Design of a High-to-Low Voltage, Low-Power, Isolated DC/DC Converter for EV Applications
Résumé
The design of a low-cost 800V-to-12V, 4 W isolated DC/DC converter for automotive applications is investigated. Such a converter is required to supply tiny systems directly from the high-voltage battery of an Electric Vehicle. In particular, a selected topology based on a Multi-Level Flying-Capacitor stage is analyzed. The converter operating mode selection is studied and simulation results reveal the interest of operating at the limit of the ZVS mode. The design of a planar transformer adapted to the application is described. Design considerations of an IC brick that includes the main blocks required to control the power stage are discussed. The performances of a 4 W prototype with two transformer designs validate the choice of the operating mode. The peak efficiency is 87.4% which confirms the interest of the selected approach compared to existing solutions
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