SiC-MOSFET composite boost converter with 22 kW/L power density for electric vehicle application

A SiC-MOSFET composite boost converter for an electric vehicle power train application exhibits a volumetric power density of 22 kW/L and gravimetric power density of 20 kW/kg. The composite converter architecture, which is composed of partial-power boost, buck, and dual active bridge modules, leads to a 60% reduction in CAFE average losses, to a 280% improvement in power density, and to a 76% reduction in magnetics volume compared to the conventional Si-IGBT boost converter. These gains were achieved with the help of optimization based on a comprehensive loss model including SiC-MOSFET switching loss and magnetic losses based on the FEM method simulated in FEMM. Experimental results for the 22 kW/L SiC-MOSFET composite converter project 97.5% average efficiency on US06 driving cycle and a CAFE average efficiency of 97.8%.