Evolution of Automotive Chopper Circuits Towards Ultra High Efficiency and Power Density

Abstract

Automotive industry is considered to be one of the main contributors to environmental pollution and global warming. Therefore, many car manufacturers are in near future planning to introduce hybrid electric vehicles (HEV), fuel cell electric vehicles (FCEV) and pure electric vehicles (EV) to make our cars more environmentally friendly. These new vehicles require highly efficient and small power converters. In recent years, considerable improvements were made in designing such converters. In this paper, an approach based on so called Snubber Assisted Zero Voltage and Zero Current Switching topology otherwise also known as SAZZ is presented. This topology has evolved to be one of the leaders in the field of highly efficient converters with high power densities. Evolution and main features of this topology are briefly discussed. Capabilities of the topology are demonstrated on two case study prototypes based on different design approaches. The prototypes are designed to be fully bi-directional for peak power output of 30kW. Both designs reached efficiencies close to 99% in wide load range. Power densities over 40kW/litre are attainable in the same time. Combination of MOSFET technology and SAZZ topology is shown to be very beneficial to converters designed for EV applications.