High Power Density DC-DC Converter for 800V Fuel Cell Electric Vehicles

Hai N. Tran; Tat Thang Le; Hyeonju Jeong; Sunju Kim; Huu Phuc Kieu; Sewan Choi

doi:10.1109/ECCE-Asia49820.2021.9479257

High Power Density DC-DC Converter for 800V Fuel Cell Electric Vehicles

Hai N. Tran
, Tat Thang Le
, Hyeonju Jeong
, Sunju Kim
, Huu Phuc Kieu
, Sewan Choi

Dept. of Electrical and Information Engineering

Seoul National University of Science and Technology (SNUST)

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

17 Scopus citations

Abstract

In this paper, a low-cost 63kW/L DC-DC converter operated at 300kHz is proposed for 800V fuel cell electric vehicles. Four modules of Dual Floating Output Boost Converter (DFOBC) are adopted to process 100kW power from the FC stack. For each module, an inverse coupled inductor and ZVT cells are employed. Advantages of the proposed converter over the Conventional Interleaved Boost Converter (CIBC) which is usually used in the previous FDC are found to be: 1) Planar core with PCB winding can be used for the main inductor; 2) Tall film capacitors are replaced by a low-profile ceramic capacitor; 3) Only a single discrete SiC mosfet is needed for the main switch of a 25kW module. A 25kW prototype of proposed converter is built and tested. The peak and full-load efficiencies confirm at 99% and 97.7%, respectively.

Original language	English
Title of host publication	Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021
Publisher	Institute of Electrical and Electronics Engineers Inc.
Pages	2224-2228
Number of pages	5
ISBN (Electronic)	9781728163444
DOIs	https://doi.org/10.1109/ECCE-Asia49820.2021.9479257
State	Published - 24 May 2021
Event	12th IEEE Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021 - Virtual, Singapore, Singapore Duration: 24 May 2021 → 27 May 2021

Publication series

Name	Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021

Conference

Conference	12th IEEE Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021
Country/Territory	Singapore
City	Virtual, Singapore
Period	24/05/21 → 27/05/21

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 7 Affordable and Clean Energy

Keywords

800V electric vehicles
coupled inductor
FCEV
PCB winding
planar core
switching loss
ZVT cell

Access to Document

10.1109/ECCE-Asia49820.2021.9479257

Cite this

Tran, H. N., Le, T. T., Jeong, H., Kim, S., Kieu, H. P., & Choi, S. (2021). High Power Density DC-DC Converter for 800V Fuel Cell Electric Vehicles. In Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021 (pp. 2224-2228). Article 9479257 (Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021). Institute of Electrical and Electronics Engineers Inc.. https://doi.org/10.1109/ECCE-Asia49820.2021.9479257

Tran, Hai N. ; Le, Tat Thang ; Jeong, Hyeonju et al. / High Power Density DC-DC Converter for 800V Fuel Cell Electric Vehicles. Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021. Institute of Electrical and Electronics Engineers Inc., 2021. pp. 2224-2228 (Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021).

@inproceedings{37744fd5604747729fcc3b7983b47c21,

title = "High Power Density DC-DC Converter for 800V Fuel Cell Electric Vehicles",

abstract = "In this paper, a low-cost 63kW/L DC-DC converter operated at 300kHz is proposed for 800V fuel cell electric vehicles. Four modules of Dual Floating Output Boost Converter (DFOBC) are adopted to process 100kW power from the FC stack. For each module, an inverse coupled inductor and ZVT cells are employed. Advantages of the proposed converter over the Conventional Interleaved Boost Converter (CIBC) which is usually used in the previous FDC are found to be: 1) Planar core with PCB winding can be used for the main inductor; 2) Tall film capacitors are replaced by a low-profile ceramic capacitor; 3) Only a single discrete SiC mosfet is needed for the main switch of a 25kW module. A 25kW prototype of proposed converter is built and tested. The peak and full-load efficiencies confirm at 99\% and 97.7\%, respectively.",

keywords = "800V electric vehicles, coupled inductor, FCEV, PCB winding, planar core, switching loss, ZVT cell",

author = "Tran, \{Hai N.\} and Le, \{Tat Thang\} and Hyeonju Jeong and Sunju Kim and Kieu, \{Huu Phuc\} and Sewan Choi",

note = "Publisher Copyright: {\textcopyright} 2021 IEEE.; 12th IEEE Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021 ; Conference date: 24-05-2021 Through 27-05-2021",

year = "2021",

month = may,

day = "24",

doi = "10.1109/ECCE-Asia49820.2021.9479257",

language = "English",

series = "Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021",

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}

Tran, HN, Le, TT, Jeong, H, Kim, S, Kieu, HP & Choi, S 2021, High Power Density DC-DC Converter for 800V Fuel Cell Electric Vehicles. in Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021., 9479257, Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021, Institute of Electrical and Electronics Engineers Inc., pp. 2224-2228, 12th IEEE Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021, Virtual, Singapore, Singapore, 24/05/21. https://doi.org/10.1109/ECCE-Asia49820.2021.9479257

High Power Density DC-DC Converter for 800V Fuel Cell Electric Vehicles. / Tran, Hai N.; Le, Tat Thang; Jeong, Hyeonju et al.
Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021. Institute of Electrical and Electronics Engineers Inc., 2021. p. 2224-2228 9479257 (Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - High Power Density DC-DC Converter for 800V Fuel Cell Electric Vehicles

AU - Tran, Hai N.

AU - Le, Tat Thang

AU - Jeong, Hyeonju

AU - Kim, Sunju

AU - Kieu, Huu Phuc

AU - Choi, Sewan

PY - 2021/5/24

Y1 - 2021/5/24

N2 - In this paper, a low-cost 63kW/L DC-DC converter operated at 300kHz is proposed for 800V fuel cell electric vehicles. Four modules of Dual Floating Output Boost Converter (DFOBC) are adopted to process 100kW power from the FC stack. For each module, an inverse coupled inductor and ZVT cells are employed. Advantages of the proposed converter over the Conventional Interleaved Boost Converter (CIBC) which is usually used in the previous FDC are found to be: 1) Planar core with PCB winding can be used for the main inductor; 2) Tall film capacitors are replaced by a low-profile ceramic capacitor; 3) Only a single discrete SiC mosfet is needed for the main switch of a 25kW module. A 25kW prototype of proposed converter is built and tested. The peak and full-load efficiencies confirm at 99% and 97.7%, respectively.

AB - In this paper, a low-cost 63kW/L DC-DC converter operated at 300kHz is proposed for 800V fuel cell electric vehicles. Four modules of Dual Floating Output Boost Converter (DFOBC) are adopted to process 100kW power from the FC stack. For each module, an inverse coupled inductor and ZVT cells are employed. Advantages of the proposed converter over the Conventional Interleaved Boost Converter (CIBC) which is usually used in the previous FDC are found to be: 1) Planar core with PCB winding can be used for the main inductor; 2) Tall film capacitors are replaced by a low-profile ceramic capacitor; 3) Only a single discrete SiC mosfet is needed for the main switch of a 25kW module. A 25kW prototype of proposed converter is built and tested. The peak and full-load efficiencies confirm at 99% and 97.7%, respectively.

KW - 800V electric vehicles

KW - coupled inductor

KW - FCEV

KW - PCB winding

KW - planar core

KW - switching loss

KW - ZVT cell

UR - https://www.scopus.com/pages/publications/85114196660

U2 - 10.1109/ECCE-Asia49820.2021.9479257

DO - 10.1109/ECCE-Asia49820.2021.9479257

M3 - Conference contribution

AN - SCOPUS:85114196660

T3 - Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021

SP - 2224

EP - 2228

BT - Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021

PB - Institute of Electrical and Electronics Engineers Inc.

T2 - 12th IEEE Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021

Y2 - 24 May 2021 through 27 May 2021

ER -

Tran HN, Le TT, Jeong H, Kim S, Kieu HP, Choi S. High Power Density DC-DC Converter for 800V Fuel Cell Electric Vehicles. In Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021. Institute of Electrical and Electronics Engineers Inc. 2021. p. 2224-2228. 9479257. (Proceedings of the Energy Conversion Congress and Exposition - Asia, ECCE Asia 2021). doi: 10.1109/ECCE-Asia49820.2021.9479257

High Power Density DC-DC Converter for 800V Fuel Cell Electric Vehicles

Abstract

Publication series

Conference

UN SDGs

Keywords

Access to Document

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