600V to 12V DC-DC Converter
Designed a 2-stage DCDC converter in Altium and brought it up. It supplies power to the LV system when the car is in its high-voltage state.
- Two off the shelf stages combined into one variable input, regulated 12V output converter
- Reduced the car's LV battery size by 83%
- Can supply up to 33A to the LV system
- Onboard capacitors added to minimize ripple current
Design
Stage 1 is a fixed 16:1 ratio converter that takes a 400 to 700V input, covering the pack's usable range. Stage 2 regulates its output down to the LV bus voltage for the LV system. Stage 1 also splits HV from LV on the board with 12.7mm clearance.
Bringup and Validation
Thermal performance was measured under load with a cooling fan on the boards, output ripple was measured on the scope across the load range, and transient response was checked by stepping the e-load.
