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Unidirectional fast switching non-isolated 100 kW fuel cell boost converter

: Kreutzer, O.; Eckardt, B.; März, M.


Institute of Electrical and Electronics Engineers -IEEE-:
16h European Conference on Power Electronics and Applications, EPE-ECCE Europe 2014. Vol.2 : 26-28 August 2014, Lappeenranta, Finland
Piscataway, NJ: IEEE, 2014
ISBN: 978-1-4799-3016-6
ISBN: 978-1-4799-3015-9
European Conference on Power Electronics and Applications (EPE) <16, 2014, Lappeenranta>
Energy Conversion Congress and Exposition (ECCE) <2014, Lappeenranta>
Fraunhofer IISB ()

This paper describes the power stage of a non-isolated unidirectional 400 V 100 kW DCDC converter for fuel cell vehicles that reaches a switching frequency of 150 kHz with industry power modules. The power modules are equipped with custom made DCB-substrates assembled with a combination of fast 600 V super-junction Si-Mosfets and SiC-Schottky Diodes. For all other components like drivers, current sensors and the auxiliary supply converter standard products have been used to facilitate an automotive specification, and a cost efficient production. The inductors are custom-made to reduce choke losses and volume. The converter reaches an efficiency of 98 % at full load (166->400 V, 590 A lowside current). Furthermore a simple and reliable DC-link discharge unit is described that discharges with constant power and is far smaller and faster than a conventional resistor solution. Based on a constant current discharge device using a Power MOSFET in linear operation, it is extended with a small analog circuit to a roughly constant power discharge device.