Double phase high-efficiency, wide load range high- voltage l ow-voltage llc dc dc converter for electric hybrid vehicles

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Engineering

DOUBLE-PHASE HIGH-EFFICIENCY, WIDE LOAD RANGE HIGH-
VOLTAGE/LOW-VOLTAGE LLC DC/DC CONVERTER FOR ELECTRIC/HYBRID
VEHICLES
ABSTRACT
In this paper, a 2.5-kW 330–410-V/14-V, 250-kHz dc/dc converter prototype is
developed targeted for electric vehicle/ hybrid vehicle applications. Benefiting from numerous
advantages brought by the LLC resonant topology, this converter is able to perform high
efficiency, high power density, and low EMI. To arrange high-output current, this paper
proposes a parallel connected LLC structure with developed novel double-loop control to realize
an equal current distribution and an overall efficiency improvement. Considering the LLC cell’s
dimensioning, this paper establishes a more precise model by taking the secondary leakage
inductance into consideration. System amelioration and design considerations of the developed
LLC are also presented in this paper. A special transformer is presented, and various types of
power losses are quantified to improve its efficiency. This converter also implements
synchronous rectification, power semiconductor module, and an air-cooling system. The power
conversion performance of this prototype is measured and the developed prototype attains a peak
efficiency of 95% and efficiency is higher than 94% from 500Wto 2 kW, with a power density of
1 W/cm3. Finally, the EMC results of this prototype are also measured and presented.

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Double phase high-efficiency, wide load range high- voltage l ow-voltage llc dc dc converter for electric hybrid vehicles

1. DOUBLE-PHASE HIGH-EFFICIENCY, WIDE LOAD RANGE HIGH- VOLTAGE/LOW-VOLTAGE LLC DC/DC CONVERTER FOR ELECTRIC/HYBRID VEHICLES ABSTRACT In this paper, a 2.5-kW 330–410-V/14-V, 250-kHz dc/dc converter prototype is developed targeted for electric vehicle/ hybrid vehicle applications. Benefiting from numerous advantages brought by the LLC resonant topology, this converter is able to perform high efficiency, high power density, and low EMI. To arrange high-output current, this paper proposes a parallel connected LLC structure with developed novel double-loop control to realize an equal current distribution and an overall efficiency improvement. Considering the LLC cell’s dimensioning, this paper establishes a more precise model by taking the secondary leakage inductance into consideration. System amelioration and design considerations of the developed LLC are also presented in this paper. A special transformer is presented, and various types of power losses are quantified to improve its efficiency. This converter also implements synchronous rectification, power semiconductor module, and an air-cooling system. The power conversion performance of this prototype is measured and the developed prototype attains a peak efficiency of 95% and efficiency is higher than 94% from 500Wto 2 kW, with a power density of 1 W/cm3. Finally, the EMC results of this prototype are also measured and presented.

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