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Fuel Cell Inverter: Circuit Design and Control

Fuel Cell Inverter: Circuit Design and Control. M. J. Khan, M. Ordonez, M. T. Iqbal, and J. E. Quaicoe Faculty of Engineering and Applied Science Memorial University of Newfoundland, St. John’s, NL, A1B 3X5. First AIF Research Forum

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Fuel Cell Inverter: Circuit Design and Control

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  1. Fuel Cell Inverter: Circuit Design and Control M. J. Khan, M. Ordonez, M. T. Iqbal, and J. E. Quaicoe Faculty of Engineering and Applied Science Memorial University of Newfoundland, St. John’s, NL, A1B 3X5 First AIF Research Forum "Beyond Kyoto – Atlantic Sustainable Power R & D Initiatives" May 19, 2006 University of New Brunswick, NB

  2. Outline • Fuel Cell Systems • Power Converters • Design & Control Challenges • State of the Technology • MUN-FC Inverter Project • Design & Development • Summary

  3. Fuel Cell Systems • Polymer Electrolyte Membrane (PEM) fuel cells are mostly considered • Electricity produced directly from electrochemical reaction • Stationary applications (residential/DG) are being widely studied • Performance is of non-linear nature Ballard NexaTM Characteristics

  4. Fuel Cell Power Converter • Variable DC output needs to be adjusted for grid/load conditions • Suitable power converter is required for effective interfacing

  5. Design & Control Challenges • Fuel Cell - Power Stage Interface • Low frequency ripple and backward current injection • Storage - Power Stage Interface • Auxiliary energy storage device (Battery, Ultracapacitor) • The Power Stage • Robustness, efficiency, cost, size and weight • Power Stage-Grid/Load Interface • Performance, safety and power quality issues

  6. State of the Technology • Commercial Systems • DRS Pivotal Power (www.pivotalpower.com) • Sustainable Energy Technologies Ltd. (www.sustainableenergy.com/) • Magnetek Power Electronics Group (www.magnetekpower.com/) • TDI Power System Solutions (www.tdipower.com/) • Ballard Power Systems Inc. (www.ballard.com) • Exploratory Systems • Texas A&M University, College Station,(http://enjeti.tamu.edu) • Colorado School of Mines, (http://egweb.mines.edu/faculty/msimoes/) • University of Central Florida, (http://floridapec.engr.ucf.edu/index.asp) • Michigan State University (http://www.egr.msu.edu/pelab/)

  7. MUN-FC Inverter Project • Targets • Approach • Capacity building • Initial prototype • Intermediate prototype • Final prototype • Timing • 2004-2006 • 2006-2007 • 2007-2008

  8. MUN-FC Inverter Project • Brief topology review DC-DC boost + Inverter + LF-Transformer DC-AC inverter + LF Transformer High Frequency Resonant Converter-PWM Inverter

  9. Design & Development • Selected topology

  10. Design & Development (Cont’d) • Challenges Prototype # 1: ZVS Phase-Shifted DC/DC converter ( ~200 kHz, Off-the-shelf magnetics) Hard-switched DC/AC inverter (Isolated load) ……………………….. Work temporarily withheld Prototype # 2: Hard switched DC/DC converter ( ~25 kHz, Custom magnetics) Hard-switched DC/AC inverter (Isolated/Grid-connected load) .. ……………………….. Work in-progress

  11. Design & Development (Cont’d) • Power stages Prototype # 2 • Optimal spacing & comp. sizing • Expected quality performance Prototype # 1 • Rudimentary design • Limited performance

  12. Design & Development (Cont’d) • Driver Circuits HCPL 3120 based driver (IGBT-Opto-isolation) Phase Shift driver (Galvanic Isolation) HCPL 316J based driver (Opto-isolation) HCPL 3120 based driver (MOSFET-Opto-isolation) HCPL 3120 based driver (with current buffer) HCPL 3120 based driver (compact design)

  13. Design & Development (Cont’d) • Auxiliary power Miniature DC-DC converter based Miniature DC-DC converter (expaned) Switching power supply with TI’s DC-DC on-board converter

  14. Design & Development (Cont’d) • Other peripherals TI’s DSP controller Payton’s magnetics Custom magnetics Thermal management Voltage sensor Current sensor

  15. Summary General • Commercial inverters: Performance vs. Cost issue • Research oriented designs: Minute improvement vs. Overall goal • Blend of two domains need to be achieved MUN FC-Inverter project • Significant achievement in capacity building • Valuable lessons learned • Development in full-swing ASPRI involvement • Clearer goals need to be outlined • Greater collaboration needed • Technical know-how need to be exchanged

  16. Further information • M. J. Khan, M. T. Iqbal, J. E. Quaicoe, ‘Design and Development of a MOSFET Driver Circuit for Phase-Shifted Zero-Voltage-Switching Full-Bridge DC-DC Converter’, NECEC 05, November 2005, St. John’s, Newfoundland. • M. J. Khan, M. T. Iqbal, J. E. Quaicoe, ‘Utility interactive fuel cell inverter for distributed generation: design consideration and experimental results’, CCECE05, May 1-4, 2005, Saskatoon, Saskatchewan, Canada • M. J. Khan, M. T. Iqbal, ‘Design Considerations of a Utility Interactive Fuel Cell Inverter’ presented at IEEE 13th, NECEC conference, St. John’s NL, 2004

  17. Acknowledgement • Faculty of Engineering & Applied Science, MUN, NL • AIF/ACOA • Blue Line Innovations Inc.

  18. Thank you • Q/A

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