Design of a Bi-directional Flyback DC/DC converter: For a stand-alone solar-powered eBike charging station

This document is the bachelor graduation thesis of BAP Group B2. Together with BAP Group B1 the objective of this project was to create a control network and DC/DC converter implementation capable of fast, analog power management with active, remote-control and -interfacing of multiple converter’s energy flows. The system will be designed to function in the solar-powered eBike charging station on the TU Delft campus. This document specifically is concerned with the design, simulation and testing of the DC/DC converter. The thesis presents a bi-directional flyback DC/DC converter design and prototype with analog power management, universal control signals and high integration potential. These aspects are accomplished by building upon the traditional flyback DC/DC converter design with respect to circuit topology, power-flow control, connectivity and accessibility. The difficult regulation and measurement of DC power flow has been reduced to a set of analog signals interpretable by any microcontroller, easing the integration of the converter into larger energy and control networks. A working prototype is presented and the inner-workings of the electrical circuit are discussed and evaluated in detail. The converter is tested beyond the limit of the design requirements and the performance is documented. Provided are possible reasons for malfunctioning and guidelines for future improvements. Design