Design of a 350 kW DC/DC Converter in 1200-V SiC Module Technology for Automotive Component Testing

Abstract

In this paper, the design and implementation of a DC/DC converter for automotive component testing with state-of-the art performance is described. The converter is the core of a battery emulator for the characterization and development of automotive batteries, electronic chargers, traction inverters, DC-DC converters, E-motors and E-axles. Cutting edge performance, flexibility and compactness are obtained by exploiting 1200-V SiC modules, high switching frequency, planar transformer technology, suitable topology solutions and fast digital control strategies. The implemented system is a liquid-cooled, bidirectional converter with galvanic isolation capable of 350 kW continuous output power, output voltage range 48–1000 V, continuous output current up to 800 A (1600 A peak), voltage/current ramp-up time below 10/2 ms and 0.1% current/voltage accuracy. The entire instrument is implemented in a standard full-height 19-inch rack cabinet.

A Comprehensive loss analysis of SiC-based DAB DC-DC converter for electric vehicle application

“…The harmonic reduction and power factor improvement switching are major challenges in converters of V2G [1]. In particular, the dual active bridge topology (DAB) is designed to transfer the energy between its ports bidirectionally enduring positive and negative current which interface between power sources and energy storage systems [2]. DAB must automatically maintain the desired output voltage in all working conditions as DC voltage sources [3].…”