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AbstractThis paper presents the development of a power interface for a fuel cell (FC) system supplying an ac load. The proposed system comprises a two stages conditioning system, including a switched capacitor dcdc boost converter and a full bridge
insulated-gate bipolar transistor (IGBT) single-phase inverter
(dcac converter). A fully digital control structure is proposed to
manage both power converters using the same control device. The
control strategy takes advantage of the parallelism of the field programmable gate arrays (FPGA) technology to share in real-time the
controllers information addressing the common problem of lowfrequency ripple of FC current when supplying ac loads. The control system has been implemented and evaluated by co-simulation,
and by experimentation with a proton exchange membrane fuel
cell (PEM-FC) system. The results show that the proposed system
allows a safe operation of the FC by limiting the current ripple
under 3%. These results also confirm that the transient response
of the conversion system permits to correctly supply the ac load.
Index TermsCurrent ripple, energy conversion, fuel cells
(FCs), neural networks, power electronics, programmable logic
arrays.
I. INTRODUCTION
UEL CELLS (FCs) are nowadays proposed as clean energy sources for stationary and mobile power applications.
Commonly stationary applications of FC are stand-alone and
grid-tied power systems [1], [2]. Power conditioning systems
(PCSs) are employed to interface FC voltage with ac loads. The
PCS includes a dcdc boost converter to adapt the FC dc output
voltage, which is normally below 50 V, to a higher dc voltage,
and a dcac converter in order to produce the ac voltage to
supply the load.
Low-frequency current ripple is a commonly related problem
in the literature, which appears when FC systems are employed
to supply ac loads. Several studies have proven that the current ripple affects the FC life duration, as well as the available
output power and its efficiency [3][6]. Those studies on one
hand reveal that an energy-efficient operation of an FC system
imposes that the current ripple must be limited to 20%. On the
Manuscript received February 3, 2014; revised May 30, 2014 and August
11, 2014; accepted August 13, 2014. Date of publication September 4, 2014;
date of current version February 16, 2015. This work was supported in part
0885-8969 2014 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications standards/publications/rights/index.html for more information.
CARDENAS et al.: DEVELOPMENT OF POWER INTERFACE WITH FPGA-BASED ADAPTIVE CONTROL FOR PEM-FC SYSTEM
Fig. 1.
297
Fig. 2.
2
.
1D
(3)
The control of the dcdc and dcac power electronics converters when the system operates as autonomous power source
must allow a good transient response and a steady-state behavior according to the standards [30]; moreover, as mentioned earlier, the low-frequency ripple of FC current must be controlled
to be below 4%. In particular, the 120-Hz oscillation must be
298
Fig. 5.
General diagram of the developed power electronics interface for PEM-FC system.
TABLE I
SYSTEM CHARACTERISTICS
Description
PEM-FC
HydrogenicsHyPMXR8
Rated power
DC output voltage
DCDC converter
Type
Working input voltage range
Maximum output voltage
Input capacitor (LVC)
Input inductors (L1 , L2 )
Switched capacitors (SC1, SC2)
Output capacitor (C3)
Filter inductor (L3 )
Filter capacitor (HVC)
Switching frequency
Power switching devices: Ultrafast diode
IGBT
DCAC Converter
Bridge Type
Rated voltage/current
Nominal dc-source voltage
Operating voltage/frequency
Switching frequency
Filter and Line Impedance
Filter inductor (L D 1 + L D 2 )
Filter capacitor (Cf )
Coupling Inductor (Lo)
Line impedance (L, R)
Value
8 kW
2035 V
One-Stage Switched Capacitor Boost
Converter
2035 V
250 V
1000 F
1.4 mH
1000 F
10 F
0.8 mH
2650 F
6 kHz
FFH60UP40S APT75GN120LG
A. AC Voltage Control
The ac voltage control implemented in this study is based
on the ADALINE&FLL [31]. This control scheme offers good
transient and steady-state behavior and has been previously evaluated with linear and nonlinear loads. A simplified diagram of
the control structure is presented in Fig. 6.
In this voltage control structure, the instantaneous signal error (S ) is computed as the difference between the reference
CARDENAS et al.: DEVELOPMENT OF POWER INTERFACE WITH FPGA-BASED ADAPTIVE CONTROL FOR PEM-FC SYSTEM
299
(4)
(5)
k
W 0 ()
(6)
W 1 ().
(7)
=0
k
=0
(9)
Fig. 7. Proposed control structure of dcdc and dcac converters for the ac
voltage control of an FC system.
KII
s
(10)
(11)
VDCM
.
VFC
(12)
As illustrated in Fig. 7, the feedback variables, like the dclink voltage (Vdc ), the load current (Irm s ), and the FC current
and voltage (IFC , VFC ), are filtered by means of the auxiliary
ADALINE low-pass filter bank (ADALINE-LPF). This filter
bank is synchronized with the ac load frequency by means
(13)
1
sin(2 f k TS )
cos(2 f k TS )
.
(14)
X(k) =
sin(2 N f k TS )
cos(2 N f k TS )
where Ts is the sampling period of the direct digital synthesis
block (DDS); W is the weight vector, which is updated considering the estimation error e(k) and the learning factor using
e(k) X(k) .
W (k + 1) = W (k) +
(15)
N
The mean or dc signal can be the computed by
ydc (k) = W (0, k) X(0, k)
(16)
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TABLE II
MAIN CHARACTERISTICS OF MEASUREMENT SYSTEM
Description (Units)
Measurement and Control System
Sample time of measurement system (s)
FPGA clock period (ns)
ADALINE-FLL
Number of analyzed harmonics
DDS sample time T 0 (s)
Number of implemented WVU T 0
WVU T 0 learning factor
FLL gain G F L L
FLL sampling period T F L L (s)
FLL error threshold M I N
FLL sliding window period T S W (ms)
Value
10
10
32
1
3
0.1
3.5
10 s
0.1
20
(17)
where VDCR is the set point of Vdc ; VDCN is the nominal value of
Vdc ; Pac is the measured load ac power; PNOM is the rated power
of the FC (or dcac converter); and mdc is the droop coefficient
(in volts per watt). In the dc-droop scheme, the operating voltage
at the rated power corresponds to the nominal value, and higher
operating voltages are set for operating powers under the rated
power. In other words, if the system is working at very low power
the dc-link voltage is set at its highest value; consequently, if
the power demand increases the dc-link voltage naturally falls
down. Otherwise, when the system is working at its maximum
power the dc-link voltage is set at its lowest value; thus, if the
power demand falls down the dc-link voltage naturally rises.
The controllers gains can be obtained offline from the transfer function of the system by means of the SISO design or
PID tuner graphical user interfaces (GUIs) of MATLAB software (MATLAB-SISOTool or MATLAB-PIDTool); tuning of
PI controller can be also obtained online by automatic tuning
techniques [32].
IV. HIL CO-SIMULATION RESULTS
The proposed control system of FC power electronic interface has been implemented and evaluated by HIL co-simulation
using the Xilinx Virtex-5 XC5VLX110T FPGA as target device
Fig. 8. HIL co-simulation results of (a) current and (b) voltage ripple when
the mean FC current is 90 A. Controllers use tuning 1.
IRipplerm s
100%
IFCm ean
(18)
CARDENAS et al.: DEVELOPMENT OF POWER INTERFACE WITH FPGA-BASED ADAPTIVE CONTROL FOR PEM-FC SYSTEM
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TABLE III
SETUP OF CONTROLLERS USED IN THE HIL CO-SIMULATION
Description
Tunning 1
Tunning 2
DC Voltage Controller
DC current controller (K P I , K I I )
DC voltage controller (K P V , K I V )
V d c nominal
Operating V d c (Vm i n Vm a x )
DC voltage droop (m d c )
Controller sample time
0.005, 5
1, 0.01
200 V
170240 V
3.3 mV/W
10 s
0.005, 1
1, 0.01
200 V
170240 V
3.3 mV/W
10 s
1
0.0432, 42.35
250 s
6 kHz
1
0.0432, 42.35
250 s
6 kHz
AC Voltage Controller
Signal error controller (K P a c )
Orthogonal components controller (K P d c , K I d c )
Controller sample time
Switching frequency
Fig. 10.
Description
Low voltage capacitor (LVC)
Switching capacitors (SC1 +
SC2)
HVC
Rated power (static
converters)
LVC + SC capacitor/power
HVC capacitor/power
Steady-state current ripple
Fig. 9. HIL co-simulation results of (a) current and (b) voltage for different
power of ac load. Controllers use tuning 2.
the ripple factor of FC current and voltage are 2.95% and 2.1%,
respectively.
Fig. 9 shows the results for the transient response of the
FC system using tuning 2; in this test, the inverter is started
at t = 100 ms with an initial ac load of 100 W; also at the
times t = 300 ms, t = 800 ms, and t = 1.3 s, the load power is
increased each time of 500 W. Fig. 9(a) shows the FC current,
and Fig. 9(b) shows the dc-link voltage (at HVC). The effect of
the voltage droop scheme on the dc-link voltage, following the
variations of the output power of the system, is well illustrated in
this figure. These results show a good behavior of the controller.
Fig. 10 shows the results of the ripple factor of the FC current for
different load power and considering the two different tunings
of the integral gain of current controller (KI I ). According to
these results, the ripple factor is always under 3% and meet
This study
6600 F
1000 F
2000 F
2200 F
1.20 kW
2650 F
3 kW
5.5 F/W
1.83 F/W
2.0%
1 F/W
0.88 F/W
2.95% (Tuning 1) 2.05%
(Tuning 2)
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TABLE V
SUMMARY OF RECENTLY PROPOSED CURRENT RIPPLE MITIGATION
TECHNIQUES
Year
Technique
Characteristics
2010
2010
2013
2014
Fig. 12.
Fig. 11.
voltage gain (G) for different duty cycle (D). The experimental results of the static gain of the dcdc converter are plotted
in Fig. 13 for the open-loop operation, and in Fig. 14, for the
closed loop. The obtained experimental values are close to those
of the theory obtained by using (3). The experimental gain is
lower than the theoretical value, which can be explained by the
converter losses.
B. Inverter Load Operation
The operation of the FC system has been validated with different ac load conditions. The first test has been carried out by
using optimal tuning of classic PI controllers for the current and
voltage loops obtained by the classic ZieglerNichols rule with
Fig. 14. Experimental results of static gain of the dcdc converter working in
closed loop at two different operation points, V d c = 180 V and V d c = 200 V.
CARDENAS et al.: DEVELOPMENT OF POWER INTERFACE WITH FPGA-BASED ADAPTIVE CONTROL FOR PEM-FC SYSTEM
303
Fig. 15. Experimental results of inverter load operation at low load power
(Ia c rm s = 4.2 A) (classic control with optimal controller tuning using ZieglerNichols rule with MATLAB SISOTool).
Fig. 16. Experimental results of current ripple for different ac load power (the
proposed control scheme using tuning 2).
Fig. 17. Experimental results of inverter load operation at low load power
(Ia c rm s = 7 A, IF C m e a n = 25.6 A). (a) Voltage waveforms and (b) current
waveforms with the proposed control scheme using tuning 2.
304
Fig. 18. Experimental results of inverter load operation at low load power
(IF C m e a n = 39.9 A). (a) Voltage waveforms and (b) current waveforms with
the proposed control scheme using tuning 2.
Fig. 20. Experimental results of transient response (a) dc-link voltage regulation, and (b) FC current and voltage. Power transient of 150 W by switching
OFF a commercial light bulb.
Fig. 21. Experimental results of transient response (a) dc-link voltage regulation, and (b) FC current and voltage. Power transient of +150 W by switching
ON a commercial light bulb.
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REFERENCES
VI. CONCLUSION
The development of a power interface for an FC system supplying an ac load has been presented. The proposed system
includes a prototype of dcdc and dcac converters, and all the
control is implemented in FPGA. The proposed control includes
the ADALINE&FLL structure implemented in hardware, which
is used to control in parallel both the inverter and the SCBC.
Additionally, a dc voltage droop scheme is adopted to improve
the response of the dcdc converter even with the low size of
the HVC.
The proposed system has been experimentally validated
showing many advantages compared with classic solutions some
of them are the low current ripple, the fast transient response,
and a reduced dc-link capacitor compared to the classic and
recently proposed alternative solutions.
All control blocks have been embedded in a single FPGA
device, working in parallel and sharing in real time the main
variables information. This fact demonstrates the validity and
potential of the proposed system by using modern digital control
systems.
ACKNOWLEDGMENT
The authors would like to thank the Xilinx University Program for the hardware, software, and technical support.
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