Seamless Controlled Parallel Bi-directional DC-DC Converter for Energy Storage

System

OUCHI Takayuki

Seamless Controlled Parallel Bi-directional DC-DC Converter

for Energy Storage System
Takayuki Ouchi1, Akihiko Kanouda1, Naoya Takahashi2 and Minoru Moteki3
1
Hitachi Research Laboratory, Hitachi, Ltd.
Hitachi, Ibaraki, Japan
2
Hitachi Industry & Control Solutions, Ltd.
Yokohama, Kanagawa, Japan
3
Hitachi Industrial Equipment Systems Co., Ltd.
Narashino, Chiba, Japan
E-mail: takayuki.ouchi.xp@hitachi.com

Acknowledgements
The authors would like to thank Mr. M. Futami, who engages at Hitachi Chemical Co., Ltd. with R&D
of lithium-ion battery, and for him and his colleague's cooperation to this work.

Keywords
Converter control, Parallel operation, Renewable energy system, Battery Management System (BMS)

Abstract
A scalable parallel bidirectional DC-DC converter system, which enables efficient seamless control
using an H-bridge topology, was developed and evaluated. Although the unified control structure is
simple, four drive-mode, both charge and discharge with buck/boost, can be handled. The proposed
system was extended for use in simple parallel converter management. This scheme achieves high
efficiency over a wide load range, especially for light loads. The only hardware required is a power
line and communication cable connection. All other functions are provided by software and operate
autonomously. A 5-kW prototype converter was constructed and evaluated, and a four-unit parallel
converter system was tested and confirmed to work well, changing load between 20-kW discharge and
20-kW charge.

I. Introduction
There is a growing demand for renewable energy systems, such as photovoltaic (PV) and wind
turbine. One problem with such systems is that the amount of energy generated is uncontrollable.
Therefore, battery storage systems are needed to handle the growing gap between supply and demand
because the large gap disturbs the stability of grid voltage; higher to destroy equipments or lower to be
an outage, and a bidirectional converter is a key component in shifting the load.
Various types of bidirectional converters have been reported [1][2]. In particular, parallel-type ones
have been developed that reduce the ripple current and improve reliability [3].
In addition, several types of energy storage systems (ESSs), such as electric vehicle (EV) charging
infrastructures [4]-[8], have been developed to secure power quality. The output power of an ESS for
home or individual use is around 10 kW [9][10].
We developed a scalable bidirectional converter system. It features simple seamless control and
achieves fast buck-boost response and smooth charge/discharge mode transition. We also developed
an autonomous parallel unit management system [11]. It enables the seamless control among parallel
converters with its features. The only hardware required is a power line and communication cable
connection. All other functions are provided by software and are completely the same between the
master and slave units. The four-parallel system was evaluated for quick load change seamlessly
between charge and discharge.

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Seamless Controlled Parallel Bi-directional DC-DC Converter for Energy Storage

System

OUCHI Takayuki

II. Seamless Control of Bi-directional Converter

An overview of a typical PV system for the home or small building is shown in Fig. 1. A high-voltage
(<450 V) DC-link bus line and several energy storage devices, such as batteries, are connected through
bidirectional DC-DC converters. The generated PV power is routed through a unidirectional DC-DC
converter and the DC-link bus line to the power conditioning system (PCS) or a battery. The routing
depends on demand at that time. Since power sent to a battery undergoes charging and discharging, the
efficiency of the bidirectional DC-DC converters is very important.

A. Selection of efficient H-bridge topology for converter circuit

The rating of the generated power varies because it is determined by the number of PV panels.
Likewise, the rated capacity of the batteries depends on the number of cells in each battery. This
means that it is important for bidirectional DC-DC converters to be scalable in terms of their rated
capacity. In typical home or individual use, the rated power of the PCS is less than 10 kW while in
small offices and buildings, it is up to 100 kW. Industrial requirements dictate that a narrow product
line-up be able to cover this wide range.
The voltage ranges that some bidirectional converters cope with, such as in EV systems, are different
in which the battery side voltage is under 100 V and the DC-link side is over 300 V. The converter
works at a large step-up ratio in discharge and at a small step-down ratio in charge mode. In other
words, it has two drive modes, boost discharge and buck charge. This voltage conversion ratio is
possible by a transformer, which limits efficiency.
PV-pa nels

DC-link
DC-DC
converter

AC

PCS
(DC/AC)

DC-link

Battery

Discha rge

discharge

Vbat

Cha rge

Q1

charge

V DC

Q3
L

Ba ttery

Bidirectiona l
DC-DC
converter

Ba ttery

Bidirectiona l
DC-DC
converter

Load

C1
Q2

IL

Driver

Q4

C2

Driver
Control IC

Fig. 1: Typical PV system for home or small

building

Fig.2: Proposed bidirectional DC-DC converter

Converter efficiency can be increased by increasing the number of battery cells in series. By doing this,
the voltage conversion ratio becomes around 1 for both directions, and non-isolated transformer-less
topology can be selectable. If increased battery voltage is partly overlapped its range to DC-link, the
relation between the battery and DC-link voltage condition is unsettled. All four-drive modes must be
used because the operational voltage range partially overlaps.

Table I: The relation of drive-mode and switching state

mode
boost discharge
buck charge
buck discharge
boost charge

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Q1
Q2
Q3
Q4
ON
OFF OFF PWM
OFF OFF PWM OFF
PWM OFF OFF OFF
OFF PWM ON
OFF

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Seamless Controlled Parallel Bi-directional DC-DC Converter for Energy Storage

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OUCHI Takayuki

Our proposed bidirectional DC-DC converter system has a non-isolated topology, as shown in Fig. 2.
This H-bridge bidirectional converter can handle four drive modes, i.e., (1) boost discharge, (2) buck
discharge, (3) boost charge and (4) buck charge. The H-bridge bidirectional converter can handle these
drive modes.
Two voltages (high-voltage DC link VDC and battery voltage Vbat) and one current (inductor current
IL) are detected in both directions by a hole current transducer. Four main switches (Q1 to Q4) are
used to control two sets of insulated gate bipolar transistor (IGBT) modules. The switching state of
IGBTs in each driving-mode are listed in Table I.

B. Seamless mode transition control structure

The conversion power is controlled by normal pulse width modulation (PWM), changing the duty of
the related IGBT switch. The duty ratios are calculated using the cascaded regulator block shown in
Fig. 3, and induced control value exchange and output IGBT drive pulse at PWM block. Its four
parallel control structures enable it to cope with four-mode driving, as shown in Table I. It selects the
one to use on the basis of voltage and current. If a proportional-integral (PI) regulator is used, the
required convergence time would prevent it from responding quickly during mode transition. The
simulated waveform from buck discharge to boost discharge, as shown in Fig. 4, displays the
occurrence of over-current and overshoot voltage because of slow convergence time. Moreover, the
overall mode-select and duty-cycle control process is complicated.
d

1
0

vref

VDC

+
-

IL

iref
PI

PI
-

vref
+
-

SEL

buck discharge

iref
PI

+
-

iref
PI

vref

boost discharge
+

PI

+
-

PI

HV-link
voltage

buck discharge

inactive

PI

Inductor
Current

PWM

inactive

PI

boost discharge
over-current at
mode change

Q3

boost charge
+

HV-link voltage overshoot

Q4

PWM

buck charge
+
-

iref

PWM

active

vref

Q1

0A

Q2

Q1 PWM

Q1 gate
Q4 gate
Q4 PWM

PWM

inactive

20A / div

Fig. 4: Simulation waveform at mode transition

Fig. 3: Basic four-mode parallel-control-block

structure of H-bridge converter with mode selector
First, we examined the unification of the buck and boost discharge control structure. Control duty d
(between 0 and 1) is defined by the discharge mode input voltage (Vbat) and output voltage (VDC), as
following equation.

d1 = Vbat / VDC
d2 = 1 - Vbat / VDC

(buck mode, VDC < Vbat)

(boost mode, VDC > Vbat)

(1)
(2)

The relation of these equations is shown in Fig. 5(a), where d1 corresponds to Q1 and d2 corresponds
to Q4. There is discontinuity where VDC = Vbat, at the time of mode change. To avoid this problem, we
shifted the range of d2 and added an exchange process to calculate the duty ratio, only subtract 1. The
improved relation displayed in Fig. 5(b) shows that the characteristics of d1 and d2 are continuous and
correspond to voltage ratio VDC/Vbat. This means that the two control structures can be unified to the
same d.

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OUCHI Takayuki

In this scheme, d is divided into two ranges, 0 to 1 and 1 to 2 for two modes. Each division refers to an
independent triangular comparative wave to determine the IGBT on-duty. If d is between 0 and 1 in
the change mode, Q1 drives by using PWM at on-duty d, and Q4 stops because d is below its duty
range (1 to 2). If d is between 1 and 2, Q1 remains in the ON state, and Q4 drives by PWM at on-duty
d -1. It then can also control stable ON/OFF state, not only PWM duty. This simplifies the overall
control structure.
2

Buck mode

Boost mode

1.8
1.6

1.6

Q4

1.4

1.2

discontinuous

1
0.8

Ctrl value

1.4

Ctrl value

Buck mode

Boost mode

1.8

switch mode
and the value

Q1

0.6

shift the range

0.8
0.6

Q4

0.4

continuous

1.2

0.4

Q1

0.2

0.2

0
0

0.5

1.5

2.5

0.5

VDC / Vbat

1.5

2.5

VDC / Vbat

(a) Conventional discontinuous modes control

(b) Developed continuous mode control
Fig. 5: Relation between voltage ratio and PWM Control value
The same process was also applied to Q2 and Q3, corresponding to buck and boost charge. As a result,
the number of control blocks is reduced from four to two.
The symmetric topology of the H-bridge circuit was designed so that switches Q1 and Q2 or Q3 and
Q4 cannot both be in the ON state at the same time, which prevents short circuits. That is, the states of
Q1 and Q2 (or Q3 and Q4) are either opposite or both OFF. This relation has been applied to a
complementary drive for the upper and bottom arm drives in normal operation.
The switching state of seamless complementary drive control is shown in Table II. Complementary
change are applied to yellow column in Table II(a), which are OFF state in Table I. The columns filled
~PWM changed from OFF state means reversed pulse of PWM, which is actually controlling current.
The relation of Q3 and Q4 in boost discharge and buck charge is same, so that their states can combine.
It also applied to the relation of Q1 and Q2 in buck discharge and boost charge mode. Finally,
developed switching state is summarized in Table II(b).

Table II: Developed relation of drive-mode and switching state

(a) complementary change
mode
boost discharge
buck charge
buck discharge
boost charge

Q1
ON
ON
PWM
~PWM

Q2
Q3
Q4
OFF ~PWM PWM
OFF PWM ~PWM
~PWM ON
OFF
PWM ON
OFF

(b) summarized
mode
boost discharge
& buck charge
buck discharge
& boost charge

Q1
ON

Q2

Q3

Q4

OFF ~PWM PWM

PWM ~PWM

ON

OFF

The developed advanced control block is simple, as shown in Fig. 6. It has two cascaded PI regulators,
an auto voltage regulator (AVR) and an ACR. The expanded d covers 0 to 2. The PWM block receives
d and creates four IGBT control pulses and outputs them. The newly introduced two-stage triangularwave and complementary drive plays no role in the determination process in the normal duty cycle for
boost/buck or charge/discharge mode selection. The unified seamless control system can quickly
respond to output power fluctuations.

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Seamless Controlled Parallel Bi-directional DC-DC Converter for Energy Storage

System

OUCHI Takayuki

Q1
AVR
vref

VDC

PI

ACR
iref

Q4

PI

PWM

IL
Ctrl value d

Q3
2

Q3, Q4

Q2

Q2, Q1

Fig. 6: Advanced unified four-mode control block of H-bridge converter.

III. Parallel Converter Control and Unit Operation

The parallel bidirectional converter system takes advantage of scalability. There is a need to combine
an ESS with a PCS for a wide rated-power range (5 to 100 kW), but the market growth of ESSs has
been weak for several years because of feed-in tariffs and other matters. We developed the smart
parallel converter management system and applied it to the proposed seamless controlled H-bridge
converter. Thus the parallel converter can cover a wide power range with a small line-up.

A. Parallel Output Current Control

A diagram of the control system for a conventional parallel converter system is shown in Fig. 7(a).
The large shaded rectangles correspond to the controller of each parallel converter (a, b, c,). The
voltage value flows in through a detection block (Det.) then flows through an AVR and ACR. The
output currents are imbalanced because detection errors are inevitable, and each one creates a
deviation in the AVR.
To balance the output currents, the AVR function is unified to the master unit and other (b, c,) are
masked. The unit acting as the master AVR calculates the total number of parallel converter Nt units,
regulates current iref_total, and transmits iref_nt to each slave ACR through an RS-485 communication
interface.
i ref _ nt = i ref

_ total

(3)

/ Nt

Each ACR receives iref_total and continues the ACR process, as shown in Fig. 7(b). The control current
of each converter is defined using (3). A smaller iref_total means a smaller iref_nt, which causes the
converter to work less efficiently.
VDC

Det.

Det. Error b
VDC

Det.
c

VDC

Det.

AVR

Iref_a

ACR

Output
Current

VDC

Det.

AVR

iref_nt

ACR

imbalanced

AVR

AVR

Iref_b

Iref_c

ACR

ACR

Output
Current

Output
Current

b
VDC

Det.

balanced

AVR

ACR

Output
Current

AVR

ACR

Output
Current

c
VDC

Det.

Output
Current

Masked

communication
(RS-485)

(a) Conventional parallel output control has

(b) Proposed parallel output control has balanced
imbalanced output
output
Fig. 7: Conventional control system and that for proposed parallel converter system

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Seamless Controlled Parallel Bi-directional DC-DC Converter for Energy Storage

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OUCHI Takayuki

The control structure was therefore extended to improve light-load efficiency. To scatter the load
between parallel converters, we introduced the parallel function auto-rotation (PFR) method [11]. The
PFR method is managed by a dual ID system for hardware and software to control parallel operation.
A power calculation process was added to the AVR and used along with an internal table to set the
number of operational units N, which is transmitted to the slave converters along with iref_total., as
shown in Fig. 8. The slave converters use these data to determine their operational state (ON or OFF).
More specifically, they compare N with their self ID (S-ID). If N is 2 and S-ID is 2 (i.e., the master ID
is 0), the state is set to OFF because only converters with IDs 0 and 1 are active while the others are
inactive. If N is 3 and S-ID is 2, the state of the converter is set to ON.
The extended control structure is depicted in Fig. 8. Each converter receives two pieces of information,
iref_total and N. First, it determines its drive state by comparing its S-ID with N. If the state is active, it
calculates its regulation current using
(4)

i ref _ x = iref _ total / N

where x corresponds to each converter; a, b, c,

Each ACR outputs its control value dx, which is passed to a PWM pulse generation block (not shown
in Fig. 8).
This extended control structure features power-tracking active-unit operation. Combined with ID
management, the system is self-driven.
a

AVR

ta ble

ACR

Ptotal

Iref_x
PI

PI

da

iref_total

I L_a

VDC b
PI
AVR

ACRPI

db

I L_b
VDC c
PI
AVR

ACRPI

dc

transition

Output ratio (% / unit)

vref

VDC

2 active

transition

3 active

converter a,b

converter c

2 active
converter a,b

converter c

time t

Fig. 9: Control current transition when number

of active units changes

I L_c

Fig. 8: AVR extension and ACR self-output

control.
When the number of active units changes, the control current is continuously changed to prevent
current becoming out of control. The controlled current transition from two active units (a and b) to
three units (a, b, and c) then back to two is illustrated in Fig. 9. The transition time was designed to be
less than 2 ms through simulation verification.

B. Load scattering
We therefore developed a scheme to distribute the load to improve total system reliability. A diagram
of the parallel control block structure is shown in Fig. 10.
The battery pack controller (BPC) sends ON/OFF signals to the AVR acting as the master converter
(converter a), which induces and sends iref_total and N to all ACRs. Each ACR determines its ON/OFF
state and controls the output current. By combination with the PFR method, the AVR function only

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Seamless Controlled Parallel Bi-directional DC-DC Converter for Energy Storage

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OUCHI Takayuki

works at master converter, but the ACR function works at each converter which has active output. The
turn-on order of ACR function in parallel system has been rotated by following S-ID of dual-ID
system. The amount of operational time and loads of each converter can be scattering.
The specifications of the proposed parallel bidirectional DC-DC converter are listed in Table III. It has
four operation modes: power compensation for seamless charging and discharging (both with buck
and boost power conversion). It has three charge modes: constant current (CC), constant voltage (CV),
and pre-charge. There are three types of protection: over-voltage protection (OVP), over-current
protection (OCP), and overheat protection. Several other internal protection controls are also applied.
The switching frequency of the IGBT drive is 20 kHz.
The bidirectional rated power is 5 kW for a single unit. An up-to-4-unit 20-kW system was tested in
this work. The number of parallel connections can easily be expanded.
iref_total , N

BPC
All: 1,2,

Master: a

ACR

AVR
Inductor current
iL_x

DC-link voltage
VDC

dx

PWM

Fig. 10: Diagram of parallel control structure

Table III: SPECIFICATIONS OF BIDIRECTIONAL DC-DC CONVERTER

Item
Battery Pack Voltage
DC-link Voltage
Rated Power
Switching Frequency
Inductance
Operation mode
Protection

Value
333 V (243 378 V)
380 V (350 400 V)
5 kW/unit
( 1 3 units )
20 kHz
600 H
Power compensation
(charge/discharge)
Charge only
(CC, CV, pre-charge)
OVP, OCP, Overheat

IV. Experimental Results

A. Single Converter unit
The characteristics of the 5-kW single prototype converter are shown in Fig. 11(a), which shows the
relation of efficiency to output power at discharge mode with a rated 333-V battery and under the 380V HV-link voltage condition. The efficiency was more than 90% at the wide load range and more than
97% over 40% 2-kW load power. The maximum efficiency was 97.8% at 5 kW.
The distribution of power conversion efficiency over the operational voltage range of a single
converter unit with a 50% load (2.5 kW) in discharge mode is illustrated in Fig. 11(b). The measured
voltage condition is shown in ~5-V steps for DC-link voltage on the vertical axis and for battery
voltage on the horizontal axis. Efficiency is indicated by the color corresponding to that in the bar at
the top of the graph, from 95.5% to 98.5%. The best efficiency conditions were located along the line
where the input and output voltages were equivalent. Efficiencies of 96.0 to 98.0% along a 0.5% step
line are also indicated in the graph. They were located almost parallel to the equivalent voltage line.

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OUCHI Takayuki

98

Vbat: 333 V
VDC: 380 V

Efficiency

97

95
94
93
92
91
90
0

2
3
4
Output power (kW)

96.5

96.0

DC-link voltage VDC (V)

Efficiency (%)

96

97.5

97.0

98.0

Battery voltage Vbat (V)

(a) Efficiency to output power

(b) Efficiency distribution over operational voltage range
Fig. 11: Characteristics of 5-kW bidirectional DC-DC converter prototype

B. Parallel Converter Operation

We compared the efficiencies for one, two, and three active units in a 3-unit parallel converter system
to evaluate the effectiveness of power-tracking active-unit operation. The threshold voltage was
modified for this measurement. The voltage condition was rated at Vbat 333 V and VDC 380 V. The
assumed single 15-kW converter characteristics are by the gray solid line in Fig. 12. They are based on
the characteristics of a single 5-kW converter. The measurement points were at less than 7 kW due to
equipment restrictions.
The efficiency for three active units completely overlapped the assumed 15-kW characteristics for less
than 7 kW. This means that efficiency for three units would match the line. At the same output power,
efficiency was the highest for one active unit while it was the next highest for two active units.
As shown in Fig. 12, the power-tracking active-unit control using the PFR control scheme improved
efficiency over a wide output range. The estimated efficiency at 15-kW rated output power was about
97.8%. This indicates that efficiency over a 13.3% load range is 96% and that over a 3.3% load range
is 90%.
Power-tracking active-unit control

98
97

Single 15 kW (assumed)

Efficiency (%)

96

1 of 3 parallel units (5 kW)

95
94

2 of 3 parallel units (10 kW)

93

3 of 3 parallel units (15 kW)

92
91
90
0

2.5

7.5

10

12.5

15

Output power (kW)

13.3

Load (%)

100

3.3

Fig. 12: Dependence of efficiency on number of units and on use of power-tracking control scheme in
3-unit parallel converter system
The experimental waveform of converter inductor current and HV-link voltage at rapid load and active
unit change is shown in Fig. 13, in case of power (a) drop down from 8.7 to 3.7-kW and (b) raise up
from 3.7 to 8.7-kW. In this case, the load changed from 3.7 kW for 2-active to 8.7 kW for 4-active
converter. The inductor current of the 1st converter around 6A raised once at the load change, when
the 3rd converter was active and raised its current. Then the second increase occurred when the 4th
converter was active and increased its current to the same level of the other converter. The voltage

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360

voltage(V)

voltage(V)

deviation was suppressed to only 4.4 V; about 1.3% of total voltage. The waveform of changing
current was well controlled as shown in Fig. 9.
+3.8V

350
340

360
350

-4.4V

340

10

10ms/div
Inductor current(A)

Inductor current(A)

10ms/div

Converter 1

5
0

Converter 4

8.7kW load
by 4 converter

3.7kW load
by 2 converter

10

Converter 1

5
0

Converter 4

3.7kW load
by 2 converter

8.7kW load
by 4 converter

(a) Increase active unit and power

(b) decrease active unit and power
Fig. 13: Experimental waveform of converter current and HV-link voltage at rapid load change

C. Operation with LiB and PCS

The four-parallel 20-kW bidirectional converter system was also tested and operated by connecting
between the PCS and lithium-ion battery (LiB). In this evaluation system, converter power is
controlled by the PCS, which is also connected to a large load and AC power line. The conversion
power varies between -20 kW (charge) to +20 kW (discharge) and works well. Top graph of Fig. 14
indicates the PCS control power (pcs_out) and compensated power (power) from the battery. It
changes power 0, +5k, -15k, +5k, -5k, +15k, -5k, 0W per minute, up to a 20-kW bidirectional instant
load change between charge and discharge modes. The waveform of LiB current through the converter
is also shown in the bottom of Fig. 14. That means that the converter controls large power conversion
and is fast and seamless at mode change with four parallel unit operation.
20
pcs_out

15

power

Power (kW)

10
5
0
-5
-10
-15
-20
0:07
80

0:09

0:11

0:13

0:15

Current (A)

discharge

40
0
-40
-80
0:07

LiB current

charge
0:09

0:11

0:13

0:15

time

Fig. 14: Changes in power and current with four-parallel converter connected between PCS and LiB

V. Conclusion
We developed and evaluated a scalable parallel bidirectional DC-DC converter system for energy
storage systems. Fast and efficient seamless control is achieved by using an H-bridge topology.

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Although it has a simple control structure, it can handle four drive modes: buck and boost for both
charge and discharge. We extended the proposed system for simple and autonomous parallel converter
management. The proposed scheme manages power-tracking active-unit control and achieved quick
response to load change. High efficiency is attained over a wide load range, and efficiency is
especially improved in the light-load range. The only hardware needed is a power line and
communication cable connection. All other functions are provided by software and operate
autonomously. The efficiency of a prototype converter at 5-kW-rated discharge was 97.8% for 333-V
battery pack power and VDC 380-V-link power. The four-unit parallel converter system with PCS and
LiB works well and converts the power bi-directionally between 20-kW discharge and 20-kW charge.

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Conference on IEEE Industrial Electronics Society, Nov. 2011, pp. 2492-2498.
[2] M. Young, The PWM strategy on DC-DC converter, IEEJ Journal of Industry Applications, vol. 28, no. 15,
pp. 123-129, 1989.
[3] W. Li, G. Jos, and C. Abbey, A Parallel Bidirectional DC/DC Converter Topology for Energy Storage
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EPE'14 ECCE Europe

ISBN: 978-1-4799-3014-2 and 978-9-0758-1520-7

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