Multi-Objective Co-Design of an Integrated Power Electronics Building Block

Model-based multidisciplinary design studies are presented for an isolated, bidirectional resonant power converter. The resonant topology chosen is a CLLC type, utilizing a split-core high frequency transformer and custom SiC MOSFET modules that implement paralleled 1.7 kV Gen 3 devices. Design goals for the converter include 500 kHz resonant frequency, 250 kW output power, and module weight of 35 pounds (15.88 kg). Electrical models are developed in L T Spice for device level studies, and in PLECS for converter-level studies. Co-design tradeoffs are identified and discussed, including zero-voltage switching, transformer design parameters, device thermal management, and electromagnetic interference (EMI) mitigation.