Hongzhi Cui

Department of Electrical Engineering

Hongzhi Cui
12/14/2020

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Abstract
This project is about to design a traction drive system for an electric vehicle. In Figure.1,
it shows the key parameters of electric car system. The battery output range is from 300V to
500V. The DC/DC converter is boost converter with bi-direction power flow. The DC/DC converter
is required 600V constant output voltage, the power flow is bi-directional capability. DC/AC
inverter is three phase inverter structure. Switching frequency of the DC/DC converter is 10kHz,
and Switching frequency of the inverter is 5kHz. In the traction drive system, there are three
typical operation points which are Maximum power with maximum torque, High speed with low
torque and low speed with high torque.

Figure 1. Drive system for an electric vehicle

Introduction
Three typical operation points need in the drive system for the electric vehicle. In Maximum
power with maximum torque, the Inverter output power is 75000W with 160A(RMS) inverter
based current. Power factor is 0.8 and fundamental frequency is 400Hz. High speed with low
torque, the Inverter output power is 50000W with 120A(RMS) inverter based current. Power
factor is 0.8 and fundamental frequency is 800Hz. low speed with high torque, the Inverter
output power is 25000W with 250A(RMS) inverter based current. Power factor is 0.8 and
fundamental frequency is 40Hz. (Table.1)

Table 1. Three Typical Operation Points

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Part 1

DC/DC converter, the Duty Ratio equation is

𝐷 = 1 − 𝑉𝑖𝑛 /𝑉𝑜𝑢𝑡 (1)

D1 = 1 – 300/600 = 1/2

D2 = 1 – 500/500 = 1/6

The duty ratio is D is defined as the on Time of S2 Figure 2. DC/DC Boost Converter

The duty ratio range of the DC/DC converter is [1/6, 1/2].

Part 2
The maximum allowable peak to peak current ripple through the inductor is 100A.

Following equation (2).

𝐷∗ 𝑉𝑖𝑛 ∗𝑇𝑠
𝐼𝑝𝑝 = (2)
𝐿

Thus;

𝐷 ∗ 𝑉𝑖𝑛 ∗ 𝑇𝑠
𝐿=
𝐼𝑝𝑝

L = (0.5 *300*(1/10000))/100 = 150 Uh

Part 3

Modulation indexes for the three operation condition (3),

𝑉
𝑀𝑜𝑑𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑖𝑛𝑑𝑒𝑥 (𝑚𝑎 ) = 𝑉𝑐𝑜𝑛𝑡𝑟𝑜𝑙 (3)
𝑐𝑎𝑟𝑟𝑖𝑒𝑟

In Maximum power with Maximum torque,

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Ma = (75000/160) / (600) = 0.78125

In High speed with low torque,

Ma = (50000/120) / (600) = 0.6744

In Low speed with high torque,

Ma = (25000/250) / (600) = 0.0.1667

Part 4

An equivalent three-phase RL load can be used to

𝑃(𝑅𝑒𝑎𝑙 𝑃𝑜𝑤𝑒𝑟)
𝑃𝑜𝑤𝑒𝑟 𝐹𝑎𝑐𝑡𝑜𝑟 = 𝑃(𝐴𝑝𝑝𝑎𝑟𝑒𝑛𝑡 𝑃𝑜𝑤𝑒𝑟) (4 - 1) Figure 3. AC/DC Three Phase Inverter

𝐼2 𝐼2 𝐼2
𝑃(𝑅𝑒𝑎𝑙 𝑃𝑜𝑤𝑒𝑟) = Q(Active Power) = = 2∗𝑝𝑖∗𝑓∗𝑋 (4 -2)
𝑅 𝑋𝐿 𝐿

In Maximum power with Maximum torque,

P(real power) = 75000 * 0.8 = 60000 W

R = 60000/(160^2) = 2.34375 Ohm

PL = √750002 − 60000^2 = 45000 W

L = 45000 / (160^2 * 2 * π *400) = 6.99e^-4 H

In High speed with low torque,

P(real power) = 50000 * 0.8 = 40000 W

R = 40000/(120^2) = 2.777 Ohm

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PL = √500002 − 40000^2 = 30000 W

L = 30000 / (120^2 * 2 * π *800 ) = 4.1446e^-4 H

In Low speed with high torque,

P(real power) = 25000 * 0.8 = 20000 W

R = 20000/(250^2) = 0.32 Ohm

PL = √250002 − 20000^2 = 15000 W

L = 15000 / (250^2 * 2 * π *40 ) = 9.549e^-4 H

Part 5

Simulate the DC/AC inverter at the three operation conditions (Figure.5 -1) by using Simulation
tool Typhoon. Assume sinusoidal triangular PWM. In each operation point, shows the load
currents (Figure.5-2), line-line inverter output voltage(Figure.5-3), one phase voltage (Figure.5-
4), V2 (Figure.5-5)and iL (Figure.5-6).

Figure 5-1. Three Phase DC/AC Inverter at Three Operation

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Figure 5-2. Loads Current at three operation condition

Figure 5-3. Line- Line inverter Output Voltage

Figure 5-4. One Phase Voltage

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Figure 5-5. V2 Voltage Signal

Figure 5-6. iL Current Signal

Part 6
IGBT module CM600DY-24A is used in the DC/DC converter. From the CM600DY-24A datasheet
and inductance form Part 2, calculate the power loss of S2 and D1 at the case that D = 0.5 and
batter output power is 75Kw.

Power switch loss = Switching loss (6 – 1) + conduction loss (6 – 2)

PSwitching loss = Eon * fsw (6– 1)

Pconduction loss = 𝑉𝑐𝑒 ∗ 𝐼𝑐𝑎𝑣 (6 – 2)

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Eon (Reverse-recovery energy) = (4 ∗ 𝑄𝑟𝑟 ∗ 𝑉𝑑𝑟𝑟 ) (6 - 3)

Eon (Reverse-recovery energy) = 0.25 * 19 * 10^-6 * 600 = 0.00285

PSwitching loss = 0.00285 * 5000 = 14.5 W

Part 7
Based on the data sheet and results from part 6, to decide the maximum heat sink thermal
resistance with maximum allowable junction temperature is 125 degree C and the ambient
temperature is 25 degree C.

Rth = (𝑇𝑗 − 𝑇𝑎 )/ 𝑃𝑠𝑤𝑖𝑡𝑐ℎ 𝑙𝑜𝑠𝑠 (7 – 1)

Rth = (125 – 25) / 19113W = 0.00523 C/W

Part 8
From the IGBT application note, to calculate power loss of three phase inverter. Assume the
DC/DC converter would be cooled separately, based on power loss calculation. Select the IGBT
for the DC/AC inverter from Powerex.

a) 1200 V IGBT modules with current capability equal or greater than 400A shall be
evaluated. Start with 1200 V standard frequency single and dual modules
- (Item Number FS450R12KE3).
b) Calculate the power loss of the inverter for all three operation conditions

Power loss = Switching loss (8 – 1) + conduction loss (8– 2)

PSwitching loss = Eon * fsw (8– 1)

Pconduction loss = 𝑉𝑐𝑒 ∗ 𝐼𝑐𝑎𝑣 (8 – 2)

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Eon (Reverse-recovery energy) = (4 ∗ 𝑄𝑟𝑟 ∗ 𝑉𝑑𝑟𝑟 ) (8 - 3)

Maximum Power and Maximum Torque

Eon (Reverse-recovery energy) = 0.25 *45 * 10^-6 * 600 = 0.00675

PSwitching loss = 0.00675 *400 = 2.7 W

Pconduction loss = (1200/2)*160* (1/2*π) = 15278.5 W

Power Loss = 2.7 + 15278.5 = 15281.2 W

High Speed with Low Torque

PSwitching loss = 0.00675 *800 = 25.4 W

Pconduction loss = (1200/2)*120* (1/2*π) = 11459W

Power Loss = 5.4 + 11459 = 11464.4 W

Low Speed with High Torque

PSwitching loss = 0.00675 *40 = 0.27 W

Pconduction loss = 1200/2*250* (1/2*π) = 23873 W

Power Loss = 0.27 + 23873 = 23873.27 W

c) Based on b), take the operation condition with highest power loss, calculate the thermal
resistance of the cold plate assuming the IGBT junction temperature is 125degree C and
the coolant temperature is 25 degree C. The calculated cold plate thermal resistance is
greater than 0.003 degree C/W.

Rth = (𝑇𝑗 − 𝑇𝑎 )/ 𝑃𝑠𝑤𝑖𝑡𝑐ℎ 𝑙𝑜𝑠𝑠 (8 – 4)

Rth = (125 – 25) /23873.27 W= 0.004188 C/W

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Part 9

Based on final selection of the IGBT, calculate the minimum power needed by the gate drive
circuit.

PGATE = 𝑉𝑑𝑟𝑣 ∗ 𝑄𝑔 ∗ 𝑓𝑑𝑟𝑣 (9 – 1)

Where Vdrv is the amplitude of the gate drive, Qg is total gate charge and fdrv is the gate -drive
frequency

Pgate = 15 * 4.3*10^-6 * 40 = 0.00258 W

Conclusion

To design a traction drive system for an electric vehicle requires the DC/DC converter is
boost converter with bi-direction power flow and DC/AC three phase inverter. Three typical
operation points are Maximum power with maximum torque, High speed with low torque and
low speed with high torque and using Typhoon Simulation simulated DC/AC three phase inverter
to achieve three operation points. The power loss of the IGBT is based on the variation of current,
voltage and temperature.

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