A Two-Quadrant Transistor Chopper for an Electric Vehicle Drive

A two-quadrant dc-dc transistor converter capable of delivering 400 A motoring current and of generating 200 A braking current is described. The chopper operates from a 108-V dc source (54 lead-acid cells) and supplies the armature current of a separately excited dc machine in an electric vehicle application (3000-lb commuter-type vehicle). The chopper employs high-current transistors specifically developed for the application and power diodes packaged together in power module form. Snubber networks which reduce both turn-on and turn-off device stresses are employed. The interaction of the snubber networks for the motoring and braking transistors is described and design considerations presented. It was found that for these snubbers a minimum on-time and a minimum off-time for the transistors must be maintained to ensure that the transistors' dynamic load lines never enter into the region of forward bias or reversed bias second breakdown. A technique is described which instantaneously detects a transistor failure and initiates the appropriate action in order to prevent machine overcurrent and overtorque. Factors are discussed which are crucial to ensure proper transitions from motoring to braking and to inhibit device power dissipation due to parasitic currents. The selection of a variable-frequency/variable-pulsewidth switching strategy and protection and control techniques unique to high-current transistor choppers are discussed.