A Low-Cost Soft-Switched DC/DC Converter for Solid-Oxide Fuel Cells

Jason Lai

关键词: BATTERY CHARGING;    CAPACITY;    COMPUTERIZED SIMULATION;    CYLINDERS;    DC TO DC CONVERTERS;    DESIGN;    EFFICIENCY;    EQUIPMENT;    FUEL CELLS;    INTERNAL COMBUSTION ENGINES;    OPERATION;    OPTIMIZATION;    PERFORMANCE;    PRODUCTION;    SIZE;    SOLID OXIDE FUEL CELLS;    TOPOLOGY;    TORQUE;    USES;   

DOI  :  10.2172/1005232
RP-ID  :  None
PID  :  OSTI ID: 1005232
Others  :  TRN: US201106%%80

美国|英语

来源: SciTech Connect

【 摘 要 】

A highly efficient DC to DC converter has been developed for low-voltage high-current solid oxide fuel cells. The newly developed 'V6' converter resembles what has been done in internal combustion engine that split into multiple cylinders to increase the output capacity without having to increase individual cell size and to smooth out the torque with interleaving operation. The development was started with topology overview to ensure that all the DC to DC converter circuits were included in the study. Efficiency models for different circuit topologies were established, and computer simulations were performed to determine the best candidate converter circuit. Through design optimization including topology selection, device selection, magnetic component design, thermal design, and digital controller design, a bench prototype rated 5-kW, with 20 to 50V input and 200/400V output was fabricated and tested. Efficiency goal of 97% was proven achievable through hardware experiment. This DC to DC converter was then modified in the later stage to converter 35 to 63 V input and 13.8 V output for automotive charging applications. The complete prototype was tested at Delphi with their solid oxide fuel cell test stand to verify the performance of the modified DC to DC converter. The output was tested up to 3-kW level, and the efficiency exceeded 97.5%. Multiple-phase interleaving operation design was proved to be reliable and ripple free at the output, which is desirable for the battery charging. Overall this is a very successful collaboration project between the SECA Core Technology Team and Industrial Team.