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This paper discusses a power converter that integrates a boost motor drive and an on-board battery charger into one module unit for a drive-system less than 30kW. The proposed circuit uses a coupled magnetic-based device (CMD) in the boost converter (BC), which can switch between a boost inductor and an isolated transformer, in respect to the boost motor drive and AC charging operation. In order to achieve high power density and high efficiency, a newly 4-legs CMD is proposed. Comparing to the 3-legs CMD, the power density is increased by 12% and the efficiency can be increased by 1.5%. As a result, the drive efficiency can be improved by 2.5% comparing to a standard non-boost motor drive. The details of the proposed circuit structure and the CMD configuration are discussed in this paper. A A4-size prototype that used GaN-FETs was built to show the validity of the proposed circuit. Experimental results show well agreement with the calculated and simulation results, where a 5kW boost motor drive with 48V and a 3kW AC100V charging were achieved in the built prototype. The motor drive efficiency is 96% at 3kW with direct drive and 94.8% at 5kW with boost drive, and the AC100V charging achieved 90% efficiency at 3kW. |
