Design and Control Implementation of High Power Bidirectional DC-DC Converter for EV Applications using DSP Controller

In a battery electric vehicle (BEV), a High power density DC-DC converter must be used to reduce the size of the EV drive train. However, in high-power applications, inductors are often the largest component in dc-dc converters. The design of an inductor that uses with two different core materials, ferrite and sendust, is studied in this paper. This has been done for the 3kW DC-DC converter, the weight and size of the inductor have been compared. In comparison to the Ferrite core, it has been noted that the area product factor and weight of the Sendust core are both lowered by 22.0% and 23.0%, respectively. In addition, the generated computational delay from the DSP controller in the control loop has been taken into consideration for the design of the control algorithm in a selected microcontroller. The average current mode control (ACMC) has been implemented in the DSP microcontroller (TMS320F28335) including the delay. Also, a 3kW prototype is developed for experimental validation.