A 300 V to 600 V 100 kW SiC MOSFET based one-cell switched tank converter (STC) is developed as a bidirectional dc-dc power transfer stage between the vehicle battery and the DC-link side of the vehicle dc-ac inverter. A continuous half-load 50 kW and short-period full-load 100 kW operation is targeted. Working principles of the proposed topology are analyzed. Design of the key components such as SiC MOSFET power modules, AC resonant capacitor and inductor is presented. A 100 kW prototype has been assembled and tested. An energy-efficient test platform is designed. The power density of the main power processing part is around 41.7 kW/L. The tested peak and full-load efficiencies are about 98.7% and 97.35%, respectively. The thermal performance has also been evaluated. Both the tested electrical and thermal results are consistent with the theoretical design.
A 25kW Silicon Carbide 3kV/540V Series-Resonant Converter for Electric Aircraft Systems
In this work, a 25 kW all silicon carbide (SiC) series-resonant converter (SRC) design is proposed to enable a single stage dc to dc conversion from 3kV to 540V (±270V) for future electric aircraft applications. The proposed SRC consists of a 3-level neutral-point-clamped (NPC) converter using 3.3kV discrete SiC MOSFETs on the primary side, a H-bridge converter using 900V SiC MOSFET modules on the secondary side and a high frequency (HF) transformer. The detailed design methods for the SRC power stage and the HF transformer are presented. Especially, a tradeoff between the complexity for the cooling system and the need for power density is addressed in the transformer design, leading to a novel multi-layer winding layout. To validate the effectiveness of the proposed SRC design, a converter prototype has been developed and comprehensive experimental studies are performed.
- Award ID(s):
- Publication Date:
- NSF-PAR ID:
- Journal Name:
- 2021 IEEE Applied Power Electronics Conference and Exposition (APEC)
- Sponsoring Org:
- National Science Foundation
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