Intrinsically-Safe Modular Power Converters for Electric Transportation

By 2030, electric vehicles (EVs) are estimated to represent more than 30% of new passenger vehicle sales. Most EVs today feature powertrains built around 400V lithium battery packs, with SOOV powertrains planned for new designs. Though the chemical and thermodynamic stability of lithium batteries have been extensively studied, the high voltage safety of EV batteries remains a pressing risk especially following accidents where on-board safety systems are compromised. As market penetration of EVs increases worldwide, the brunt of the high-voltage safety risk will be borne by passengers, first responders, manufacturing workers, and maintenance workers. In this work, the authors present an intrinsically safe and modular 48 volt DC powertrain architecture that meets and surpasses current EV power and performance specifications while delivering the additional benefits of low-voltage touch safety and reduced isolation requirements, providing flexibility in the design of the battery pack and maintaining high motor drive efficiency.