Interleaved High-Gain DC-DC Converters with Low Input Ripple and Voltage Stress for Passenger Fuel Cell Vehicles

Passenger fuel cell vehicles (FCVs) require high-gain DC/DC converters to achieve voltage matching between the low-power fuel cell (FC) stack (50–200 V) and the vehicle DC bus (400–800 V). To address the challenges in existing step-up DC/DC converters in relation to balancing the requirements of high voltage gain, wide input voltage range, low input current ripple and voltage stress, the common ground of input–output, and high efficiency in passenger FCV applications, this paper proposes three types of high-gain DC/DC converters based on an interleaved structure, incorporating quadratic Boost, quasi-Z source, and switched-inductor impedance networks. These designs effectively balance the scenario requirements of passenger FCVs. Meanwhile, taking one of the proposed converters (Interleaved-Quadratic Boost; I-QB) as an example, its steady-state performance such as voltage gain is analyzed and compared in detail with existing voltage step-up DC/DC converters. Furthermore, a scaled-down SiC-based experimental platform is constructed. Steady-state experiments validate the converter’s maximum voltage step-up capability of ten times, wide input voltage range of 30–80 V, input current ripple of less than 0.3 A, and low voltage stress on devices (≤Uo/2), thereby confirming the feasibility of these converters and the correctness of the performance analysis. The dynamic experimental results indicated that under input voltage step changes of 50–80 V and 100–50% load step changes, the I-QB converter exhibits a minor voltage overshoot with settling time under 200 ms. The prototype achieves a peak efficiency of 94.2%, confirming these converters’ suitability for passenger FCV powertrains.