20 kHz for the current-loop and 2.5 kHz for the voltage-loop controllers. • The FBCFC without clamp circuit shows high voltage overshoots across the MOSFETs resulting in increase switching and conduction losses and reducing the converter’s efficiency. FBCFC with voltage doubler but without clamp circuit: secondary voltage (ch3), drain-source voltage across S1 (ch4) Proposed FBCFC: primary voltage (ch3), FC current (ch4), clamp switch voltage (ch2)

20. converter system implementation 20 Simulated and Experimental Converter Efficiency

21. conclusions 21 • FC experiments showed that the number of measurement points using Nexa log file is not sufficient to plot the accurate transient response characteristics of the FC stack. It is observed that the modelled FC matches very well with the real FC system results • A two-loop digital controller with anti-windup protection has been developed for a 1.2kW active clamp FBCFC topology with a voltage doubler. • The experimental results have validated the accurate modelling for the FC converter system. • Simulation and practical measurements of the proposed converter and other configurations at different loads have shown that the proposed configuration has the highest efficiency.

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