Hybrid-Modulation-Based Bidirectional Electrolytic Capacitor-Less Three-Phase Inverter for Fuel Cell Vehicles: Analysis, Design, and Experimental Results

This paper presents a novel six-pulse low-frequency (LF) fluctuating high-voltage dc-bus-based power system architecture for fuel cell vehicles (FCVs) application. A novel hybrid modulation scheme consisting of six-pulse modulation at LF scale and modified secondary modulation and 33% pulse width modulation at high-frequency (HF) scale is proposed. Three-phase ac waveforms for the propulsion system of FCVs are generated from LF fluctuating high-voltage dc bus. The proposed modulation technique significantly reduces the switching losses of the bidirectional dual-stage inverter: 1) soft-switching of both sides of the front-end current-fed full-bridge converter is realized; and 2) at any moment, only one leg of back-end three-phase inverter is switched at HF, while the other two legs are kept in on or off states. This tremendously reduces the bidirectional inverter's switching losses and improves the system efficiency. The LF fluctuating high-voltage dc bus allows the elimination of large electrolytic dc-link capacitor, which contributes to a more reliable and compact design. This paper presents the operation, analysis, and design of a bidirectional inverter implementing the proposed hybrid modulation technique. Simulation results obtained from power electronics simulation software PSIM and experimental results from the lab prototype clearly validate the effectiveness of the proposed modulation technique.