Analysis of power losses and efficiency up to 60 kW DC-DC converter for hybrid electric vehicle with different inductive core materials

A DC-DC converter with different inductor core materials, voltage levels and frequencies is designed to investigate the losses and efficiency for both buck and boost mode. Semiconductor and inductor losses are analytically analyzed at 900 V and 450 V systems to study the behavior at two voltage levels. A comparison of the two voltage level systems using ferrite and iron powder as a core material is done. An EC-70 core shape is used to determine its effect on a converter´s efficiency and power losses. Furthermore the weight and losses of the converter are studied at different frequencies. Readymade inductors are not commercially available for higher power levels instead they have to be designed for hybrid electric vehicle applications.