Maximizing the Potential of WBG Devices for EV Battery Chargers

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1 Maximizing the Potential of WBG Devices for EV Battery Chargers Hua Kevin Bai Presentation for Knoxville, TN August 24 th, 2018

2 Battery Chargers- Si Version 11kW charger (grid side, 2011) (2010) 2/29 11kW charger (battery side, 2011) 2

3 Battery Chargers WBG Version DC-grid non-isolated charger, kW charger (GaN vs Si), kW charger (GaN vs SiC), V/11kW charger, /29 20kW SiC charger,

4 Puzzles Why do they sit on the desk collecting dust? What are their/my problems? What shall we fight for next? 4/29

5 Efficiency? 5 Juncheng Lu, Hua Bai, et al, A Modular Designed Three-phase High-efficiency High-power-density EV Battery Charger Using Dual/Triple-Phase-Shift Control, IEEE Transactions on Power Electronics, online. 5

6 Size? On-board Charger(Brusa vs ours) Off-board Charger(Two vendors vs ours) Juncheng Lu, Hua Bai, et al, A Modular Designed Three-phase High-efficiency High-power-density EV 6 Battery Charger Using Dual/Triple-Phase-Shift Control, IEEE Transactions on Power Electronics, online. 6

7 Pros and Cons Highest efficiency; Highest power density. Highest cost; Differentiation. Juncheng Lu, Allan Taylor, Guanliang Liu, Hua Bai*, et al, Applying Variable-Switching-Frequency Variable- Phase-Shift Control and E-mode GaN HEMTs To An 7 Indirect Matrix Converter based EV Battery Charger", IEEE Transactions on Transportation Electrification, vol.3, no.3, 2017, pp

8 My Team Debates OEMs/Investors High efficiency reduces the bill. Less than one meal per year High efficiency reduces the coolant usage We have coolant. Why not use it? High power density saves the space Love it, but has to be cheap High power density saves the weight Love it, but has to be cheap We offer multifunction Needs differentiation Can t you just be happy for our chargers? Because I need sell them 8/29

9 My Team Debates OEMs/Investors 9/29

10 Agenda Reducing the cost; Differentiation Design. 10/29 10

11 GaN Chargers Grid L grid Q 1 Q 3 Q 5 S 1 S 3 S 5 S 7 C BUS1 C r L r CBUS2 Battery Q 2 Q 4 Q 6 S 2 S 4 S 6 S 8 Three Phase PFC Full Bridge LLC Single-phase charger 4*8=32 pcs 14*2*$5=$140 (conventional design) Reduce the switch number? 1) Thermal challenge! 2) Market challenge! 4*8*3=96 pcs 96*$6=$576 11/29

12 Lessons Learned 1. Topology: eliminates caps, increases PD, shifts the stress to switches, adds cost; 2. Switch: expensive, thermal challenged, in need of parallelization, adds cost; 3. We care about: efficiency > power density > cost OEMs care about: cost > power density > efficiency 12/29

13 Hybrid Switch 2 GaN HEMTs Si MOSFET MCU PWM GaN Driver Delay V G_MOS MOSFET Driver GND Hybrid Switch Solution Rationale behind: 1. Si is cheap; 2. Si has more options; 3. The cost is reduced with no efficiency drop. 13/29

14 Challenges 1. Are we able to parallel fastest switches with slowest switches? 2 10V Si Gate -0V GaN Gate -10V -20V 14.5us 16.0us 18.0us 20.0us V(GaN_top1:GATEIN,C15:1) V(Si_top1:GATE,GaN_top1:SOURCEIN) Time 14/29

15 Challenges 1. Are we able to parallel fastest switches with slowest switches? 20 - Rg=3 - Cgs=1nF Voltage undershoot TO247 TO264 D 2 PAK HSOF-8 Packages 15/29

16 Challenges 2. How much cost can we on earth save? Are Si automotive qualified? GaN HEMTs: $6 Exotic packaged Si (HSOF-8): $5! Delay Chip: $1. D 2 Pak Si: $3 (-$3*2*8*3=-$144) Liyan Zhu and Hua Bai, Transient Analysis in Gate-Drive Loops of GaN+Si Hybrid Switches", IEEE 6th 16 Workshop on Wide Bandgap Power Devices & Applications, 2018;

17 Hybrid Switch fs= 100kHz, Vin= 400V, I peak = 80A T GaN 50, T heatsink 35, T diff 15 17/29

18 Challenges 3. Can we save more? GaN HEMTs: $6 Si D 2 Pak Si: $3 1 GaN + 2 Si: -$(3*2+6)*8*3=-$288 GaN Liyan Zhu and Hua Bai, Transient Analysis in Gate-Drive Loops of GaN+Si Hybrid Switches", IEEE 6th 18 Workshop on Wide Bandgap Power Devices & Applications, 2018;

19 Agenda Reducing the cost; Differentiation Design. 19/29 19

20 EV Charger Can we create our own grid? Solar+ G2V Solar to Grid V2G Chenguang Jiang, Hua Bai*, et al, The Power-Loss Analysis and Efficiency Maximization of A Silicon-Carbide MOSFET Based Three-phase 10kW Bi-directional EV 20 Charger Using Variable-DC-Bus Control, Journal of Emerging and Selected Topics in Power Electronics, vol.4, no.3, 2016, pp

21 V2L Charger EV Isolated DC/DC Converter CN1 ic1 ic2 o CN2 uc1 icn uc2 in iln sn1 LN sn2 sa1 sa2 sb1 sb2 sc1 sc2 Lf Lf Lf ia ib ic Cf Cf Cf Creating stable N Creating stable 3Ф V V + - C 1 u N N1 + - u N 2 N C N 2 S 1 u ph S 2 ilf R f Lf u Cf Cf + - C f i O i - Local Load uph L s R f f ilf + io icf 1 Cf s ucf 21/29

22 u spwm = i L u spwm s = u c u spwm s = 1 j ω C //R L V2L Charger + j ω L i L (t) R L C s + 1 L C R L s 2 + L s + R L u c i L s = R L R L C s + 1 R L R L L C s 2 + L s + R L RL=100Ω RL=1Ω RL increasing L:120uH C: 4.7uF RL=1Ω fr=6.6khz RL=100Ω 22/29

23 V2L Charger R L = R L R v R L + R v Virtual Resistance i Lf R f L f u ph R v C f i ph i Cf u c_v u spwm_v s = R v L C s 2 + R v R v R L + 1 L s + R v Yongsheng Fu, Yang Huang, Hua Bai, et al, A High-Efficiency SiC Three-Phase Four-Wire Inverter with Virtual Resistor Control Strategy Running at V2H Mode, IEEE 23 6th Workshop on Wide Bandgap Power Devices & Applications, 2018;

24 V2L Charger

25 V2L Charger Mag(% of Fundamental) Fundamental frequency Resonant frequency Without Virtual Resistor Switching frequency Frequency (khz) Mag(% of Fundamental) Fundamental frequency With Virtual Resistor Switching frequency /

26 Summary Academia: efficiency > size > cost; Automotive OEMs: cost reliability > size > efficiency; Hybrid-switch solution is a intermediate solution; V2L and V2H functions will be emphasized more; What s the next for the EV charger? 26/29

27 Acknowledgement EV OEM Tier-I Tier-2 Entrepreneur Government 27/29

28 Acknowledgement Invitation of CURENT; Students: Yang Huang, Liyan Zhu Philip Mike Johnson, Allan Taylor Guanliang Liu, Juncheng Lu, etc. 28/29

29 Thank you! Questions? 29/29

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