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MPPT Controlled Battery Charger Design and Simulation

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Majlesi Journal of Mechatronic Systems Vol. 6, No. 3, September 2017

MPPT Controlled Battery Charger Design and Simulation

Bassam Y. Al-Hanahi1, Burak Akın2
1- Department of Electrical Engineering, Yildiz Technical University, Istanbul, Turkey.
Email: bassam.alhanahi@gmail.com (Corresponding author)
2- Department of Electrical Engineering, Yildiz Technical University, Istanbul, Turkey.
Email: bakin@yildiz.edu.tr

Received: June 2017 Revised: June 2017 Accepted: July 2017

ABSTRACT:
In this paper, the design of MPPT controlled DC-DC boost converter for PV charger application is presented. Duty
cycle of the designed boost converter, which operates in 50 KHz, is controlled directly by P & O algorithm in order to
track maximum power point of the PV panel that is changing in response of variation insolation of sunny day. The
designed Boost converter is used as interface unit for matching 24V battery bank (20AH, 12V, C/5) with CANADIAN
SOLAR CS5C-90 panel. The overall system is built and validated by using MATLAB SIMULINK. The simulation
results show that the average efficiency of proposed MPPT controlled DC-DC converter is 98.34%, which is calculated
by comparing the tracked PV power by designed converter and the proposed maximum power of the panel for different
level of insolation. The results express the effective operation of designed converter system by tracking MPP for PV
panel in different insolation situations.

KEYWORDS: Boost Converter, MPPT Algorithms, Solar Panel.

1. INTRODUCTION concurrence. Therefore, the power generated from the

Non-renewable energy sources have a limited solar cells is not always completely extracted [2, 3].
supply, often releasing harmful gases and their prices are In order to continuously obtain the available power
increasing continuously. These have become the main from the solar panels, it is necessary to match the
driving forces to use renewable energy sources, such as optimal impedance between the load and PV panel. This
solar, wind, biomass and hydropower energy. As matching can be done by inserting an interface unit
compared to other sources, solar energy is more between PV system and load. This unit is called a
attractive since it is environmentally clean, abundantly maximum power point tracking (MPPT). In this manner,
available, cheap, and easily transferrable to other forms the MPPT system tracker continuously tracks the peak
of energy. One practical application of solar energy is power condition by monitoring the output voltage and
solar photovoltaic panels as a source of electricity. PV current of the solar panel and determines the optimum
systems can be basically grouped into stand-alone and operating point of PV panel; thus increasing the
grid connected systems. Stand-alone systems are not part efficiency of extracting power from the solar panels.
of the grid and are essential for regions that are remote MPPT system consists of two main components. Firstly,
from public grid. These systems contain energy storage MPPT algorithms which determine the required
systems such as rechargeable batteries in order to supply operating point for maximum power generation of PV
energy in case of dark or low insolation conditions [1]. panels. Secondly, DC-DC converters which perform the
However, PV systems have many major problems. tracking action by controlling its duty cycle according to
Firstly, the efficiency of converting solar energy into the determined operating point [4].
electricity is low (10 to 16% efficiency for amorphous Numerous MPPT techniques have been presented in
silicon solar cells). Secondly, i-v characteristics of solar literature. These techniques differ in terms of
cell are highly nonlinear and depend on temperature and complexity, convergence speed, steady state
insolation level. Further, because of dependence of oscillations, cost, effectiveness and flexibility [5].
energy produced by the solar system on the energy MPPT algorithms could be systematically grouped into
required by the load; the direct connection of the PV three main groups.
panel and load reduces the conversion efficiency of the First is referred to as the Hill climbing MPPT such
PV panel if the impedance of load line and optimal as, Perturb and Observe (P&O) [7] and Incremental
impedance of PV array, which corresponds to maximum Conductance (IC) [8]. These techniques are the most
power point of i-v curve of PV panel, are not in popular used MPPT technique for low-cost applications

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Majlesi Journal of Mechatronic Systems Vol. 6, No. 3, September 2017

because its cost is low and implementation is easy [5]. simulation results show that proposed MPPT system
However, they have oscillatory behavior around the ensures the operating of PV system in MPP with average
MPP which reduces the system efficiency [6]. The tracking efficiency of 98.43%, despite of the variation of
second category is soft computing techniques such as, solar insolation. This result is compared with efficiency
Fuzzy Logic Controller (FLC) [9] and Artificial Neural of 92% and 98.26 % listed in [2] and [15] respectively.
Network (ANN) [10]. These techniques offer more In addition, the design and implementation of MPPT
robust, flexible and fast convergence MPPT schemes systems in [15-16] are complicate and costly in
and are well suitable for partial shading conditions [5]. comparison with proposed system in this paper
However, these methods have disadvantages like
difficult algorithm, tricky implementation and expensive 2. PV SOLAR CHARGE CHARACTERSTICS
[6]. The last group is based on approximated MPPT 2.1. PV Array Model
algorithm such as, Fractional Short Circuit [11] and PV panels comprise of many solar cells, which are
Fractional Open Circuit Voltage (FOV) [12]. These connected part by part in integrated series and parallel,
MPPTs are characterized by limited accuracy. However, as building blocks. A solar cell converts sun energy into
they do offer a reliable and lower cost solution because electricity by means of the photoelectric action that
of fewer sensors and simpler algorithm required for could be found in specified types of semiconductor
implementation [5]. materials such as silicon i.e. generates electric voltage
According to calculated operating point by MPPT and current on exposure to light. The ideal PV cell is
algorithm, DC-DC converter is used for regulating modelled as single diode circuit as shown in Fig. 1. This
operating point of PV panel. Different converter circuit contains of a current source, a diode in parallel
topologies like buck, boost and buck boost are used for with source, series resistors Rs, and parallel Rsh to
MPPT design. A comparison between buck and boost represent dissipation of PV cell [16].
converter is performed in [6]. Boost converters have The relation between voltage and current of PV panel
superiority on buck converters since it can track MPP can be described, mathematically, as in (1):
with maximum efficiency, require small rating devices
and work for wide range of input voltage [6]; however, 𝑉 + 𝑅𝑠 𝐼 𝑉 + 𝑅𝑠 𝐼 (1)
𝐼 = 𝐼𝑃𝑉 − 𝐼𝑜 [𝑒𝑥𝑝( ) − 1] −
it is only applicable when the load voltage is higher than 𝑘𝑇 𝑅𝑝
the PV voltage which limits the capability of MPPT.
Another comparison between buck, boost and buck- where, I is the PV cell current (A). IPV is the PV cell
boost converter is performed in [13]. In this comparison, photocurrent (A). Io is the diode saturation current. T is
the input resistance of converters is compared to match the cell temperature (K). Rs and Rp are the series and
the MPP impedance of panel. Despite of less efficiency shunt resistance of PV cell (ohms) and V is the output
compared to boost converter, Buck– boost converter is voltage of PV cell (V) [17].
preferred for enhancing capability of MPPT which will The equation (1) of the ideal PV cell does not define
be independent of load resistance or voltage. In the I-V characteristic of a practical PV array. Practical
literature, the duty cycle of the converter is adjusted arrays are manufactured by using several connected PV
using two different method of control. The first method cells and the determination of the characteristics is done
depends on a PI or hysteresis controller. The other at the terminals of the PV array.
method is characterized by directly controlling the duty If the array is composed of Np parallel connections
cycle of the power converter; this mode is called direct of cells the PV and saturation currents may be expressed
duty cycle MPPT control [5]. as in (2) and (3):
In this paper, the design and modelling of MPPT
system is simulated by using SIMULINK. In this 𝐼𝑃𝑉 = 𝐼𝑃𝑉,𝑐𝑒𝑙𝑙 ∗ 𝑁𝑃 (2)
simulation, CANADIAN SOLAR CS5C-90 panel is
used to charge 24V battery bank (12V 20AH C/5), which 𝐼_𝑂 = 𝐼_(𝑂, 𝑐𝑒𝑙𝑙) ∗ 𝑁_𝑃 (3)
is represented ideally by constant voltage, through
MPPT system. MPPT system composes of boost where Rs is the equivalent series resistance of the
converter which its duty cycle is controlled directly by array and Rp is the equivalent parallel resistance [17].
P&O algorithm. In literature, many systems have been
proposed for MPPT function as in [2] and [14-15].
However, in the paper, the designed system has
advantages of high tracking efficiency with ease of
implementation.
The simulation of proposed system is run for
different insolation and constant temperature to simulate
the real solar irradiation through sunny day. The Fig. 1. Single Diode Circuit Modelling of Ideal PV
Cell.

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2.2. Boost Converter Model

Boost topology is chosen for DC-DC converter since
it is capable of transferring maximum energy from PV
panel to load irrespective of different irradiation of sun
through the day. The topology of converter is shown in
Fig. 2. It consists of dc source VS, inductor L, power
switch S, diode D, output capacitor C, and output load
R. When the switch S is in the on state, the current in the
inductor increases linearly and the diode D is off at that
time. The load is supplied by the output capacitor. When
the switch S is turned into off state, both the source and
the energy stored in the inductor is transferred through
the diode to the output load [18].
The converter waveforms in the CCM are presented in
Fig. 3. As shown in the waveform for inductor voltage, in
the first period the inductor is supplied with VS and in the
second period the (VS-VO) voltage with reversed polarity
is induced across the inductor to keep flowing of current in
the same direction, where VO is the output voltage [18].
Fig. 3. Boost Converter Waveforms in the CCM.
According to the inductor voltage waveform, change of
inductor current in both periods could be written as in (4) From equation (6), the average output voltage could
and (5). be obtained as in (7).

𝑉𝑆 1
∆𝐼𝐿𝑃 = 𝐷𝑇 (4) 𝑉𝑂 = 𝑉 (7)
𝐿 (1 − 𝐷) 𝑆

𝑉𝑂 − 𝑉𝑆 The output voltage of the converter could be

∆𝐼𝐿𝑛 = (1 − 𝐷)𝑇 (5)
𝐿 controlled between VS < VO < Vmax, where Vmax is the
maximum required output voltage [18].
In steady state operation, the positive and negative
periods of inductor voltage waveform are equal and 2.3. Boost Converter Design Process
accordingly the rising and falling of inductor currents. To design and size the components of boost
The equations (4) and (5) could be written as (6). converters, many factors should be considered such as,
input voltage to converter, output voltage magnitude,
𝑉𝑆 𝐷𝑇 = (𝑉𝑂 − 𝑉𝑆 )(1 − 𝐷)𝑇 (6) DC-DC converter efficiency, output voltage ripple,
input power, desired output power, input current, output
current and duty cycle of PWM controller.
There are five components that should be chosen
when boost converter is designed. These are power
switching device, diode, inductor, output capacitor, and
input capacitor. [18].
1- Power switching device: The main switching device
must withstand the maximum current and voltage
stresses and also operate at the desired frequency [18].
2- Diode: Diode must be characterized by capability of
Fig. 2. Boost Converter Topology Equivalent Circuit. withstanding the required reversed off–state voltage
stress as well as the maximum and average current. In
addition, it must have low forward voltage drop, reduced
reverse–recovery, and fast switching capability [19].
3- Inductor: the design of boost inductor depends on the
maximum required ripple current which is determined at
minimum duty cycle and maximum input voltage. The
value of boost inductor is determined for specific load as
shown in (8), where Fs is the operating switching
frequency.

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Majlesi Journal of Mechatronic Systems Vol. 6, No. 3, September 2017

within the tolerance band.

𝑉𝑆 ∗ (𝑉𝑜 − 𝑉𝑆 )
𝐿= (8)
∆𝐼𝐿 ∗ 𝐹𝑆 ∗ 𝑉𝑜

Regarding the current flowing in inductor, the boost

converter can operate in continuous mode of operation
(CCM) and discontinuous mode of operation (DCM).
For CCM of operation, the minimum inductance
required (Lmin) is calculated as in (9).

𝑉𝑆 ∗ (𝑉𝑜 − 𝑉𝑆 )
𝐿𝑚𝑖𝑛 = (9)
2 ∗ 𝐼𝑆 ∗ 𝐹𝑆 ∗ 𝑉𝑜

where Is is the source current. When Fs is selected,

there should be a trade-of between minimizing the size
of the inductor and limiting the loss of the power
switching device. Generally, high-frequency of Fs is
imposed and it should be checked if the current ripple is
correct by low frequency [19-20].
4- Output capacitor: Output capacitor must be designed
carefully to perform two important functions. Firstly, it
must limit the output voltage ripple as well as withstand
the required ripple current stress. The second function, it
must supply the required output current to the load when
the diode in off state. The minimum value of the output
capacitance that provides the specified output voltage
ripple (∆VO) is calculated as in (10) [19-20]. Fig. 4. MPPT P& O Algorithm Chart.

𝐼𝑜 ∗ 𝐷 This tolerance band can be controlled by step size of

𝐶𝑚𝑖𝑛 = (10) perturbation. The selection of step size is tradeoff
𝐹𝑆 ∗ ∆𝑉𝑜
between steady state oscillation and speed of
5- Input capacitor: The minimum value of input performance of algorithm [21].
capacitor is necessary to regulate the input voltage due
to the current requirement of power supply. This 4. SIMULATION OF PROPOSED SYSTEM
minimum value can be increased in case of noisy input 4.1. PV Array Model
[20]. Fig. 5 shows the simulated PV system which is
constructed by Simulink in MATLAB. The simulated
3. PERTURB AND OBSERVE (P&O) system consists of PV array, MPPT controller, DC-DC
ALGORITHM boost converter and the battery.
The P&O algorithm is the most commonly used In this simulation, CANADIAN SOLAR CS5C-90
technique because its cost is low and implementation is panel is used for simulating PV array. The specification
easy. The algorithm based on that the gradient (dP/dV) parameters of the used PV panel are listed in Table 1.
of P-V curve is equal to zero at MPP of PV panel. Fig. 4 The maximum power of 90W is given Under Standard
represents P&O algorithm chart [21]. Test Conditions (STC) of irradiance of 1000 W/m2,
In this technique, the power supplied by the PV panel spectrum AM 1.5 and cell temperature of 25°C.
at the instant n is calculated by measuring the voltage
and current of PV array. Then the operating voltage of Table 1. Specification of Parameters of PV panel.
the PV array at instant n+1 is observed and the new Parameter Value
power is calculated. Powers at instants (n) and (n+1) are
STC (standard test conditions) CS5C-90M
compared and difference power ∆P is calculated.
In this algorithm, the signs of ∆P and ∆V of Nominal Maximum Power (Pmax) 90 W
successive sampling times (n, n+1) determine the Optimum Operating Voltage (Vmp) 18.0 V
direction of fixed perturbation in the next sampling Optimum Operating Current (Imp) 4.99 A
period to reach MPP. Because of the steady state Open Circuit Voltage (Voc) 22.3 V
oscillation of operation produced by this algorithm, the
instantaneous power obtained from the panel is held Short Circuit Current (Isc) 5.34 A

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Majlesi Journal of Mechatronic Systems Vol. 6, No. 3, September 2017

Fig. 5. Simulated PV System Components and Arrangement.

The specification of boost converter is listed in Table 2, 4.2. Simulation Operation and Results
which is designed by using equations (7-10). 24V The simulation is run for different insolation and
battery bank (12V, 20AH, C/5) is used, which is constant temperature to simulate the real solar
represented ideally by constant voltage source in the irradiation through a sunny day. The variation of
simulation. temperature through a day could be taken constant
approximately; because the decreasing of open circuit
Table 2. Specification of boost converter. voltage of PV array is associated with increasing of short
circuit current of PV array.
Parameter Value Remakes
The transition between insolation levels could be
Switching Frequency 50 KHz Chosen represented by ramp changing as shown in Fig. 6 for
(1000, 800, 500) KW/m2.
Maximum Output 4A Battery Information Fig. 7 represents P-V and V-I curves of
Current CANADIAN SOLAR CS5C-90 for (1000, 800, 500
Switching Device IGBT Chosen Ideally KW/m2) insolation levels. These curves represent
maximum power that can be extracted from PV panel in
Diode Schottky Chosen Ideally different level of insolation.

Inductance 90.2 µH Equation (6) &

∆I=0.2
Output Capacitor 42 F Equation (8)

Input Capacitor 100µF Chosen as ∆V =

0.05

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Majlesi Journal of Mechatronic Systems Vol. 6, No. 3, September 2017

Fig. 8. Simulation output of PV voltage over 2 (s).

Fig. 6. Simulated Insolation Levels Waveform.

Fig. 9. Simulation output of PV current over 2 (s).

Fig. 7. P-V & V-I curves of CS5C-90 in (1000, 800,

500 KW/m2) insolation levels.
Fig. 10. Simulation output of PV power over 2 (s).
The simulation outputs are shown in Fig. (8), Fig.
(9), and Fig. (10). The numerical results of simulation Table 3. Outputs of simulation process.
are tabulated in Table 3 averaged over simulation period
Irradiance PPV VPV,av IPV,av PPV1,av Ef.*
for each level of insolation. KW/ (W) (V) (A) (W) %
Based on Table 3, the efficiency of MPPT system in
m2 Fig.9 Fig. 12 Fig.12 Fig.13
tracking MPP can be calculated from ∆PPV which
represents the difference between actual and tracked 1000 89.82 17.445 5.112 89.18 99.3
Pmax. 800 72.18 17.462 4.010 70.02 97
Fig. 11 shows the efficiency curve of designed
MPPT system in term of solar insolation. The average 500 45.11 17.40 2.568 44.68 99
efficiency of propose MPPT system is 98.43%.The
*Ef.: Efficiency
simulation results show that the designed MPPT system
charge the battery by tracking the MPP of PV panel in
different insolation condition effectively.

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Majlesi Journal of Mechatronic Systems Vol. 6, No. 3, September 2017

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