General Analysis and Design Guideline for a Battery Buffer System With DC/DC Converter and EDLC for Electric Vehicles and its Influence on Efficiency

In this paper, the general design of a battery buffer system (BBS) consisting of a dc/dc converter and electric double layer capacitors for an electric vehicle is presented. This is intended to save the regenerative braking energy and to support the battery during acceleration. The design of a multiphase converter in interleaved operation with nonideal coupled inductors is stated to minimize volume and power losses while maintaining given current ripple limitations. A reduced sensor current-sharing control method is developed and its correct choice of the sensor position is explained. The peak efficiency of the designed and built converter can be measured to nearly 99%. The corresponding BBS is implemented in a lead-acid battery powered electric lift truck propulsion system. The system operation with and without the BBS is compared to examine the behavior and the overall efficiency. It can be shown that the traction battery stress can be strictly reduced as well as the temperature rise in the battery. Furthermore, the efficiency can be increased in the range of 5–6%. The battery’s lifetime improvement is estimated by means of the difference in the temperature rise to approximately 20%.