A High-Gain Multilevel dc–dc Converter for Interfacing Electric Vehicle Battery and Inverter

An isolated multilevel bidirectional dc–dc converter is presented in this article to interface the low-voltage (LV) battery and the high-voltage (HV) propulsion inverter in electric vehicles. The proposed topology achieves a HV step-up ratio in the motoring mode by reconfiguring two split capacitor half-bridge circuits in series/parallel through the symmetrical modulation of a voltage bidirectional, two quadrant switch. This reconfiguration generates a high-frequency multilevel voltage output at the dc-bus side of the inverter, which reduces the output filter volume. The dc-bus voltage is regulated by the duty cycle modulation of the intermediary switch in the motoring mode, simplifying the sensing and control. During regenerative braking, the converter is operated with phase shift modulation between the HV half bridges and the LV full bridge to regulate the battery voltage. The presented modulation strategies achieve zero voltage switching for the full-bridge devices over a wide load range. A comprehensive analysis of the proposed multilevel converter in motoring and braking modes along with the design constraints and soft switching boundary conditions is presented in this article. Detailed experimental results on a 1.5-kW laboratory prototype are presented to verify the design approach and illustrate the converter performance.