Design considerations for high-voltage DC bus architecture and wire mechanization for hybrid and electric vehicle applications

In electric and hybrid electric vehicle applications high-voltage (HV) DC bus is shared by multiple power converter units and energy storage systems. Each of these components should meet a set of common HV bus design requirements besides their own functional requirements. Selection of an appropriate HV DC bus architecture is intertwined with control dynamics and filter component sizing, together with a set of design metric for automotive applications. This paper discusses these items with simulation results and design trade-offs. Some vehicle level test data is also presented here in support. This paper describes HV DC bus architecture and component selection particularly for Extended-Range Electric Vehicle application. The analysis covered in this paper, in deciding an appropriate DC bus architecture, emphasizes on HV DC Bus ripple, resonance and voltage transients during various vehicle drive profiles.