From Chip to Converter: A Complete Cost Model for Power Electronics Converters

The unified knowledge on power converter design and manufacturing technology establishes a powerful tool, where the cost and topology realization can be analyzed simultaneously. This paper collects the design practice and cost estimation of various components in a power electronics converter and unites that to a choice of the assembling and manufacturing processes and resulting cost of the complete converter. The outcome of this work specifies the power converter at predefined power level and cooling condition and demonstrates the cost drivers of the complete unit depending on production volumes. As a case study, the cost of an inverter for a full electric or hybrid vehicle application is estimated and the results are compared with figures available in the literature, yielding the conclusion that the validity of such figures is highly dependent on production volumes and power levels. The essence of this paper is a set of general, reliable, and fast design models and production charts, in accordance with realistic cost estimates for the sake of system optimization and development of cost effective electric drives from small series to large volumes.