Design and Protoype Development of DC-DC Converter for Formula Student Vehicle

Abstract

This thesis details the development and implementation of a phase-shifted full-bridge (PSFB) DC/DC converter, incorporating a current doubler rectifier, specifically de-signed for high efficiency and compact size in Formula Student vehicles. The research includes a comparative evaluation of different converter topologies, including center-tapped and bridge rectifiers, as well as synchronous and diode rectifiers. A key focus is on achieving Zero Voltage Switching (ZVS) by optimizing dead time and ensuring the complete discharge of switch capacitance before activation to reduce switching losses. The designed converter steps down an input voltage range of 300V to 600V to a regulated output of 10V to 15V, with a power range of 150W to 300W. The converter’s efficiency is projected to be 92%. The theoretical design of the converter is validated through comparison with simulation and experimental results.