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Electrical and Electronics Engineering: An International Journal (ELELIJ) Vol 2, No 2, May 2013

A BATTERY CHARGING SYSTEM & APPENDED ZCS


(PWM) RESONANT CONVERTER DC-DC BUCK:
TECHNIQUE FOR BATTERY CHARGER TO YIELD
EFFICIENT PERFORMANCE IN CHARGING SHAPING
IrfanJamil*1, Zhao Jinquan2, Rehan Jamil3, Rizwan Jamil4and Abdus Samee5
12
, Department of Energy & Electrical Engineering, Hohai University, Nanjing, China
1
irfan.edu.cn@gmail.com
3
School of Physics & Electronic Information, Yunnan Normal University, China
3
ch.rehan.jamil@gmail.com
4
Heavy Mechanical Complex (HMC-3) Taxila, Rawalpindi, Pakistan
4
rizy951@gmail.com
5
Chashma Centre of Nuclear Training, PAEC, Pakistan
5
drabdussameepk@yahoo.com
ABSTRACT
This paper presents technique for battery charger to achieve efficient performance in charging shaping,
minimum low switching losses and reduction in circuit volume .The operation of circuit charger is switched
with the technique of zero-current-switching, resonant components and append the topology of dc-dc buck.
The proposed novel dc-dc battery charger has advantages with the simplicity, low cost, high efficiency and
with the behaviour of easy control under the ZCS condition accordingly reducing the switching losses. The
detailed study of operating principle and design consideration is performed. A short survey of battery
charging system, capacity demand & its topologies is also presented. In order to compute LC resonant pair
values in conventional converter, the method of characteristic curve is used and electric function equations
are derived from the prototype configuration. The efficient performance of charging shaping is confirmed
through the practical examines and verification of the results is revealed by the MATLAB simulation. The
efficiency is ensured about 89% which is substantially considered being satisfactory performance as
achieved in this paper.

KEYWORDS
ZCS, PWM Resonant Converter, dc-dc Buck, Battery Charger

1. INTRODUCTION

In recent years, with the enhancement of power electronics technology and control strategies in
power electronics devices coupled with the increasing demand of high efficiency in battery
charger system has invoked enormous attention from the research scholars around the world.
Battery charger system technology is currently being incorporated in urban industrial areas to
maintain with these demands lot of work is on towards. Therefore, many battery chargers with
different ratings and functionalities are being developed for high output efficiency since few

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Electrical and Electronics Engineering: An International Journal (ELELIJ) Vol 2, No 2, May 2013

years. The battery charger usually works to globalize the energy saving and to serve in fast
transportation systems. The use of battery charger brings convince life solution during the
traveling from urban to rural areas. Many techniques were fetched out by the scientists since
battery charger device was developed for renewable energy generation, electronic communication
power supplies, electric vehicles, UPS or an uninterruptible power supplies, PV systems and
portable electronics products. Many charging methods have been developed to improve the
battery charger efficiency in the last few decades. In order to achieving high efficiency in battery
charger, append the traditional battery charger with the technique of ZCS ( Zero-Current-
Switching) resonant buck topology which delivered the efficient performance in charging
shaping[11-12-13-14].

This work looks at the issues which associates ZCS PWM (Zero-Current-Switching Pulse width
Modulation) converter, buck topology with the battery charger. This paper develops a novel high-
efficiency battery charger with ZCS PWM buck topology which has simple circuit structure, low
switching losses, easy control and high charging efficiencies [1-3]. Zero Current Switching
resonant buck converter is analyzed and mode of operation is also studied. Various waveforms &
charging curve period were noted down during the piratical examine using MATLAB software.
The curve of charging efficiency during the charging period shows 89% charging output
efficiency of novel proposed prototype.

Fig.1 Block Diagram for the Proposed Novel Battery Charger

2. BATTERY CHARGERING SYSTEM & CAPACITY DEMAND

Today’s most modern electrical appliances receive their power directly right away the utility grid.
Many devices are being developed everyday which requires electrical power from the batteries in
order to achieve large mobility and greater convenience.

The battery charger system utilizes the battery by working to recharge the battery when its energy
has been drained. The uses rechargeable batteries include everything from low-power cell phones
to high-power industrial fork lifts, and other construction equipment. Many of these products are
used everyday around-the-clock commonly in offices, schools, and universities, urban and
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civilian areas [8-9]. In fig. 2 shows that the Battery Capacities of Various Battery-Powered
Devices which are used in different rate of watt per hours level in cell phones, laptops, power
tools, forklifts and golf crafts etc.[10].

Fig.2 Battery Capacities of Various Battery-Powered Devices

A battery charger system is a system which uses energy drawn from the grid, stores it in an
electric battery, and releases it to power device. While engineers are used modern techniques to
usually design the battery charger systems, which maximize the energy efficiency of their devices
to make certain long functioning & operation time between charging; however they often neglect
how much energy is used in the conversion process of ac electrical power into dc electrical power
stored in the battery from the utility grid.

Apparently, energy savings can be possible if the conversion losses are reduced which associated
with the charging batteries in battery-powered products & output voltage can be controlled via
switching frequency. We can achieve these savings using different techniques including
battery charger topology that is readily available today and is being employed in existing
products. The same technique and topology is discussed in this paper which increases the
efficient performance in charging shaping of novel battery charger.

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Fig.3Structure of a multi- piece battery charger system. The efficiency calculation is made over a
24 hour charge and maintenance period and a 0.2C discharge for the battery. (Prepared for
California Energy Commission Contract by EPRI Solution Ltd.,) [10].

3. METHODS OF BATTERY CHARGING SYSTEM & ITS


TOPOLOGIES
Methods of efficiency improvements in battery charger systems in use today have substantially
lower possibilities due to a lack of cognitive skills in the charger and battery which commonly
consume more electricity than the product they power. The energy savings are achieved in
millions of battery charger systems that are presently in operation worldwide by reducing
inefficiencies in charger and battery. Battery charger systems work in three modes of operation.
In charge mode of operation, the battery is accumulating the charge while the maintenance mode
of operation occurs when battery is fully charged and charger is only started to supply energy to
undermine the natural discharge. No-battery mode of operation shows that the battery has been
physically disconnected from the charger [8-9].

Fig.4SwitchModeBatteryChargerPowerVisibility

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There are lots of methods which are recognized to achieve the higher efficiency in battery charger
systems, including:
• Higher voltage systems

• Switch mode power supplies

• Synchronous rectification

• Improved semiconductor switches

• Lithium-ion batteries

• Charge and discharge at lower current rate

• Off-grid charger when no battery is present.

Topologies Normal Estimated


Efficiency Improved
Range(%) Efficiency
Range (%)
Switch Mode 40%- 60% 50%- 70%

SCR 30%- 55% 45%- 60%

Ferro resonant 25%-50% 45%-55%

Linear 2%- 30% 20%- 40%

TABLE: 1 Efficiency improvements in charger topologies

Table.1 show that the efficiencies of normal and improved range are measured less than 15%,
comparable systems with overall efficiencies of 65% or greater are technically feasible in charger
topologies for battery charger system. The linear and switch mode chargers are analogous to
linear and switch mode power supplies with the exception that the charger topologies also
incorporate charge control circuitry on their outputs. Most multi- or single-piece chargers are
either linear or switch mode chargers. These two categories are found commonly in consumer
applications, particularly in the residential public sector. Ferro-resonant and SCR(silicon
controlled rectifier) battery chargers form a large percentage of the chargers utilized in developed
industrial applications [10]. This paper provides basic idea about the method of use of switch
mode power supplies such as dc-dc converters are considered as they can achieve higher
efficiency in battery charger scheme.

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4. CIRCUIT ANALYSIS DESCRIPTION FOR NOVEL BATTERY


CHARGER
The circuit analysis describes the study of ZCS (Zero Current Switching) Resonant buck
converter and the circuit is proposed as Novel Zero Current Switching Pulse width
Modulationconverter dc-dc dc buck for battery charger [5]. The various Modes of operations of the
said circuit are analyzed. As well as output voltage of the battery charger and the normalized
voltage gain are also obtained.

4.1. ZCS Resonant Buck Converter

Buck ZCSresonant converters are used for resolving the high high-switching
switching frequency losses,
reducing the circuit volume and controlling the switches with ease. Therefore, they control the
output voltage via switchingg frequency. The switches of Zero-Current
Current Switching resonant
converters turn ON &OFF at zero current due to the current produced by resonant inductorL
inductor  and
resonant capacitor C that the resonance flows across the switch. The resonant circuit holds a
switch S, resonant components inductor L and capacitorC .

The resonant converters are usually which contains the serial or parallel connections of inductors
and capacitors to enable the switch to achieve the ZCS (Zero Current Switching)& ZVS (Zero
Voltage Switching)went under resonance conditions
conditions. The produces the occurring result of
effective switching losses, switching stress and EMI (Electromagnetic Interference) problems[4-
problems
6-7-8]. The advantages of ZCS converters are that they have llow
ow switching losses, can eliminate
the EMI (Electromagnetic Interference) problems, easy control of the switches and low stress
over the switching elements MOSFETs.

Fig.5 Traditional ZCS Resonant Buck Converter

This paper develops a novel battery charger append with ZCS PWM converter dc dc--dc buck. The
novel circuit contains auxiliary switch S1 which is connected in the serious with the resonant
capacitor Cr and forward diode Ds is placed as parallel to the auxiliary switch S1 as shown in fig. 6
[1-3-5].
5]. In general way, battery is disabled to work for recharging if the energy source is not
available. Without energy source battery can’t recharge and charging method is replenished the

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energy, to ensure that battery operates continuously; enabling it provides a normal power supply
to load. This study keeps the idea to dev
develop a ZCS PWM battery charger [15-16].

Fig.6 Proposed a Novel ZCS PWM Converter dc


dc-dc
dc Buck for Battery Charger

4.2. Mode of Operation

The operation of novel battery charger circuit is divided into various modes of operations. The
equivalent circuit of novel charger is shown in fig. 7 and modes are fatherly divided into 5 modes
respectively as shown in fig. 8 [2].

Fig.7 Equivalent Circuit of ZCS PWM Converter dc


dc-dc Buck

Mode
de 1 Mode 2
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Mode 3

Mode 4 Mode 5

Fig.8 Modes of operation of ZCS PWM Converter dc


dc-dc Buck

Lr I 0
Mode 1: ∆ t1 = t1 = (1)
Edc
Mode 2: ∆t2 = (t2 − t1 ) = ∆t1 (2)

1  −1  I 0 Z 0  
Mode3: ∆t3 = (t3 − t2 ) = sin   + D (3)
ω0   Edc  
CV
{
Mode4: ∆t4 = ( t4 − t3 ) = r r 1 − cos ωo ( t3 − t2 ) 
I0
} (4)

Mode5: ∆t5 = TS − ∆t1 − ∆t2 − ∆t3 − ∆t4 (5)


vDm
The output Voltage gain of novel charger can be determined from the voltage
throughout the freewheeling diode as is given by

E0 1 t 
=  1 + ( t2 − t1 ) + ( t3 − t2 ) + ( t4 − t3 )  (6)
Edc Ts  2 
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Electrical and Electronics Engineering: An International Journal (ELELIJ) Vol 2, No 2, May 2013

4.3. Normalized Voltage Gain

The normalized voltage gain is derived by the substituting the operating modes of proposed
novel Zero Current Switching resonant buck converter battery charger into output voltage of
novel charger.

The normalized voltage equation is gained by substituting number the equations (1), (2), (3)
and (4) into (6)

E0  3 L M 1  −1  M   Cr R0   −1  M  
 
= fS  r + sin   + D + 1 − cos sin   + D   (7)
Edc  2 R0 2Df 0  Q   M   Q   
3 L M 1 C QZ 
M = fS  r + α + r 0 [1 − cos α ] (8)
 2 QZ 0 2Df0 M 
3 M Q 
M = f ns 2D  + α + [1 − cos α ] (9)
2 Q M 

The efficiency of novel battery charger is given by

E0 I 0
η= (10)
 Ts

Vs (1 Ts ) ∫ iLr ( t ) .dt 
 t0 

5. DESIGN CONSIDERATION
A lead-acid battery rated @ 12 V, 48 A h with an internal resistance of 0.1 ohm is used as a load
under investigates of practical examine. The battery first discharges to 13 V, and then charge to
16 V. The circuit charger components values are fixed as follows: input voltage VS = 21V , output
voltage V0 = 16V , output current I 0 = 7A , switching frequency f S = 84kHz , f ns = 0.7 chosen
from the fig. 9 based on the normalized voltage gain M = E0 Edc = 16 21 = 0.76 . Normalized
load characteristic curve of novel ZCS resonant buck converter for battery charger is obtained by
using MATLAB. The values of f 0 and Cr can be calculated fatherly by determining the resonant
frequency f 0 and obtaining for fixed switching frequency choosing the power quality factor Q
from the fig.9 as well.

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Fig.9 Normalized Load Characteristics curve (Versus M and fns) for novel battery charger

The output impedance can be calculated from the output voltage E0 and the output current I 0 is
given as

E0
R0 = = 16 / 7 = 2.285 (11)
I0
The characteristic impedance is computed as given

R0 = 2.285Ω , Q = 1 (12)

Z 0 = R0 Q = 2.285 1 = 2.285Ω (13)

The resonant frequency is calculated from switching frequency and f ns chosen from the Fig. 9
and set is based on normalized voltage gain.

f0 = fs / f ns = 84kHz / 0.7 = 120kHz


(14)

The LC-resonant
resonant pair will be der
derived for which fatherly computing the LC-filter
filter pairs of novel
design parameters.

The resonant inductor Lr is given by

Z0
Lr =
ω0

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Electrical and Electronics Engineering: An International Journal (ELELIJ) Vol 2, No 2, May 2013

Z0 2.285
Lr = = = 3.00 µ H
ω0 2λ *120 *103
(15)

The resonant capacitance Cr is given by

1 1
Cr = = = 0.58µ F (16)
Z 0ω0 2.285* 2λ *120 *103

LC- filter pairs of ZCS battery charger are set as follows

L0 = 100 Lr = 300µ H
(17)

C0 = 100Cr = 58µ F
(18)

Table.2 presents the experimental circuit parameters& values for the developed novel high-
efficiency battery charger with a buck ZCS PWM converter. A deign circuit parameters are
considered & listed below in Table. 2 for practical examine [3].

PARAMETER VALUES
Input Voltage Edc 21V

Output Charging Voltage E0 16V

Resonant Inductor Lr 3.0µH

Resonant Capacitor Cr 0.58µF

Switching Frequency fs 84kHz

Resonant Frequency f0 120kHz

Filter Inductor L0 300 µH

Filter Capacitor C0 58 µF

Output Charging Current I0 7A

Table.2 ZCS buck novel charger

The duty cycle is determined by using the parameters from above Table. 2

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Electrical and Electronics Engineering: An International Journal (ELELIJ) Vol 2, No 2, May 2013

Lr I 0 2.285*10−6 *7
∆ t1 = t1 = = = 0.760 µ s
Edc 21
(19)

∆ t2 = ∆ t1 = 0.760 µ s
(20)

t 2 = ∆ t2 + t1 = 1.52 µ s (21)
1  −1  7 * 2.285  
∆ t 3 = (t3 − t2 ) =
2D *120*103 sin  21  + D  = 5.497 µ s
   
(22)

t3 = ∆ t 3 + t2 = 5.497 µ s + 1.52 µ s = 7.017 µ s (Disruption time for switches S and S1) (23)

Total time period is computed as given

Ts = 1 f s = 1( 84*103 ) = 11.904 µ s (24)


Duty Cycle D = tON f S = 5.497 µ s 11.904µ s = 0.461 (25)

The discharging time interval of capacitor is calculated as

0.58*10−6 * 21
∆t 4 = ( t 4 − t3 ) =
7
{ }
1 − cos  2D *120*103 * 7.017 *10−6  = 0.819 µ s (26)

t 4 = ∆ t4 + t3 = 0.819 µ s + 7.017 µ s = 7.84 µ s (27)

The design has reasonable range since t 4 < Ts

5.1. Practical Calculations of Novel Charger

As for the practical examine to calculate the ideal values of novel design, resonant inductor is
3.0uH and resonant capacitor 0.58uF were chosen.

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Fig.10 Practical Circuit Prototype of Novel Battery Charger

The resonant frequency f 0 is computed as given by

f0 =
ω0
=
(1 ( 3.0*10 −6
* 0.58*10−6 ) ) = 120.1kHz (28)
2D 2D

Output Impedance Z 0 of actual practical value is given by

Lr 3.0*10−6
Z0 = = = 2.274Ω (29)
Cr 0.58*10−6

5.2. Duty Cycle of Novel Charger

Lr I 0
∆t1 = t1 = = 1.01µ s (30)
Edc
∆t2 = (t2 − t1 ) = ∆t1 = 1.01µ s (31)

t2 = ∆t2 + t1 = 2.02µ s
(32)
1  −1  7 * 2.274  
∆t 3 = ( t 3 − t 2 ) = sin  21  + D  = 5.315µ s (33)
2D *120*103    

t3 = ∆t3 + t2 = 5.315µ s + 2.02µ s = 7.335µ s (34)

Total time period of novel design is

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Electrical and Electronics Engineering: An International Journal (ELELIJ) Vol 2, No 2, May 2013

TS = 1 f S = 1( 84*103 ) = 11.904 µ s (35)

The duty cycle D of switch S is determined as

tON t3 7.335µ s
D= = = = 0.616 (36)
TS TS 11.904 µ s

The duty cycle Ds of switch S1 is calculated as

t3 − t2 7.335µ s − 2.02 µ s
Ds = = = 0.446 (37)
TS 11.904 µ s

The discharging time of the capacitor is determined as

0.58*10 −6 * 21
∆t 4 = ( t 4 + t3 ) =
7
{ }
1 − cos  2D *120 *103 *5.315*10−6  = 1.65µ s (38)

t4 = ∆t4 + t3 = 2.87 µ s + 7.335µ s = 10.205µ s (39)

After practical application, the design still can work within a reasonable range since
10.205µ s < 11.904µ s = t4 < Ts

6. SIMULATION & EXPERIMENT RESULTS


A prototype ZCS PWM converter dc-dc buck for battery charger is established [14]. The
experiment results were confirmed through MATLAB software as simulation tool is used in this
paper. Fig. 11 shows that the waveforms of switch signal VG & iLr . The current iLr is declined to
zero when the switch is cut off. As a consequence, the switch can be cut off and turned on
without retaining current meanwhile achieving zero current switching with low switching losses.
Fig. 12 shows that the trigger signal on the switchesS&S1, VG denotes the trigger signal on switch
S whereas VGs denotes the trigger signal on switch S1 as well. To increase the charging current,
1
trigger signal will be delayed by 0.088µs.

In Fig.13 shows that the signal on the switch S1, VGs denotes the trigger signal on switch S1 and
1
resonant capacitor voltage VCr on the switch S1. The resonant capacitor voltage VCr can be charged
once the switch is triggered. Fig. 14 shows that the waveforms of iLr , VCr , iCr .The inductor current
iLr is increased from 0A to 8A during 0-0.9995µs, and maintained a constant value during

0.0995µs-0.999 µs. The resonance then began when the auxiliary switch is turned on after

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0.999µs. The current iLr is declined to zero when the switch is cut off, thus it has achieving zero-
zero
idm
current-switching.. Fig. 15 shows that the waveform of diode current & diode voltage Vdm . The
i
waveform of dm went down from 15A to zero during the 00-0.0995µs when the inductor current iLr
is being charged.. The diode Dm was cut off when iLr = I 0 due to the reverse bias voltage, and the
current remained at zero after 0.0995
0.0995µs.
s. The diode Dm was then turned on again, and the diode
i
current dm goes from 0A to 7A until 0.0997
0.0997µs when VCr is finished the discharging. Fig. 16 shows
Voltage Curve during the Charging Period
Period. The variation curve of terminal voltage of the battery
showing that charging the battery from 15V to 16.5V takes about 0.1 hour. Fig. 17 shows the
simulation results Charging
ing Current during the charging period of proposed novel charger. The
maximum charging current appro
pproximately 7.5A and mean about 7.6A is founded.

Fig.11 Waveforms of V &i Fig.12 Waveforms of Trigger Signal on


G Lr
V &V
G Gs1

Fig.13 Waveforms of V & VCr Fig.14 Waveform of i , VCr and i


Gs1 Lr Cr

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Fig.15 Waveforms of i &V Fig.16 Voltage Curve during the Charging Period
dm dm

Fig.17 Charging Current during the charging period

Fig. 18shows the practical chharging efficiency variationcurve ofthenovelchargerappro


pproximatelyis
89.5%.Thechargingtimeintervalis36
360minutesandthemeanefficiencyis calculatedabout89%.

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Fig.15 Charging Efficiency during the charging period

7. CONCULSION
This paper addresses the technique of ZCS PWM (Zero Current Switching Pulse width
Modulation) resonant Converter dc dc-dc
dc buck append with battery charger circuit which
demonstrates the effectiveness of developed methodology. The research methodology of ZCS
PWM converter for novel battery charger relate relatess the idea to gain high efficiency, low circuit
volume, minimum switching losses and satisfactory performance in charging shaping. The brief
discussion is done in battery charger system and on useable functional methods. The short study
of circuit descriptions,
ions, operating modes, output voltage gain and normalized voltage gain is also
summarized. The simulation results are cited for its 89% efficiency that occurs during charging
period of proposed novel prototype. The practical examine is accord high repetiti
repetitious
ous work which
gives gratification fulfillment with the theoretical predictions in this paper.

ACKNOWLEDGEMENTS

The authors would like to acknowledge financial support of this project from College of Energy
& Electrical Engineering and College of International Education, Hohai University
University,, China.
China

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AUTHORS

IrfanJamil was born in Punjab province, City Multan, Pakistan on Feb 25, 1987. He
received his bachelor degree in Electrical Engineering and its Automation from
Harbin Engineering University, Harbin, China in 2011. Currently he is pursuing his
Master degree at Hohai University, Nanjing, China. During these days he is doing
master research as a Visiting Research Scholar at Tsinghua University, Beijing
China. His research interest involves in Power electronics and Power system
Automation.

32
Electrical
ctrical and Electronics Engineering: An International Journal (ELELIJ) Vol 2, No 2, May 2013

RehanJamil was also born inn Punjab province, City Multan, Pakistan on Feb 25,
1987. He received his bachelor in B.Sc. Electrical (Electronic) Engineering from
Federal Urdu University of Arts, Science & Technology Islamabad Pakistan in 2009.
Currently he is pursuing his Master degre
degree at Yunnan Normal University, Kunming
China. His research interest involves in Electronics, Renewable energy power
generation.

Engr. RizwanJamil was born in Punjab province, City Multan, Pakistan on


August 21, 1976. He received his bache
bachelor degree in Mechanical Engineering
from University of Engineering & Technology, Lahore, Pakistan in 2000 and
received his Master degree in Power Engineering from NED University of
Engineering & Technology, Karachi, Pakistan in 2003. Currently, he is work
working in
Heavy Mechanical Complex-3 (HMC
(HMC-3) as a Senior Engineer since 2003. He is
involved in research & development of different equipment’s as per ASME, API,
AWS code/standards for power sector.

Dr.Abdus Sameegraduated
graduated as Ph
Ph.D. in electrical power engineering at Harbin
Institute of Technology in 2009. Currently he is working as Associate Professor at
Chashma Centre of Nuclear Training, Pakistan. He is also a visiting faculty member
of Pakistan Institute of Engineering and Applie
Applied Sciences. His research interests
include modeling and simulation of electrical systems, non
non-linear dielectrics, cable
insulation aging and degradation, space charge behavior in solid insulation, pulsed
power plasma application in biology, environment and water waste.

Prof. JinquanZhao was born in Yangquan, Shanxi province, China, on June 26


1972. He received his B.S. and Ph.D. degrees, all in electrical engineering, from
Shanghai Jiao tong University, Shanghai, China, in 1993 and 2000, respectively.
From 1993 to 1995, he was an engineer in Guangzhou Power Company,
Guangzhou, China. From Dec 2000 to Sept 2003, he was a postdoctoral associate in
Cornell University, Ithaca, New ew York. He was also postdoctoral associate in
eijing, China. Currently he isPh.D.
Tsinghua University, Beijing, isPh.D.-professor in College of
Energy &Electrical Engineering,, Hohai University, and Nanjing, Chi China. He has
been published more than 28 papers in many international conferences. His
research interests in the area of voltage stability analysis and control, OPF and its
applications.

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