| Abstract: |
This work provides the structural optimization, design and high-fidelity parametric assessment of a new low-volume, high-power-density DC-DC resonant power converter specifically designed for future electric vehicle (EV) battery charging infrastructure. Facing the pressing requirements for compactness and thermal efficiency in fast-charging topologies, this work explores a silicon carbide (SIC) based P–I coupled interleaved full-bridge LLC resonant topology with an elevated switching frequency of 500 kHz. Weconducteda multi-parametric empirical study along a range of loading conditions (10% to 110% of the nominal36 kW output rating) and an input DC-link voltage between 400 V and 800 V in order to characterization experimental boundaries of efficiency profiles. In order to achieve this, raw operational data comprised of switching transitions, magnetizing loop dynamics, core losses, and synchronous rectification parameters were carefully logged and collated over various stages. The experimental results analyzed exhibit a maximum conversion efficiency of 97.85% at full-load allowing the proposed system to give an impressive volumetric power density of 2.14 kW/L making it a considerable benchmark improvement over traditional silicon based systems. Mathematical formulations and statistical regression analyses give us confidence that high-frequency switching transitions are able to achieve ZVS across the full operating envelope without incurring thermal or electromagnetic interferences that would be prohibitive. This work provides a repeatable data-driven framework to church-tune the core geometries and bridge-switching paradigms, showing how wide-bandgap co-integration with efficient planar magnetics meets the promises of ultra-compact pervasive infrastructure for sustainable automotive-based transportation. |
