Reliability Investigations of DC-DC Converter for EV Charger Application

The future of Electric Vehicles (EVs) relies on the widespread availability of reliable and cost-effective charging infrastructure. The performance and sustainability of such systems depend heavily on the reliability, feasibility, and compatibility of power electronic converters used in charging stations. This paper presents a novel reliability estimation methodology designed for flexibility, simplicity, and enhanced accuracy in evaluating converter configurations. The proposed approach integrates the standards of MIL-HDBK-217F and FIDES to ensure standardized reliability constants. It is applied to a 3.3 kW DC–DC boost converter for EV charger applications and evaluated through MATLAB/Simulink simulations at 50 kHz under open- and closed-loop conditions. The methodology incorporates both historical and experimental data using a hybrid bottom-up and top-down statistical logic for improved parameter estimation. Reliability and cost analyses are performed considering component voltage, current, blocking capability, and loss characteristics. The results demonstrate that the proposed approach enables efficient component selection, improved reliability, and an economically viable converter design suitable for commercial EV charging stations.