Total volume evaluation of high-power density non-isolated DC–DC converters with integrated magnetics for electric vehicles
ISSN 1755-4535
Received on 3rd March 2017
Revised 29th June 2017
Accepted on 21st July 2017
E-First on 25th August 2017
doi: 10.1049/iet-pel.2017.0157
www.ietdl.org
Wilmar Martinez1,2 , Camilo Cortes1, Masayoshi Yamamoto3, Jun Imaoka4, Kazuhiro Umetani5
1Universidad Nacional de Colombia, Bogota, Colombia
2Aalto University, Espoo, Finland
3Nagoya University, Nagoya, Japan
4Kyushu University, Fukuoka, Japan
5Okayama University, Okayama, Japan
E-mail: whmartinezm@unal.edu.co
Abstract
One of the main problems in electric vehicles is the volume of their electrical systems because their bulky
components carry additional mass and high cost to the total system. On this topic, interleaving-phases and magnetic coupling
techniques have been reported as effective methods for increasing the power density of the DC–DC converters that work
between the storage unit and the motor inverter. In that sense, a volume assessment of these topologies would provide a better
understanding of the problems to be faced when an electric power train is designed. In this paper, a volume modelling
methodology is introduced with the purpose of comparing four different DC–DC converters: Single-Phase Boost, Two-Phase
Interleaved with non-coupled inductors, Loosely Coupled Inductor (LCI), and Integrated Winding Coupled Inductor (IWCI). The
analysis considers the volume of magnetic components, power devices (conventional and next-generation), cooling devices and
capacitors. The methodology can be used as a part of an optimization procedure to minimize the volume of DC–DC converters.
Conclusively, LCI and IWCI were found effective to miniaturize power converters with a power density of 8.4 W/cc and 9.66
W/cc, respectively. Moreover, a maximum efficiency of 98.04% and 97.61% was obtained for a 1kW LCI and IWCI prototypes,
respectively.
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