Fuel Economy, Hypermiling, EcoModding News and Forum - EcoModder.com - View Single Post - Boost Converter for high voltage electric vehicles

cts_casemod · 08-04-2015, 02:14 PM

Had to byte the wallet and order two inductors from coilws. Was hopping to get them this week, but the order is still pending. Maybe they are out of stock...

Last week I made a small prototype, feeding from a 12VDC transformer and boosting into a 100W 30V LED. This worked as expected with a unity power factor. Even bumping two series LED's to 60V resulted in very good PF.

Now, the switches to use. Fast mosfets would be desirable, but I'm a bit skeptical about their long term reliability. A brick IGBT such as a infineon FF450R12ME4 would be virtually indestructible and would allow buck as well.

These are pricey, at $200 each, but its easy enough to spot them on fleebay for $50-80.

I've been having a chat with some members, specially regarding this other design 10kW / 60A DIY charger open source design - DIY Electric Car Forums PStechPaul found that the boost stage for the last units produced actually uses a similar inductor. So, 12KW is realistic, which is great news.

Lastly I'm pondering if a PCB or a DC-LINK setup composed of aluminum links similar to that on the inverter for the power connections. What do you guys think?

08-04-2015, 02:14 PM	#7 (permalink)
cts_casemod EcoModding Apprentice Join Date: Nov 2012 Location: East Midlands Posts: 180 Thanks: 13 Thanked 81 Times in 52 Posts	Had to byte the wallet and order two inductors from coilws. Was hopping to get them this week, but the order is still pending. Maybe they are out of stock... Last week I made a small prototype, feeding from a 12VDC transformer and boosting into a 100W 30V LED. This worked as expected with a unity power factor. Even bumping two series LED's to 60V resulted in very good PF. Now, the switches to use. Fast mosfets would be desirable, but I'm a bit skeptical about their long term reliability. A brick IGBT such as a infineon FF450R12ME4 would be virtually indestructible and would allow buck as well. These are pricey, at $200 each, but its easy enough to spot them on fleebay for $50-80. I've been having a chat with some members, specially regarding this other design 10kW / 60A DIY charger open source design - DIY Electric Car Forums PStechPaul found that the boost stage for the last units produced actually uses a similar inductor. So, 12KW is realistic, which is great news. Lastly I'm pondering if a PCB or a DC-LINK setup composed of aluminum links similar to that on the inverter for the power connections. What do you guys think? Last edited by cts_casemod; 08-05-2015 at 04:36 AM..