infineon公司的IPW60R080P7是CoolMOS™第七代平臺, 600V CoolMOSª P7高壓功率晶體管,採用超級結(SJ)原理和Infineon開拓的技術,組合了快速開關SJ MOSFET和極容易使用如非常低的激勵電路趨向,體二極管對抗硬交換的傑出魯棒性和極好的ESD能力.此外,極好的低開關和導通損耗使得開關應用變得更有效率,更加緊湊和更加涼爽.本文介紹了採用CoolMOS™ P7超級結MOSFET的2kW高效工業電池48V充電器參考設計主要特性,包括有電池溫度監測器,當輸入小於127V AC時自動配置輸出功率到1000W,用於並聯應用的RS485總線通信,多種顏色LED指示器,用來標示電池狀態,充電,誤差和故障,集成了電池管理系統(BMS),以及短路保護,反向極性保護,AC電壓過壓和欠壓保護,不用外接融絲的過熱保護和自動重置以及用於電池的熱探針.主要用在電動自行車電池充電器,電動摩托車電池充電器和電動車電池充電器.本文介紹了IPW60R080P7主要特性和優勢以及最大指標,以及工業電池48V充電器參考設計主要特性,電源板和控制板電路圖,材料清單和PCB設計圖.
The CoolMOS™ 7th generation platform is a revolutionary technology for high voltage power MOSFETs, designed according to the superjunction (SJ) principle and pioneered by Infineon Technologies. The 600V CoolMOS™ P7 series is the successor to the CoolMOS™ P6 series. It combines the benefits of a fast switching SJ MOSFET with excellent ease of use, e.g. very low ringing tendency, outstanding robustness of body diode against hard commutation and excellent ESD capability.
Furthermore, extremely low switching and conduction losses make switching applications even more efficient, more compact and much cooler.
IPW60R080P7主要特性:
• Suitable for hard and soft switching (PFC and LLC) due to an outstanding commutation ruggedness
• Significant reduction of switching and conduction losses
• Excellent ESD robustness >2kV (HBM) for all products
• Better RDS(on)/package products compared to competition enabled by a low RDS(on)*A (below 1Ohm*mm²)
• Fully qualified acc. JEDEC for Industrial Applications
IPW60R080P7優勢:
• Ease of use and fast design-in through low ringing tendency and usage across PFC and PWM stages
• Simplified thermal management due to low switching and conduction losses
• Increased power density solutions enabled by using products with smaller footprint and higher manufacturing quality due to >2 kV ESD protection
• Suitable for a wide variety of applications and power ranges
IPW60R080P7潛在應用:
PFC stages, hard switching PWM stages and resonant switching stages for e.g. PC Silverbox, Adapter, LCD & PDP TV, Lighting, Server, Telecom and UPS.
IPW60R080P7最大指標:
採用CoolMOS™ P7超級結MOSFET的2kW高效工業電池48V充電器參考設計
This document presents design considerations and results from testing a 2 kW industrial battery charger that is capable of charging 48 V based lead-acid and Li-ion batteries. The design is based on a dual-boost PFC and a half-bridge LLC DC-DC power supply solution, with natural convection cooling, using:
600 V CoolMOS™ P7 superjunction (SJ) MOSFETs for hard-switching and soft-switching topologies
IDH16G65C6 CoolSiC™ Schottky diode 650 V G6 for an attractive price-performance ratio
BSC030N08NS5 OptiMOS™ 5 80 V power MOSFET for reverse polarity protection
IDB15E60 600 V silicon power diode
ICE3PCS01G PFC controller IC for active Continuous Conduction Mode (CCM) power
ICE2HS01G resonant mode controller
ICE5QR2280AZ CoolSET™ QR Flyback controller
2EDN7524F EiceDRIVER™ 2EDN family of non-isolated dual gate drivers
IRS21814 600 V high- and low-side gate driver IC
XMC1403-Q064X0200 AA 32-bit XMC1000 industrial microcontroller
This application note provides a detailed description of the main features and operation under both steady-state and abnormal operating conditions of a 2 kW highly efficient natural convection-cooled industrial battery charger for 48 V lead-acid and Li-ion batteries. This demo board solidly confirms how different Infineon Technologies devices, ranging from power semiconductors to the controllers for the internal converters as well as for the accurate charging profile, perfectly fit a range of industrial applications.
工業電池48V充電器參考設計主要特性:
Different battery types (chemistries) can be charged, as explained in section 3.1.
Different battery charging capacities can be selected, as indicated in Table 4.
Clear signalization of the operation status of the charger during normal operation, as described in section 3.3, and when an error is present, as described in section 3.4.
Accurate charging profile according to the chemistry type selected as well as the measured temperature of the battery during the charging process, as described in the “Lead-acid and Li-ion charging profiles” section.
In case larger batteries need to be charged or faster charge capability is needed, the battery charger can be connected in parallel with another unit to achieve this. This operation is clearly explained in section 5.
High Power Factor (PF) and low Total Harmonic Distortion (THD) response at high-line, as shown in Figure 23.
Efficiency higher than 92 percent from 20 percent of the rated load (2 kW) upward when Vin = 230 V AC, and efficiency higher than 91 percent of the rated load (1 kW) upward when Vin = 90 V AC, during CCM.
High performance achieved by using Infineon Technologies best-in-class devices:
− TO-247 600 V CoolMOSTM P7 SJ MOSFETs for both dual-boost bridgeless PFC and half-bridge LLC topologies, along with single TO-220 650 V CoolSICTM sixth-generation Schottky diodes.
− EiceDRIVERTM 2EDN non-isolated gate driver as well as 600 V high- and low-side driver ICs.
− QR Flyback controller ICE5QR4780AZ CoolSET™.
− Super SO8 OptiMOS™ MOSFETs for battery management system control.
Robust and realiable operation under different abnormal conditions:
− Power Line Disturbance (PLD) events, like AC-Line Drop-Out (ACLDO) and voltage sag, as shown from Figure 30 to Figure 33.
− Surge events that do not represent a serious threat to the integrity of the industrial battery charger according to what it is specified in the Surge immunity (EN61000-4-5)Surge immunity (EN61000-4-5) test in section 8.6.
In case higher battery voltages are required, section 6 provides a list of changes that would be necessary to make at hardware level. Two different battery voltage ratings are considered: a) 72 V (range 67.2 V to 86.4 V at 30 A max.) and b) 144 V (range 134.4 V to 172.8 V at 15 A max.).
The 2 kW industrial battery charger offers a charging solution that operates on any single-phase 90 V AC to 265 V AC grid worldwide with a 94.7 percent peak efficiency. The charger has two charging profiles implemented: one for Li-ion batteries and the other for lead-acid batteries. The respective charging profiles correspond to the latest trends of battery charging. With the selectable nominal battery capacity (Cnom) feature, the charging current can be automatically adjusted in order to charge different battery sizes and amp-hour ranges to help customers achieve battery charging flexibility.
The charger is designed based on a dual-boost PFC that provides high PF of greater than 0.9 and meets PFC regulation as per IEC61000-3-2 Class A, followed by a converter stage realized by a half-bridge LLC configuration. Infineon’s latest 600 V CoolMOS™ P7 SJ MOSFET enables the design with natural convection cooling. The design has a battery management control system capable of charging both 48 V lead-acid and Li-ion batteries in the different charging modes – constant voltage and CCM.
The battery management control system implemented is designed to optimally charge lead-acid (WET, GEL, AGM, EFB and VRLA) as well as Li-ion (LiPo, Li2MnO3, Li2Mn2O4, Li4Ti5O12 and LiFePO4) batteries used on electric vehicles including E-scooters, E-bikes and low-speed vehicles. Furthermore, an RS485 bus communication protocol feature allows for a master/slave operation that can extract 4 kW max. charging power when connecting two chargers in parallel configuration, ensuring seamless power distribution and a fast charging feature for Li-ion batteries.
圖1. 工業電池48V充電器參考設計外形圖
Some of the main features are listed below:
Battery temperature monitor
Auto-configures output power to 1000 W when connected to less than 127 V AC to prevent nuisance breaker trips
RS485 bus communication for parallel operation
Multi-colored LED indicator for battery status, charging, error and fault indication
Convection cooled
Battery Management System (BMS) integration
Protected against short-circuit, reversed polarity, over- and under-AC-voltage, over-heating Without external fuses and with an automatic reset
Control of the charge time and automatic detection of faulty batteries
Thermal protection with internal probe
Thermal probe for battery
Dimensions: 258 × 123 × 80 mm
Weight: 7.5 kg
工業電池48V充電器參考設計特性應用:
E-bikes – pedelecs battery charger
E-rickshaws – E-scooters battery charger
Forklifts – E-carts battery charger
Micro E-cars – logistics EV battery charger
工業電池48V充電器參考設計輸入特性:
工業電池48V充電器參考設計輸出特性:
工業電池48V充電器參考設計不同負載下的效率:
圖2. 2kW工業電池48V充電器參考設計功能組塊圖
圖3.兩級EMI濾波器和浪湧限流電路
圖4.兩級升壓半無橋PFC轉換器電路
圖5.LLC轉換器和XMC微控制器間接口電路
圖6.輔助電源設計電路
圖7.主板框圖
圖8.帶控制器接口的雙PFC升壓電路
圖9.EMI濾波器和浪湧電流限流電路圖
圖10.用於PFC控制的電流變壓器次級邊檢測電路
圖11. PFC控制電路
圖12. LLC半橋轉換器初級和次級電路與控制器接口電路
圖13. 包括反饋迴路控制電路的 LLC控制器電路
圖14. 電池檢測電路
圖15. 偏壓電源電路
圖16. 使能電路
圖17. 工業電池48V充電器參考設計PCB設計圖:頂層
圖18. 工業電池48V充電器參考設計PCB設計圖:內1層
圖19. 工業電池48V充電器參考設計PCB設計圖:內2層
圖20. 工業電池48V充電器參考設計PCB設計圖:底層
工業電池48V充電器參考設計電源板材料清單:
控制板電路圖
圖21. 工業電池48V充電器參考設計控制板框圖
圖22. 工業電池48V充電器參考設計控制板電路圖:ADC相關電路
圖23. 工業電池48V充電器參考設計控制板電路圖:XMC微控制器輸入電壓電源
圖23. 工業電池48V充電器參考設計控制板電路圖:通信接口端口電路
圖24. 工業電池48V充電器參考設計控制板電路圖:基於主數字XMC1400的接口電路
圖25. 工業電池48V充電器參考設計控制板電路圖:LED指示器電路
控制板PCB佈局圖
圖26. 工業電池48V充電器參考設計控制板PCB設計圖:頂層
圖27. 工業電池48V充電器參考設計控制板PCB設計圖:內1層
圖28. 工業電池48V充電器參考設計控制板PCB設計圖:內2層
圖28. 工業電池48V充電器參考設計控制板PCB設計圖:底層
控制板材料清單:
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