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The power conversion system powers all of the vehicle’s low voltage systems from the HV pack. The team has historically used Vicor DCM modules (Vicor DCM3623TA5N17B4T70) for isolated LV power, however they offer relatively poor efficiency at our expected loads (75-85%) at our expected loads .
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The Vicro Vicor module is a highly integrated device with no opportunity to improve it’s performance, so we have decided to investigate creating our own converter.
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Isolated output
> 60W continuous power output
More efficient than the Vicor module
90-153VDC Input from HV battery
130.68V nominal
~12V output
Goals
10W efficiency of > 90%
30W efficiency > 94%
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ZVS is achieved by the above using an active clamp flyback. LLC is another popular ZVS topology, but it only operates at resonance at a fixed buck ratio which may hurt efficiency for us since the pack varies in voltage greatly.