Volume Comparison of DC-DC Converters for Electric Vehicles 1 Shimane University (Japan) 2 Universidad Nacional de Colombia (Colombia) Wilmar Martinez 1,2 , Shota Kimura 1 , Jun Imaoka 1 , Masayoshi Yamamoto 1 and Camilo Cortes 2 Background DC-DC Converters Modeling Power Losses Parameters Thermal Metal Resources Saving Downsizing of Power Converters Solution Interleaving Phases Magnetic Integration Results Evaluation Conclusion • A volume modeling methodology of 4 DC-DC converters • Geometry Sizing, Inductor Modeling, Loss Calculation, Heat Sink Modeling with Next Generation Devices • Interleaving Phases and Magnetic Coupling are effective • IWCI offers the smallest volume • LCI offers the lowest losses and small volume • Next Generation Devices offer up to 75% reduction of the heat sink volume Semiconductors’ Losses Battery Inverter Motor DC/DC Converter Electric Vehicle Applications Ｈigh efficiency and High Power Density are required Downsizing of Magnetic Components and Cooling Devices Cost Reduction C o S 1 V i V o D 1 Magnetic component Single-Phase inductor L N C o D 1 S 1 S 2 V i V o D 2 Magnetic component Integrated winding coupled inductor L 2 L 2 L 1 -M 2 +M 1 +M 1 N 1 N 2 N 2 Loosely-coupled inductor L 2 L 2 -M 2 N 2 N 2 Non-coupled inductors L 2 L 2 N 2 N 2 e A A e A w w A w A Window area Sectional area e A w A e A e A e A w A e A e A e A A e A w w A w A Sectional area of the external leg Window area w A w A e A c W e A e A e A Core Geometries winding A winding A winding A winding A   DC resistance R DC AC resistance R AC δ : Depth of the skin 2 winding A 2 winding A 2 winding A 2 winding A e A e A e A Length of the winding A w N winding A N  T J T C T H T AMB R ΦJC R ΦCH R ΦHA P Loss b H L c d t s L W HS A n: number of channels n b / 20 Turns Lowest Inductor Losses Loss HA CH JC AMB J P R R R T T ) (          V c R R R n R air P air A th FIN th d th HA , , , , 5 . 0 2 1 1             HS HS d th A d n R  . ,  HS FIN th tL c R   , hLc R A th 1 ,  c sw core V f B P 55 . 1 5 . 2 max 14 10 5 . 4    Parameters Value Input Voltage [V] 80 Output Voltage [V] 200 Power [kW] 1 Switching Frequency [kHz] 50 Duty Cycle 0.6 Input Ripple Current [%] 20 Output Ripple Voltage [%] 0.1 Transistors Mosfet CoolMos Diodes Si Diode SiC Diode ࡾ ࡰࡿሺ࢕࢔ሻ [mΩ] 38 19   [V] 1 0.8 ࡯ ࢙࢙ [pF] 4560 9900 ࡾ ࡰ [mΩ] 40 16 ࡯ ࢕࢙࢙ [pF] 390 160 ࡽ ࢘ [nC] 30 - ࢚ ࢘࢙ࢋ [ns] 27 27 ࢚ ࢘࢘ [ns] 60 - ࢚ ࢌ [ns] 19 5 Single-Phase Interleaved LCI IWCI Transistor Losses [W] Si CoolM Si CoolM Si CoolM Si CoolM 6.89 4.05 2.77 1.71 2.86 1.76 2.86 1.76 Diode Losses [W] Si SiC Si SiC Si SiC Si SiC 14.55 5.01 6.80 2.25 6.80 2.25 6.80 2.25 Single-Phase Interleaved LCI IWCI Transistor Heat Sink Volume [cc] Si CoolM Si CoolM Si CoolM Si CoolM 7.86 4.52 3.19 2.05 3.29 2.10 3.29 2.10 Diode Heat Sink Volume [cc] Si SiC Si SiC Si SiC Si SiC 27.60 6.10 9.06 2.71 9.06 2.71 9.06 2.71 Heat Sinks’ Volume Inductors’ Losses Heat Sink Copper Losses Core Losses Single-Phase Interleaved LCI IWCI