Trade Study and Design of a TRL-4, 100 ¿C, 28- to 600-V Bidirectional DC

Report No. ARL-TR-5430
Authors: Damian Urciuoli, Robert A. Wood, and Charles W. Tipton
Date/Pages: January 2011; 32 pages
Abstract: We present the design of a 10-kW, bidirectional, 28- to 600-V, high temperature, technical readiness level (TRL)-4, converter power-stage in support of the Ground Combat Systems (GCS) heavy brigade combat vehicle modernization program. Five different converter topologies are compared. A current-fed, converter with a low-voltage-side (LVS) active clamp and a configurable voltage doubling high-voltage-side (HVS) are selected to meet the high voltage conversion ratio and high power density requirements. Simulations of synchronized and interleaved operation are performed to assess operation over source voltage ranges and identify component values to meet distortion spectrum specifications. Converter component selection allows for synchronous rectification to reduce system losses. Commercial-off-the-shelf (COTS) devices are specified and analyses of component volume reductions and loss savings for two silicon carbide (SiC) device replacement options are shown. A powerdense, three-dimensional model of the proposed converter package design is presented.
Distribution: Approved for public release
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Last Update / Reviewed: January 1, 2011