Super-Capacitor (SC) modules are crucial in Hybrid Energy Storage Systems (HESS) designed for robotics. This paper details their implementation, with a significant emphasis on the synergy between SCs and batteries to address demanding power requirements. It focuses on SC aging resulting from high temperatures. A systematic approach to voltage selection, encompassing optimal operating parameters, durability projections, and energy efficiency is presented. The equilibrium between power demands and SC capacities is achieved through considerations of intermediate voltage, energy fluctuations, and filtering techniques. The significance of module capacitance is highlighted, employing data-driven techniques to select optimal cell capacitance across various scenarios. In summary, this data-driven approach seamlessly integrates theory, empirical measurements, and meticulous design, effectively engineering SC modules within HESS for cutting-edge robotic applications.

In this paper, the design of a modular high-power transformer for constant gain LLC converter used in 2-stage Fast EV charger is investigated. Two modular approaches are compared, input-parallel-output-parallel (IPOP) and input-series-output-parallel (ISOP) transformers with stacked cores. The Pareto optimization of total power losses and volume is applied to evaluate different modular designs. The design method based on Ansys PExprt software tool is developed and explained. Finally, the selected design is validated by 3D FEA thermal simulation in ICEPAK.

In this publication, specifications of a modular fast EV charging converter are selected based on standards and the state-of-the-art. According to these specifications, a 2-stage cascaded conversion approach is proposed, with separated isolation and charging regulation stage. This enables the design optimization of the each stage for different functionality. Furthermore, a partial power (PP) processing is implemented in the regulation stage to improve the efficiency. Two different 2-stage isolated topologies using PP structure are proposed, employing either 2 or 3 voltage levels. The converters use SiC or Si devices, depending on the voltage stress on the devices for each topology. Additionally, the gain of the PP converter of the regulation stage and the turns ratio of the transformer are analyzed and optimized to reduce the RMS of inductors and switches, as well as the inductor peak energy. The design calculations are done considering full-ZVS condition on all switches, except for the balancer switches with applied ZCS instead. Finally, the two topologies are compared and discussed.

Nowadays, high-speed turbines for electric power generation represent a good idea for commercial, industrial and military applications, where small size and lightweight, low maintenance, reliability in a wide range of environments and good efficiency are required. However, the main equipment in such power generating units are the electrical generator systems, the AC-DC power electronic converter and the output inverter, when AC output load is unavoidable. Multi-level power electronic topologies have been under research and development for more than one decade and have been found successful in variable-speed drive applications. The new power converter topology, called Five-Level E Type Inverter (5L E-Type Inverter), is presented and analyzed in this paper with reference to the back-to-back configuration with a multi-level rectifier. The thermal models of the IGBTs and diodes have been created taking into account the parameters provided by the manufactures and employing multi-dimensional look-up tables in Plexim/PLECS environment. Simulation results are performed through Matlab/Simulink in order to evaluate efficiency and losses distribution for switches and diodes of the proposed 5L E-Type inverter configuration.

One of the main problems in autonomous electric vehicles is the energy storage, because a high autonomy and high power condition demand large mass, big volume and high cost of the storage unit. Consequently, in order to avoid power losses and to downsize the storage unit and the electric systems, the electric power train in the vehicle must be as efficient as possible. This paper proposes a methodology to optimize the efficiency of a DC-DC converter that interface the storage unit with the motor's drive. In this way, with the purpose of increasing the efficiency, this methodology combines three techniques: 1) The use of low-loss components such as Si CoolMos, GaN and SiC diodes and Mosfets, and Multilayer Ceramic Capacitors, 2) a complete power loss analysis as a function of the switching frequency and a calculation method of core losses based on the approximation of Fourier Series, and 3) the Area Product Analysis of magnetic components. With this methodology, it is possible to achieve high efficiency and high power density, which is suitable for automotive applications. The methodology has been verified with a set of tests on a 1kW prototype. As a result of the proposed methodology, a power efficiency of 99% was experimentally obtained.

A single-phase diode boost rectifier is proposed in this paper. The core of the proposed rectifier is a multi-switch dc-dc converter with two terminals; an input and an output. The input is parallel-connected with the dc bus capacitor, while the output is connected between the rectifier plus rail and the dc bus plus rail. The converter controls the rectifier current and the dc bus voltage. The rectifier current is controlled constant or pseudo-constant in order to reduce the input current total harmonic distortion (THD). The dc bus voltage is boosted above the mains peak voltage. In contrast to the ordinary single-switch boost rectifiers, the switches of the proposed boost rectifier are rated on a fraction of the dc bus voltage and a fraction of the input current. It makes this topology compact and efficient. Power rating, size and losses depend on the dc bus voltage to rectifier voltage ratio. For example, if the ratio is low, the efficiency is 98 to 99%. The proposed boost rectifier has been analyzed and experimentally verified on a 4 kW prototype variable speed drive. The results are presented and discussed.