New design concepts and realisation of DC/DC coupling reactors for light EVs

Light-power applications of the cascaded DC/DC/AC power conversion structure are considered, with reference to a new EV scooter traction AC drive. The development of the coupling integrated T+L reactor is a key point for this low-power range, concerning all efficiency, weight size and cost items. On the basis of established knowledge in medium-power applications, a new arrangement of windings and cores is presented for the first time, together with suitable electromagnetic model for design. A novel approach for forced air-cooling design is presented accordingly, together with accurate experimental verifications of the windings thermal properties in the resulting arrangement.