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Research Article | Open Access | Download PDF
Volume 13 | Issue 8 | Year 2026 | Article Id. IJECE-V13I8P113 | DOI : https://doi.org/10.14445/23488549/IJECE-V13I8P113

A Four-Switch Six-Port Non-Isolated DC–DC Converter with Finite-Control-Set Predictive Regulation for 100 kW Electric-Vehicle Traction Integration

Aishwarya Ranjan Gangajaliwale, Rupesh C. Jaiswal, Sunil K. Moon, Anil S. Shirsat

Received Revised Accepted Published
29 May 2026 12 Aug 2026 19 Aug 2026 31 Aug 2026

Citation :

Aishwarya Ranjan Gangajaliwale, Rupesh C. Jaiswal, Sunil K. Moon, Anil S. Shirsat, "A Four-Switch Six-Port Non-Isolated DC–DC Converter with Finite-Control-Set Predictive Regulation for 100 kW Electric-Vehicle Traction Integration," International Journal of Electronics and Communication Engineering, vol. 13, no. 8, pp. 212-243, 2026. Crossref, https://doi.org/10.14445/23488549/IJECE-V13I8P113

Abstract

This paper presents the design, modeling, and predictive regulation of a non-isolated six-port DC-DC converter intended for 400 V Electric-Vehicle (EV) traction power-trains at the 100-kW operating level. The topology aggregates three input sources-a 98 V auxiliary input (V1), a 200 V high-voltage battery pack (V2), and a 48 V series-aid battery (V3)-and delivers regulated power to a 400 V traction bus (100 kW), a 24 V auxiliary bus (1 kW), and a 12 V housekeeping rail (250 W) using only four MOSFETs. A shared inductor pathway (L1+L2) carries the dominant boost current, while two dedicated inductors (L3 and L4) serve the auxiliary buck stages. A six-state discrete-time model is derived and embedded in a single-step finite-control-set model predictive controller (FCS-MPC) operating at Ts = 10 μs. At every sample, the controller enumerates the sixteen valid combinations of M1–M4, propagates the predicted state vector through a Tustin-discretized plant, and selects the combination that minimizes a weighted quadratic tracking cost subject to inductor-saturation and capacitor-voltage limits. PLECS simulation reports regulation bands of ±350 mV at 400 V, ±24 mV at 24 V, and ±17 mV at 12 V, with 32.6 dB cross-port disturbance attenuation at 1 kHz under a 250 A traction-bus step. A twenty-nine-line loss audit closes to 3 587 W and predicts an efficiency of 96.6 % at 101.25 kW; a two-stage common-mode filter attenuates the 200 kHz second harmonic by 41.7 dB in simulation, which is 2.3 dB short of the 44 dB budget required for CISPR 25 Class 5 and therefore identifies filter margin recovery as an open item for hardware validation. A comparison with four multi-port EV converters reported between 2022 and 2026 places the proposed design two to three orders of magnitude above the power level at which those designs were validated, so the comparison establishes the power-class gap this work addresses rather than an efficiency ranking.

Keywords

Multi-port DC-DC converter, Electric vehicle, 400 V traction, Model predictive control, Finite control set, MIMO power electronics, Lyapunov stability, Magnetic saturation, EMI filter.

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