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This is a bit of an open question but I am seeking advice on further research and also some search terms so I can find the best solution.

The project requires a 48V source from a battery pack which needs to be boosted to 600V-800VDC (allowing a smaller CSA cable to be used), this will then be stepped down again to a more useable voltage for a load with a 500W power requirement.

I would ideally like to use a dedicated management IC but cannot find anything that meets the voltage/power requirements, so looking for advice on what SMPS or power conversion topologies to investigate further.

SamGibson
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Suze1990
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  • why step up and then down? And: can your 18V source 500W at all? You'll probably want to describe your application in way more detail to get sensible answers! – Marcus Müller May 07 '21 at 22:21
  • Asking about a mystery load always makes things harder... – Harper - Reinstate Monica May 07 '21 at 22:28
  • The step-up and step-down is so a smaller CSA of cable can be used in the application – Suze1990 May 07 '21 at 22:31
  • 500W is too much for a flyback, I'd look into a phase-shifted full-bridge or maybe even an LLC. If you just need to boost the voltage to keep the cable diameter down you might do an unregulated resonant converter into a step-up transformer and let the other end handle the regulation. – John D May 07 '21 at 22:59
  • John D thanks for the comment I was looking at flyback and push pull as it allows greater power, a full bridge LLC seems like a good option, complex but worth researching further. – Suze1990 May 08 '21 at 07:42

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This isn't a 'use an IC' type of problem. You're asking for a 500W high-voltage inverter, which is a board- or box-level solution that involves safety type approvals.

In this case, if this is your first foray into the market, please consider an off-the shelf inverter / step-down pair from a reputable vendor like Schneider, Alpha, etc.

I also suggest that you use AC. This has some implications for safety, especially breakers and the possibility of using galvanic isolation for your hardware.

hacktastical
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