Automated Layout Optimization Methods of a Bidirectional DC-DC ZVS Converter Using PowerSynth

This research paper presents an advanced methodology for optimizing the design and automation of a bidirectional DC-DC converter with zero-voltage switching (ZVS). The optimization not only considers size, weight, power, and cost (SWaP-C) but also focuses on achieving an efficient and power-dense layout. It utilizes the PowerSynth tool for layout optimization. The paper introduces optimization algorithms for component selection to achieve high power density and employs the PowerSynth tool for physical layout optimization. It illustrates the tradeoff between low inductance and maximum junction temperature for different layout arrangements, aiding in selecting the optimum layout. In the optimization process, tradeoffs and critical design issues between low volume and high power are considered for the modular structure of the bidirectional boost converter. A Monte Carlo optimization method is utilized, exploring the design solution space. The physical layout solutions, including temperature and inductance values from PowerSynth, serve as input data for thermal analysis in Para Power, evaluating the associated risk for each layout design. Ultimately, this study aims to integrate mathematical design analysis with the PowerSynth 2 tool’s layout optimization to automate and optimize the physical design of a ZVS bidirectional DC-DC converter.