用于1600V电动卡车和电动飞机动力系统的500-kW谐振开关电容变换器

Hybrid/battery power electric trucks or aircraft draw more attention nowadays since they can eliminate greenhouse gas emissions and other harmful gases to human health. For such a megawatt-level electric power train design, a 1600-V system is more attractive due to the use of lighter, thinner wiring, and potentially much faster battery charging speeds, compared with the traditional 400- or 800-V voltage bus. In this article, a 500-kW three-phase interleaved resonant switched-capacitor dc-dc converter is proposed and developed for such 1600-V applications. The operating principle is discussed, and a detailed power loss analysis is provided, including MOSFET losses, passive component losses, and busbar losses. An effective high-power testing method has also been proposed to validate the proposed converter’s performance at the rated voltage and rated current. Both the simulation and experimental results are provided, indicating a peak efficiency of 99.1% and an efficiency of 98.7% at full-load conditions of 500-kW hardware prototype.