110 kW IGBT Buck Converter Design

I’m working on an electric-vehicle project that needs a robust, high-efficiency DC-DC chopper built around an IGBT module. The converter must operate as a buck stage and meet the following ratings:

• DC input: 360 V, 300 A
• DC output: 0 – 170 V, up to 650 A
• Continuous power: 110 kW

Thermal performance, switching strategy, and layout all need to be optimised for maximum efficiency, as that is the key driver for this build. Compactness and cost matter, but only insofar as they don’t compromise efficiency targets or reliability in an EV environment.

Deliverables I need from you
• Complete electrical schematic with IGBT selection, gate-driver circuitry, magnetics, snubbers, protection and measurement points
• Detailed design calculations that justify component ratings and predict losses
• Simulation files (PSpice, LTspice, MATLAB/Simulink or similar) showing steady-state and transient behaviour across the full 0-170 V range
• Preliminary thermal model and heatsink sizing for the chosen switching frequency
• Bill of materials with manufacturer part numbers and availability notes
• PCB layout guidelines or Gerber files if layout is included
• Short design report summarising efficiency, expected ripple, and protection strategy (over-current, over-temperature, soft-start, etc.)

Acceptance criteria
1. Simulated efficiency ≥ 94 % at nominal load
2. Output ripple within ±2 % of set voltage across the usable range
3. Component junction temperatures < 125 °C at 40 °C ambient with the proposed cooling solution
4. All protection features trigger within safe limits without nuisance tripping

If you have previous EV powertrain or high-current converter experience, please highlight it when you reply. I’m ready to move quickly once I see a solid technical approach and timeline.