Hybrid-mode interleaved boost converter design for fuel cell electric vehicles

Highlights: • A high power interleaved boost converter is designed for a 150 kW high-power fuel cell electric vehicle application. • A hybrid-mode scheme is used: Mode I and mode II are used with each boost converter operating in continuous conduction mode and discontinuous conduction mode. • Boundary conditions for different modes are determined with respect to switching duty ratio and load conditions. • With the proposed scheme, the power density is improved by 44.2% and 34.3% in terms of the converter volume and weight. - Abstract: For Fuel Cell Electric Vehicles, DC-DC power converters are essential to provide energy storage buffers between fuel cell stacks and the traction system because fuel cells show characteristics of low-voltage high-current output and wide output voltage variation. This paper presents a hybrid-mode two-phase interleaved boost converter for fuel cell electric vehicle application in order to improve the power density, minimize the input current ripple, and enhance the system efficiency. Two operation modes are adopted in the practical design: mode I and mode II are used with each boost converter operating in continuous conduction mode and discontinuous conduction mode. The operation, design and control of the interleaved boost converter for different operating modes are discussed with their equivalent circuits. The boundary conditions are distinguished with respect to switching duty ratio and load conditions. Transitions between continuous conduction mode and discontinuous conduction mode are illustrated for the whole duty ratio range. The expressions for inductor current ripple, input current ripple and output voltage ripple are derived and verified by simulation and experimental tests. The efficiency and power density improvements are illustrated to verify the effectiveness of the proposed design scheme.