Integrated DC-DC converter design for Electric Vehicle powertrains

In this paper, an integrated, reconfigurable DC-DC converter for plugin and hybrid Electric Vehicles (EV) is proposed. The converter integrates functionality for both EV powertrain and charging operation into a single unit. During charging, the proposed converter functions as a DAB converter, providing galvanic isolation. For powertrain operation, the converter functions as an interleaved boost converter. During light load powertrain operation, the efficiency of the converter can be further improved by employing the integrated DAB. The proposed integrated converter does not require any extra relays or contactors for charging and powertrain operation. By using such integration, the overall volume and weight of the power electronics circuits, passives and associated cooling system can be improved. In addition, the power flow efficiency from EV battery to the high voltage DC bus for the motor inverter can be improved. The experimental results of the prototype are presented to verify the functionality of the proposed converter.