Analysis of Transition Mode Operation and Characteristic Curves in a Buck–Boost Converter for Unmanned Guided Vehicles

This study presents the development of a buck–boost converter for application in unmanned guided vehicles (UGVs). The converter was designed with its input connected to a lithium iron phosphate battery pack and its output connected to an inverter. This configuration enabled the inverter, which powered the drive motor, to receive a stable DC voltage, thereby mitigating the effects of battery voltage fluctuations and enhancing the overall system stability. A pulse-width modulation (PWM) controller was employed to regulate the developed buck–boost converter. During the transition from buck mode to buck–boost mode, both power MOSFETs were simultaneously turned on; however, the datasheet of the PWM controller did not provide operational details or characteristic curve analysis for this mode. Therefore, this study derived the relationship between voltage gain and duty cycle ratio for the transition mode. To analyze the input voltage versus duty cycle characteristics, the linear equation was employed. This analytical model was adjusted to meet different converter specifications developed for experimental validation. Furthermore, the external-connect test capacitor method was used to extract the equivalent parasitic inductance and capacitance present in the practical circuit of the buck–boost converter. Based on these parameters, a snubber circuit was designed and connected across the drain–source terminals of the power MOSFETs to suppress voltage spikes occurring at the junctions. Finally, the developed buck–boost converter prototype was installed on an unmanned guided vehicle to convert the power from the lithium battery pack into the input power required by two inverters. A computer host was used to control the motor speed. By measuring the output voltage and current of the buck–boost converter, its electrical functionality and performance specifications were verified. The dimensions of the developed UGV chassis prototype were 40 cm in length, 45 cm in width, and 18.3 cm in height.