High Voltage Architecture of An Electric Vehicle
To advance electric vehicle (EV) technology, I developed a comprehensive Altium schematic for a DC/DC converter and inverter within the High Voltage Architecture project. The goal was to optimize the performance of both components to meet the stringent requirements of the Terp's Racing Electric Vehicle. The project focused on the following key aspects:With the goal of advancing electric vehicle (EV) technology, I undertook the development of a comprehensive Altium schematic for a DC/DC converter and inverter within the High Voltage Architecture project. This ambitious endeavor aimed to optimize the performance of both components, ensuring they meet the stringent requirements of the Terp's Racing Electric Vehicle. The project focused on the following key aspects:
Inverter:
Objective:
The primary goal of the inverter was to efficiently transform DC power from the vehicle's battery into AC power for the electric motor. The parameters included achieving a compact size, lightweight design, and high peak output power to enhance overall system performance.
Chosen Component:
The CM200DZ inverter from Cascadia Motion, with its small form factor and increased peak output power of 225 kW, perfectly aligned with the project goals, addressing spatial constraints and maximizing performance.
Considerations:
Temperature, Size, and Weight: The inverter's operating temperature range, size (330 x 188 x 97 mm^3), and weight (6.75 kg) were critical considerations impacting the vehicle's performance, design, and integration.
Economic Factor: The cost of the inverter played a pivotal role in influencing the project budget, emphasizing the importance of a cost-effective solution.
Compatibility: Ensuring compatibility with the chosen motor and other components was crucial, influencing the overall design and system performance.
Standards Compliance:
The inverter design adhered to IEEE 1547-2018 for proper interconnection with the electric power system and FSAE rules (EV.8.2.1, EV.9.2.1, T.4.2.5, EV.5.8.1) for safety and performance.
DC/DC Converter:
Objective:
The DC/DC converter aimed to regulate and convert high-voltage DC power to a lower voltage for auxiliary systems in the vehicle. High power density, flexibility, and safety were paramount.
Chosen Component:
The Vicor DCM3714xD2J13D0yzz DC/DC converter was selected for its compact design and high power density of 206W/in³, aligning with the project's goal of maximizing space efficiency.
Considerations:
Voltage Compatibility: The converter's voltage range (180-420 Vdc) was aligned with the overall high voltage architecture, ensuring proper power distribution and compatibility with the accumulator.
Inrush Current: Managing inrush current during startup (e.g., 7.0A) was a critical constraint, requiring careful consideration to prevent impacts on other system components.
Installation Complexity: The advanced features of the DC/DC converter introduced considerations of installation and maintenance complexity during the design phase.
Standards Compliance:
The DC/DC converter design followed IEEE 3004.8-2017 and FSAE rules (T.9.1.1, EV.3.3.2, EV.6.5.4, EV.7.5.4) to ensure compatibility, safety, and compliance.
Inverter and DC/DC Converter Technologies:
Inverter Types:
Electric car inverters were explored in detail, distinguishing between onboard and offboard inverters, such as centralized, distributed, and string inverters. The project emphasized the importance of choosing the appropriate type and technology for optimal EV performance.
DC/DC Converter Evolution:
The evolution of DC/DC converters from electromechanical devices to modern semiconductor-based solutions was discussed. Different types of converters, including non-isolated, magnetic, and isolated converters, were highlighted, showcasing their suitability for EV applications despite challenges such as noise generation and cost considerations.
In conclusion, this Altium schematic project not only delved into the intricacies of designing an inverter and DC/DC converter for an electric vehicle but also emphasized the broader landscape of EV inverter technologies and the critical role of DC/DC converters in advancing the electric vehicle industry.
Inverter:
Objective:
The primary goal of the inverter was to efficiently transform DC power from the vehicle's battery into AC power for the electric motor. The parameters included achieving a compact size, lightweight design, and high peak output power to enhance overall system performance.
Chosen Component:
The CM200DZ inverter from Cascadia Motion, with its small form factor and increased peak output power of 225 kW, perfectly aligned with the project goals, addressing spatial constraints and maximizing performance.
Considerations:
Temperature, Size, and Weight: The inverter's operating temperature range, size (330 x 188 x 97 mm^3), and weight (6.75 kg) were critical considerations impacting the vehicle's performance, design, and integration.
Economic Factor: The cost of the inverter played a pivotal role in influencing the project budget, emphasizing the importance of a cost-effective solution.
Compatibility: Ensuring compatibility with the chosen motor and other components was crucial, influencing the overall design and system performance.
Standards Compliance:
The inverter design adhered to IEEE 1547-2018 for proper interconnection with the electric power system and FSAE rules (EV.8.2.1, EV.9.2.1, T.4.2.5, EV.5.8.1) for safety and performance.
DC/DC Converter:
Objective:
The DC/DC converter aimed to regulate and convert high-voltage DC power to a lower voltage for auxiliary systems in the vehicle. High power density, flexibility, and safety were paramount.
Chosen Component:
The Vicor DCM3714xD2J13D0yzz DC/DC converter was selected for its compact design and high power density of 206W/in³, aligning with the project's goal of maximizing space efficiency.
Considerations:
Voltage Compatibility: The converter's voltage range (180-420 Vdc) was aligned with the overall high voltage architecture, ensuring proper power distribution and compatibility with the accumulator.
Inrush Current: Managing inrush current during startup (e.g., 7.0A) was a critical constraint, requiring careful consideration to prevent impacts on other system components.
Installation Complexity: The advanced features of the DC/DC converter introduced considerations of installation and maintenance complexity during the design phase.
Standards Compliance:
The DC/DC converter design followed IEEE 3004.8-2017 and FSAE rules (T.9.1.1, EV.3.3.2, EV.6.5.4, EV.7.5.4) to ensure compatibility, safety, and compliance.
Inverter and DC/DC Converter Technologies:
Inverter Types:
Electric car inverters were explored in detail, distinguishing between onboard and offboard inverters, such as centralized, distributed, and string inverters. The project emphasized the importance of choosing the appropriate type and technology for optimal EV performance.
DC/DC Converter Evolution:
The evolution of DC/DC converters from electromechanical devices to modern semiconductor-based solutions was discussed. Different types of converters, including non-isolated, magnetic, and isolated converters, were highlighted, showcasing their suitability for EV applications despite challenges such as noise generation and cost considerations.
In conclusion, this Altium schematic project not only delved into the intricacies of designing an inverter and DC/DC converter for an electric vehicle but also emphasized the broader landscape of EV inverter technologies and the critical role of DC/DC converters in advancing the electric vehicle industry.
Computer Engineering
at
University of Maryland, College Park
Comments