An experimental investigation of unique high stepup boost converter for electric vehicle and solar photovoltaic

High step-up DC–DC converters are essential in electric vehicle (EV) and photovoltaic (PV) applications, where low-voltage inputs must be efficiently boosted to higher levels. Conventional converters suffer from high switching losses, bulky components, and unstable regulation under dynamic conditions. To address these challenges, this paper proposes a compact transformer based high step-up boost (HGB) converter integrated with an SG3525 PWM controller and an analog proportional–integral (PI) compensation network. The novelty of the design lies in the jointly optimized transformer winding structure (20-gauge/8-turns primary, 32-gauge/176-turns secondary with center tap) and robust analog PI compensation, which together achieve high gain with reduced duty ratio stress and stable voltage regulation. A hardware prototype was developed and tested under both programmable DC source and real PV input conditions. Experimental results confirm that the converter reliably steps up 12 V to 200 V DC, with efficiency consistently close to 90% across load levels from 5.6 W to 40 W. Gate pulses and switching behavior were validated through simulation, showing correct complementary drive at 50 kHz and safe device stress margins. Ripple analysis further shows that inductor current ripple remains below 15%, and capacitor voltage ripple remains below 2%, ensuring smooth operation. The converter also demonstrated strong linear gain response, maintaining duty ratios between 60% (at 8.5 V input) and 40% (at 12 V input). Real-time PV tests confirmed regulated output under fluctuating irradiation, with voltages ranging from 140 V to 225 V. These results establish the proposed converter as an efficient, compact, and experimentally validated solution for renewable energy systems and EV powertrains.