SiC MOSFET gate driver supply converter: design review for traction inverter application

The aim of this project is to develop an isolate gate driver power supply stage, suitable to be used for driving Silicon-Carbide MOSFETs of a traction inverter. It is shown the effectiveness of the flyback DC-DC topology in applications in which isolation, space and cost are a major concern. The preliminary design phase is based on the evaluation of the different component-requirements that are necessary to produce the desired outputs. The main focus of the project was the realization of a model of the converter to perform simulations of the real device. This phase was crucial in order to validate the design approach and to select the proper electronic solutions such as protection circuits and filters. It has been also realized a model able to simulate the control features embedded in the gate driver and it has been evaluated the effect of the variation of circuit parameters on the behavior of the control itself. The realization of such control strategy, it is based on simplified information available on the technical documentation of the gate driver. The results of the simulations are coherent with the behavior of the driver reported in the datasheet, however no precise information is available on how the internal structure of the controller actually is, making the simulated one a possible approximation. Finally it is realized a PCB design of the converter, considering the real application in terms of dimensions and the needs of placing six identical converter on the same board. After some initial considerations on how to build the desired disposition, it is presented a solution that respected the requirements. Each trace and zone is properly dimensioned according to the amount of current it needs to handle and a complete control board design is realized in order to verify the initial requirements.