Hardware Design and Testing of 200kW opportunity charging application

The objective of this thesis is to show the work done during the internship period at the company IKOS CONSULTIG. IKOS is the reference company in the railway industry with expertise recognized by major stakeholders in the industry. The project under review concerns the 200kW charging converter with IGBT technology, which powers the Opportunity Charger, with inverted pantograph, for charging Electric Buses. DC/DC converter, that is forced-ventilated, consists of multiple power stages, such as Buck-Boost module, R-Bridge module, which ensure the ability both to work with wide ranges of input and output voltages and to provide galvanic isolation from the power grid. With a nominal efficiency greater than 97%, the charging converter works with a nominal input voltage is 700Vdc with wide range from 400Vdc to 900Vdc, while the output voltage range is from a minimum of 400Vdc to a maximum of 1000Vdc. The maximum output current is 300A, while the input current is around 385A. The charging converter is deployed along bus routes in the city of Milan. Being part of the Validation&Verifivation team, two types of Tests were performed on the converter: - Design Testing: with the objective of testing the proper functioning of the components, and verifying that everything defined in the Design phase works. - V&V Testing: with the objective of testing that the product complies with the operating limits imposed by European and international standards (EN and IEC). Only a few tests will be presented within the thesis, namely what are called "critical tests", such as: - Temperature Rise Test; - Output characteristics Test; - EMC Test;