A 500kW 1600V Zero-Voltage Switching Resonant Switched-Capacitor DC-DC Converter for Electric Trucks and Electric Aircraft Application

In contrast to the conventional 800V architecture found in electric trucks and electric aircraft batteries, the 1600V battery system has garnered more attention. This is due not only to its capability to offer greater energy for electric trucks and electric aircraft through a larger battery bank, but also its potential to enable faster charging using lighter and slimmer wiring, while generating less heat. The current study introduces a novel approach involving a three-phase interleaved zero-voltage switching (ZVS) resonant switched capacitor converter (SCC). This design targets the conversion from 1600V to 800V specifically for electric truck and electric aircraft usage. The paper delves into an analysis of SiC MOSFET losses while incorporating a cooling system design, alongside optimization of resonant capacitors and inductors. As outlined in the paper, the projected power density stands at 93.6 kW/L, accompanied by an estimated efficiency of 99.3% under 500kW load conditions.