Design of a High Efficiency High Power Density DC/DC Converter for Low Voltage Power Supply in Electric and Hybrid Vehicles

In this dissertation, a 2.5kW 400V/14V, 250kHz DC/DC converter prototype is developed targeted for electric vehicle/hybrid vehicle applications. Benefiting from numerous advantages brought by LLC resonant topology, this converter is able to perform high efficiency, high power density and low EMI. A first part of this dissertation is the theoretical analysis of LLC: topology analysis, electrical parameter calculation and control strategy. To arrange high output current, this thesis proposes parallel connected LLC structure with developed novel double loop control to realize an equal current distribution. The second part concerns on the system amelioration and efficiency improvement of developed LLC. A special transformer is dimensioned to integrate all magnetic components, and various types of power losses are quantified based on different realization modes and winding geometries to improve its efficiency. This converter also implements a robust synchronous rectification system with phase compensation, a power semiconductor module, and an air-cooling system. The power conversion performance of this prototype is presented and the developed prototype has a peak efficiency of 95% and efficiency is higher than 94% from 500W to 2kW, with a power density of 1W/cm3. The CEM analysis of this converter is also developed in this thesis.

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