Hybrid electric vehicle fuel minimization by DC-DC converter dual-phase-shift control

The paper introduces an advanced DC-link variable voltage control methodology that improves significantly the fuel economy of series Hybrid Electric Vehicles (HEVs). The DC-link connects a rectifier, a Dual Active Bridge (DAB) DC-DC converter and an inverter, interfacing respectively the two sources and the load in a series HEV powertrain. The introduced Dual Phase Shift (DPS) proportional voltage conversion ratio control scheme is realized by manipulating the phase shifts of the gating signals in the DAB converter, to regulate the amount of DAB converter power flow in and out of the DC-link. Dynamic converter efficiency models are utilized to account for switching, conduction, copper and core losses. The control methodology is proposed on the basis of improving the individual efficiency of the DAB converter but with its parameters tuned to minimize the powertrain fuel consumption. Since DPS control has one additional degree of freedom as compared to Single Phase Shift (SPS) voltage control schemes, a Lagrange Multiplier optimization method is applied to minimize the leakage inductance peak current, the main cause for switching and conduction losses. The DPS control scheme is tested in simulations with a full HEV model and two associated conventional supervisory control algorithms, together with a tuned SPS proportional voltage conversion ratio control scheme, against a conventional PI control in which the DC-link voltage follows a constant reference. Nonlinear coupling difficulties associated with the integration of varying DC-link voltage in the powertrain are also exposed and addressed.