Modelization and experimental validation of CHB inverters for EVs and efficiency comparison with IGBT and SiC inverters on realistic driving cycles

Pongnot, Gaël; Desreveaux, Anatole; Mayet, Clément; Labrousse, Denis · 2024 · Crossref

DOI: 10.36227/techrxiv.171043141.19227108/v1

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Summary

This study addresses the need for improved energy efficiency and range in electric vehicles (EVs) by evaluating Cascaded H-Bridge (CHB) inverters as an alternative to conventional two-level inverters (2LI). While CHB architectures offer modularity and resilience, their efficiency relative to standard Insulated Gate Bipolar Transistor (IGBT) and Silicon Carbide (SiC) inverters has not been comprehensively assessed across the entire powertrain. The authors aim to fill this gap by modeling and experimentally validating a 49-level CHB inverter using low-voltage Si MOSFets and comparing its consumption against 2LI systems during realistic driving cycles. The methodology employs Energetic Macroscopic Representation (EMR) to model the system, separating electrical and mechanical dynamics to reduce computation time. The CHB prototype consists of 24 modules per phase, each containing four battery cells and an H-bridge, totaling 288 cells. The system utilizes Nearest Level Control (NLC) to minimize switching losses. The model accounts for losses in batteries, power electronics, and the permanent magnet synchronous machine (PMSM). Experimental validation was conducted on a static prototype with a 30 kWh battery capacity, testing three operating points ranging from 2000 to 5200 rpm. The simulation results closely matched experimental data, with efficiency deviations of less than two percentage points. The study compares the CHB inverter with IGBT and SiC-based 2LI inverters across various driving cycles. The CHB configuration allows for the use of low-voltage MOSFETs with reduced on-resistance, though it requires a higher number of battery cells to achieve grid-compatible voltages. The analysis considers all loss sources from the battery to the road, including battery internal resistance and switching losses. Results indicate that while the CHB architecture incurs increased battery losses due to the higher number of cells and current interactions, it achieves a net reduction in energy consumption during urban driving cycles compared to the 2LI counterparts. The significance of this work lies in demonstrating that CHB inverters are a compelling choice for sustainable commuter vehicles, particularly in urban environments where frequent stops and starts characterize the driving profile. By integrating energy storage directly with power electronics, the CHB structure eliminates the need for an onboard charger and supports Vehicle-to-Grid applications. The study concludes that a systemic approach, accounting for the interaction between batteries and electronics, is essential for accurate efficiency evaluation, revealing that the benefits of reduced switching losses and improved waveform quality in CHB inverters can outweigh the penalties of increased battery losses in specific usage scenarios.

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