The UK has been a hotbed for exciting new green technologies in recent months, and now a consortium led by technology consultancy Prodrive has developed a bi-directional DC-DC converter with the ability to deliver a 600V output from a 380V source.
The converter, which has been designed to help reduce the cost, weight and package space associated with hybrid and electric vehicle battery packs, can maintain its output even when the source voltage slumps to as little as 200V. It balances the voltage between the motor and the energy storage system, providing a boost or reduction in voltage as necessary. This allows for more energy to be reclaimed under braking and provides more under acceleration, helping the vehicle to be more efficient.
To further improve efficiency, electric motors require wider speed ranges with speed proportional to voltage in motors. With electric vehicles and hybrids progressing from 300V to 600V systems, there is a significant challenge because battery chemistry dictates the voltage per cell and so doubling the voltage with the same chemistry means doubling the number of cells – which in turns increases cost and weight.
However, with the DC-DC converter, the potential of the battery is higher than the nominal voltage of the pack and so it allows smaller battery packs to be used while still supporting more powerful motors. In turn, the voltage of the batteries can fluctuate with changing load, while the converter always presents the full voltage required by the motor.
It is based on a dual interleaved topology that delivers up to 97 per cent efficiency while minimising component sizes.
Joining Prodrive within the consortium are the University of Manchester, Sloan Electronics Ltd, LDV Ltd, HILTech Developments, International Transformers and Newcastle University. The work has also received support from the Technology Strategy Board.
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