With increasing calls of electrification for transportation (e.g., electric vehicles, hybrid or electric aircraft), the need for systematic guidelines that gauge passive component specific energy density for weight-optimized converter design has become apparent. Observing a lack of data sets and corresponding modeling process for passive components that usually dominate a converter's weight, this work proposes a transformation that estimates the specific energy density of passive components from comprehensively surveyed volumetric energy density data and empirical specific density models, and thus forms a convenient guideline for converter weight optimization. The proposed model is then applied to a converter designed for electric aircraft applications to showcase the component mass estimation and selection process along with estimation accuracy.
Level II electric vehicle (EV) on-board chargers provide AC-DC conversion capability in order to charge onboard high-voltage (HV) batteries. Bidirectional EV chargers can allow the EV to also act as an AC source in vehicle-to-grid services. In both charging and inverter applications, it is desirable for chargers to have high power density, high power-handling capability, and low weight. This paper showcases the architecture and control of an optimized bidirectional EV charger system that can convert from both low-line (120 V AC ) and high-line (240 V AC ) AC voltages to a 400 V DC output. The operation and control of the complete system, thermal management, enhanced power stage design, and start-up procedure are discussed. Experimental results demonstrating DC-AC high power operation and system start-up are reported.
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