Experimental Verification of 500kW Resonant Switched-Capacitor Converter for Electric Trucks and Electric Aircraft Application

Electric trucks and aircraft draw more attention nowadays since they have now direct vehicle emissions which are harmful to human health and the major source of greenhouse gases. Compared with traditional 400V or 800V EV battery architecture, a 1600V battery system attracts more attention which can use lighter, thinner wiring to charge at unprecedented speeds with less heat. In this paper, a three-phase interleaved resonant switched capacitor converter is proposed and designed for 1600V to 800V applications. The operation principle is discussed with a detailed analysis of converter power loss, including MOSFET loss, passive component loss and busbar AC and DC loss. Due to constraints associated with laboratory testing equipment, an equivalent circuit has been devised for separately testing the converter under high current and high voltage conditions. The test results align closely with the calculated values, indicating a peak efficiency of 99% and an efficiency of 98.7% at full load conditions of 500 kW.