Total volume evaluation of high-power density non-isolated DC-DC converters with integrated magnetics for electric vehicles

One of the main problems in electric vehicles is the volume of their electrical systems because their bulky components carry additional mass and high cost to the total system. On this topic, interleaving-phases and magnetic coupling techniques have been reported as effective methods for increasing the power density of the DC-DC converters that work between the storage unit and the motor inverter. In that sense, a volume assessment of these topologies would provide a better understanding of the problems to be faced when an electric power train is designed. In this paper, a volume modelling methodology is introduced with the purpose of comparing four different DC-DC converters: Single-Phase Boost, Two-Phase Interleaved with non-coupled inductors, Loosely Coupled Inductor (LCI), and Integrated Winding Coupled Inductor (IWCI). The analysis considers the volume of magnetic components, power devices (conventional and next-generation), cooling devices and capacitors. The methodology can be used as a part of an optimization procedure to minimize the volume of DC-DC converters. Conclusively, LCI and IWCI were found effective to miniaturize power converters with a power density of 8.4 W/cc and 9.66 W/cc, respectively. Moreover, a maximum efficiency of 98.04% and 97.61% was obtained for a 1kW LCI and IWCI prototypes, respectively.