This master’s thesis provides theoretical basis, design, manufacturing, and testing of high-current safety switch for an automotive bidirectional switching converter.
The design of the switch follows the guidelines of the 48 V automotive standard and other specific requirements applied to vehicles with limited powertrain electrification, i.e. mild hybrids. The coupling method of the safety switch and bidirectional converter is described in more detail along with topology specific requirements. Individual safety switch assemblies are intentionally composed of predominantly discrete components due to the current electrical component shortage. Special attention was paid to the design of the overcurrent protection, which protects the bidirectional switching converter from short circuit. Operation of individual assemblies is presented alongside circuit schematics created with Altium Designer. Operation of safety switch is presented and explained. Testing and verification of the manufactured prototype determined that the switch meets basic requirements, but certain shortcomings were identified. In conclusion, improvements are described that would enhance the operation of the switch.
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