A High-Efficiency Wide Voltage Range Bidirectional DC-DC Converter for Electrified Ground Vehicles

Hybrid and fully electrified tactical vehicles represent a crucial element of the ArmyÆs electrified technologies. Such vehicles can both charge from and provide power to tactical microgrids using onboard battery storage and/or generators, adding resilience and redundancy to power infrastructure. Benefits of the electrified vehicles also include improved operational capabilities such as ōsilent watchö (which reduces the acoustic and thermal signatures of the vehicle), improved fuel efficiency, and reduced engine runtime. To realize these benefits and meet the ArmyÆs goals, advanced power electronics are needed to work at high?temperature, achieve greater power density, and enable advanced functionality. Silicon Carbide (SiC)?based power electronic devices offer these advantages over silicon devices. To meet this need, Creare proposes a wide voltage range SiC?based DC?DC converter that serves as a crucial interface between high?voltage battery packs and the ArmyÆs high?voltage common vehicle bus. SiC devices will minimize size and maximize lifetime and reliability, while the wide voltage range enables flexibility to integrate advanced high?voltage battery packs into vehicles. Emerging high?voltage batteries (above 800 VDC) offer increased charge and discharge rates, increased electrical efficiency, reduced battery size, and increased vehicle range. During the Sequential PhaseĀII, we will leverage our existing DC?DC converter designs to develop the high?voltage range Universal High?Voltage Converter (UHVC). We will complete a detailed design, fabrication of a full?scale test prototype, and testing of the prototype at Creare. CreareÆs DC?DC converter offers the benefits of higher power density and a simpler thermal management interface and adaptability to a wide range of interface voltages when compared to existing products.