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

Alessio Alemanno, Fabio Ronchi, Carlo Rossi, Jacopo Pagliuca, Matteo Fioravanti and Corrado Florian
Additional contact information
Alessio Alemanno: Department of Electrical and Electronic, Information Engineering “Guglielmo Marconi”, University of Bologna, 40136 Bologna, Italy
Fabio Ronchi: Arca Tecnologie s.r.l., 40026 Imola, Italy
Carlo Rossi: Department of Electrical and Electronic, Information Engineering “Guglielmo Marconi”, University of Bologna, 40136 Bologna, Italy
Jacopo Pagliuca: Loccioni, 60030 Angeli di Rosora, Italy
Matteo Fioravanti: Loccioni, 60030 Angeli di Rosora, Italy
Corrado Florian: Department of Electrical and Electronic, Information Engineering “Guglielmo Marconi”, University of Bologna, 40136 Bologna, Italy

Energies, 2023, vol. 16, issue 5, 1-29

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.

Keywords: DC-DC converter; battery emulator; SiC; SiC modules; planar transformer; DAB converter; interleaving; high switching frequency; ZVS commutations; low inductance bus bar; low ESL capacitors (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2023
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