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Abstract—Analysis of an experimentally measured daily load cell system output voltage drop with loading, and slow response
profile reveals that the residential power demand has a high per- of the fuel cell system to transients. DC–DC converters are used
centage of low power duration over a day. In a stand-alone resi- to overcome low fuel cell voltage level and fuel cell system
dential fuel cell power system, the power inverter designed for the
peak power requirement will be operating at light loads, where its output voltage drop with loading [12]–[14]. Batteries and/or
efficiency is lower, most of the time. Thus, improving the light-load supercapacitors are employed to compensate for slow response
efficiency will provide considerable hydrogen (energy) savings for of the fuel cell system to transients [7], [10], [15], [16]. What
the stand-alone residential power system. A solution to improve is missing in the literature is the consideration of the demand
the power inverter efficiency at light loads is proposed. Both sim- characteristics of a stand-alone residential house in the design
ulation and experimental results are given. Results show that the
light-load efficiency can be improved by employing and uniquely of the power inverter. The demand characteristics are important
controlling a parallel IGBT–MOSFET switch combination in a for stand-alone power systems and can be used to have a better
half-bridge inverter topology. It is also shown that substantial sav- inverter design.
ings on hydrogen usage can be realized through the use of new In order to capture the load characteristics, experimental load
inverter design in stand-alone operations. measurements are completed in a residential house in Troy,
Index Terms—Hydrogen savings, inverter efficiency, residential NY, with high resolution [1]. Measurements revealed that the
load, stand-alone fuel cell power system. residential power demand stays low most of the day. On the
other hand, the examination of a typical inverter efficiency curve
shows that it has low efficiencies at light loads. Thus, improve-
I. INTRODUCTION ment of the light-load efficiency will provide energy savings.
A novel power inverter design is introduced for this purpose.
HE ELECTRICAL output of a fuel cell system is dc volt-
T age and must be converted to ac voltage for residential
applications. Power electronic circuits such as dc–dc converters
Both simulation and experimental studies are completed for the
proposed inverter topology and is shown that substantial energy
(hydrogen) savings can be achieved with the proposed design in
and inverters are employed for this transformation. An overview
the stand-alone operation.
of power electronics applications in renewable energy systems
This paper is organized as follows: In Section II, the load
such as wind, fuel cell, and solar energy is summarized in [4]
characteristics and the need for the new inverter topology are ex-
and [5]. Various power electronic circuit topologies and control
plained. In Section III, simulation results are given. Cost consid-
techniques have been proposed for fuel cell power systems in
erations are investigated through energy and hydrogen savings.
the literature. A DSP-based control is used in [8]. Ultracapaci-
Experimental results are also given. In Section IV, conclusions
tors are used in the design of the power conversion unit in [10].
are made.
A different approach is taken in [11]. Instead of having a dc
link in the intermediate stage, an ac link is used. Several 10
kW inverter designs that translate the low dc output of a solid
oxide fuel cell (SOFC) to 120/240 V 60 Hz signal for residential II. SYSTEMS APPROACH FOR THE DESIGN OF THE
use are given in [6]–[8]. A 1-kVA fuel-cell-based uninterrupt- NEW POWER INVERTER
ible power system (UPS) design is introduced in [9]. A wide In the stand-alone residential fuel cell power system, both
input voltage and high efficiency dc–dc converter topology for fuel cell system characteristics and demand-side characteristics
fuel cell applications is given in [14]. Z-source inverter topolo- should be considered in defining an inverter design strategy. In
gies for a fuel cell system with ultracapacitors are discussed general, the specifications for the stand-alone residential fuel
in [16]. cell power inverter can be summarized as [6] follows.
In the literature, due consideration is given to the fuel cell 1) Generate 120/240 ± 10% V, 60 ± 0.1% Hz ac output volt-
system characteristics such as low fuel cell voltage level, fuel age from the unregulated dc fuel cell voltage (typically
40–80 V) for operation in the U.S.
Manuscript received May 27, 2008; accepted November 25, 2008. Date of 2) AC output voltage total harmonic distortion must be less
current version August 20, 2010. The work of U. S. Selamogullari was supported than 5% (IEEE 519).
by Yildiz Technical University, Istanbul, Turkey. Paper no. TEC-00182-2008.
U. S. Selamogullari is with the Department of Electrical Engineering, Yildiz 3) The energy storage is needed to compensate for the slow
Technical University, Istanbul 34349, Turkey (e-mail: selamu@alum.rpi.edu). response of the fuel cell system.
D. A. Torrey is with the Advanced Energy Conversion, Malta, NY 12305 4) A charging algorithm is needed that will keep the state of
USA.
S. Salon is with the Rensselaer Polytechnic Institute, Troy, NY 12180 USA. charge of the backup source within acceptable limits (e.g,
Digital Object Identifier 10.1109/TEC.2010.2047057 0.75–1).
0885-8969/$26.00 © 2010 IEEE
742 IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 25, NO. 3, SEPTEMBER 2010
TABLE II
SWITCHES USED IN THE SIMULATIONS
Fig. 7. Possible worst-case loading scenario for the considered house [3].
TABLE IV TABLE VI
SUMMARY OF SAVINGS FOR EACH IGBT–MOSFET COMBINATIONS BASED ON SUMMARY OF SAVINGS FOR IGBT–MOSFET COMBINATIONS BASED ON
UTILITY ENERGY COST HYDROGEN COST
TABLE V
ADDITIONAL COST FOR THE NEW INVERTER DESIGN
Fig. 14. Total savings based on hydrogen cost and additional cost of the new
design are shown. Break-even points are shown.
C. Experimental Study
In order to verify the simulation results, an experimental setup
is configured and the parallel IGBT–MOSFET switch combina-
tions are tested to obtain efficiency readings. A block diagram
of the experimental setup is shown in Fig. 15. Fig. 18. Gate Signals for each switch and control signal for selection.
The modulation index is 0.9 and the dc bus is 360 V during
the experiment. A 20 kHz switching frequency is used and two TABLE VII
SWITCHES USED IN THE EXPERIMENTS
separate gate drives are employed to control each switch in the
parallel IGBT–MOSFET combination. Analog devices fixed-
point ADMFC340 DSP is used to produce the gate signals. A
dead-time zone is used to select between switches. A Voltech
PM3000A universal power analyzer is used to measure input
and output powers. A Tektronix TDS 3014 oscilloscope is used The switches used in the experiment are given in Table VII.
to capture the experimental data. The output filter inductance Since shoot-through has occurred when the load current was
value is 680 µH and the output filter capacitance value is 20 µF. increased with the SPW20N60S5 MOSFET for several tries,
The dc-bus voltage, load voltage after the output filter, and no experimental data can be collected for this MOSFET type.
load current for 50 Ω loading and 9 Ω loading are captured and Experimentally obtained efficiency values with IRFPS29N60L
shown in Figs. 16 and 17, respectively. When the load current MOSFET are summarized in Table VIII.
increases as in the 9 Ω loading case, the dc-bus voltage drops to Obtained efficiency gains for HGTG30N–IRFPS29N switch
350 V due to losses in the rectifier circuitry, as shown in Fig. 17. combination are shown in Fig. 19. Both experimental results
Experimentally measured gate signals and control signal for and simulations results are given. As seen, experimental results
switch selection are shown in Fig. 18. As seen, when the control show smaller efficiency gains at light loads compared to simu-
signal goes low, gate signals for the MOSFET becomes OFF lated cases since the real circuit conditions cannot be taken into
(−15 V) and IGBT gate signals becomes ON. account in simulations.
748 IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 25, NO. 3, SEPTEMBER 2010
TABLE VIII prove the light-load efficiency since the stand-alone residential
EXPERIMENTAL RESULTS FOR EFFICIENCY VALUES
power demand stays low most of the day. In the new design, a
low-power switch (MOSFET) is integrated into the high-power
inverter design. The unique feature of the design is that only
one of the switches in parallel IGBT–MOSFET combination is
active at any instant depending on the load current feedback.
Both simulation and experimental results are given to show the
light-load efficiency can be improved and considerable savings
can be achieved.
In this study, only the resistive loading case is investigated
since the use of semiconductor switches is maximized under
resistive loading. Thus, the benefit of the hybrid switch can be
fully investigated. If an inductive load or RL load is used then
the use of antiparallel diode will increase. Both in simulations
and experimental study, an output filter is employed. Thus, the
inverter actually sees an inductive load. Since the filter induc-
tance value is small (680 µH), the effect of the inductor on the
results is assumed to be negligible.
The 20 kHz switching frequency is used based on [7]. If the
switching frequency is reduced, for example, to 5 kHz, the hy-
brid switch will perform better since the conduction time will be
larger with low switching frequency during a switching period.
The larger the conduction times at light loads, the better the
performance of the hybrid switch since the MOSFET switches
perform better at light loads with larger conduction times. Be-
sides, the switching losses will be reduced and total efficiency
will increase. Although it is not considered in here, a Schottky
Fig. 19. Obtained efficiency gains for HGTG30N–IRFPS29N switch combi- diode can be used in series with the MOSFET switch to pre-
nation. Both experimental results and simulations results are given. vent potential hazard of overcurrent in the the body diode of the
MOSFET and to eliminate slow reverse-recovery characteris-
tics of the body diode. However, this will introduce additional
Efficiency improvement is achieved at power levels below
losses. The effect of switching frequency and the use of series
500 W with the proposed topology change. As the load power
Schottky diode on the performance of the hybrid switch are
increases efficiency gain disappears. When the combined effi-
going to be investigated in a future study.
ciency curve is used, the yearly energy savings is calculated as
In the proposed topology, only one switch is active at a time.
45.041 kW·h/year.
For a sinusoidally changing load current, the MOSFET switch
Yearly savings amount in dollars is found as $6.706
can be active until its current limit is reached; then, the MOSFET
per year and $67.06 for assumed 10-year lifetime using
can be turned off and the IGBT switch can be turned on within
14.89 cents/kW·h. The hydrogen amount saved over a year is
each half cycle. The effect of such a control strategy on efficiency
calculated as 1.3705 kg. Using $2.5 per kilogram, the total sav-
improvement and hydrogen savings is the subject of a future
ings in terms of less hydrogen use is $3.4263 per year and $34.26
study.
over the ten-year lifetime. The return time is then 4.804 years
Although results are tied to switch selection and might vary
based on hydrogen savings.
for different switch combinations due to different device manu-
The experimental results also show that it is feasible to employ
facturing processes, device characteristics, etc., this study points
parallel IGBT–MOSFET switch combination in a half-bridge
out that considerable hydrogen savings could be achieved if
topology to increase light-load efficiency. The obtained results
light-load efficiency is improved in the stand-alone residential
are tied to selected switches and may vary with different switch
fuel cell power system. Cost analysis shows a quick return time
combinations due to device manufacturing processes, character-
for the additional cost of extra switches.
istics, parasitics, temperature, etc. Due to these dependencies, it
The proposed design can be used for any stand-alone residen-
is not possible to generalize the outcome. Thus, benefits of such
tial power system where the load demand stays low most of the
switch combinations should be investigated for every applica-
time.
tion individually.
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[19] K. F. Hoffmann and J. P. Karst, “High frequency power switch-improved technic Institute (RPI), Troy, NY, since 1978, where he is currently a Professor
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