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First GREP Project
First GREP Project
First GREP Project
First GREP Project
First GREP Project
First GREP Project
First GREP Project
First GREP Project
First GREP Project
First GREP Project
First GREP Project
First GREP Project
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First GREP Project

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3kW PFC for Electrical Car Charger, …

3kW PFC for Electrical Car Charger,
Automotive Products Business Unit,
Pavia, Italy

Published in: Automotive, Business
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  • 1. COMPANY CONFIDENTIAL 13kW PFC for Electrical Car ChargerAlex Lollio, Global Rotation EngineerAutomotive Products Business UnitPavia Design Centre, ItalyOctober, 2012 - April, 2013Project Manager : Davide GiacominiProgram Mentor : Massimo Grasso
  • 2. COMPANY CONFIDENTIALOutline• Introduction• Electrical Car Charger• PFC Topologies• IR Portfolio• Overview of the IR115x PFC Controller• 3kW Interleaved PFC Demoboard Realization Steps:• FIRST STEP: Current Sense Transformers• SECOND STEP: Clock Synchronization and Interleaving• THIRD STEP: Current Sharing• Measurement Results• Board Image and Specifications• Measurement Results (PF, Efficiency, Input Current after Load Step)• IC Pinout Proposal• Conclusion
  • 3. COMPANY CONFIDENTIALLevel 1: OnBoard ChargerLevel 3:Charger Station1.5kW < Power < 3.5kW16h < Charge Time < 7hLevel 2:External Charger3.5kW < Power < 10kW7h < Charge Time < 2.5h10kW < Power < 25kW2.5h < Charge Time < 1hElectrical Vehicle Charger Classificationhttp://avt.inl.gov/pdf/phev/phevInfrastructureReport08.pdfCharge Time for 25kWh battery
  • 4. COMPANY CONFIDENTIALLevel 1 AC/DC Onboard ChargerEach Electrical Vehicle has an Onboard charger :• High volume addressable market• The target power is between 1.5kW and 3.5kW• AC input : 16A@140V/240V → 2.2kW/3.8kW(www.imsresearch.com)• DC Output: 200 - 450VAC SOURCEAC/DC PFC DC/DC High VoltageBatteryAC/DC PFC IS THE FOCUS OF THIS WORKONBOARD CHARGER140V - 240V 200V - 450V+-
  • 5. COMPANY CONFIDENTIALPower Factor Correction: Working PrincipleThe goal of the PFC is to obtain a phase alignment between the input voltage andinput currentAC INPUT140V/240V385V DC OUT385V0VCONTROLLER• PFC Figure of Merit → PF = P/(VRMS x IRMS) = Watts/V.A.• The switch is the mayor contributor of switching loss (20kHz<FS<150kHz)• The diode works in hard switching mode (reversed current when turning OFF)CurrentVoltageLEGEND
  • 6. COMPANY CONFIDENTIALInterleaved PFC: Working PrincipleVINL1COUTVORLOADL2IINS1S2I1I2ICOUTIOUTBenefit of interleaving:• Input Ripple Current reduction• Output Ripple Current reduction• Better thermal management• Core Magnetic size halvedESINGLE = ½LIIN²EINTERLEAVED = ½L(IIN/2)² + ½L(IIN/2)² = ¼LIIN²S1S2ΔIL1ΔIL2IIN=IL1+IL2I1I2ICOUTIIN/2
  • 7. COMPANY CONFIDENTIALElectrolytic Capacitor lifetime PFCDual Phase PFCSingle Phase PFCEPCOS B43740Lifetime of the output capacitor is doubled in the interleaved PFC
  • 8. COMPANY CONFIDENTIALIR PortfolioIR products for Interleaved PFC Application:L1COUTVORLOADL2IINS1S2I1I2ICOUTIOUTCONTROLLERCONTROLLER• IGBT• Controller IR115x FamilySingle Phase PFCThe Goal of this work is to adapt the IR115x SinglePhase PFC Controller to a Dual-Phase InterleavedPFC Implementation
  • 9. COMPANY CONFIDENTIALOutline• Introduction• Electrical Car Charger• PFC Topologies• IR Portfolio• Overview of the IR115x PFC Controller• 3kW Interleaved PFC Demoboard Realization Steps:• FIRST STEP: Current Sense Transformers• SECOND STEP: Clock Synchronization and Interleaving• THIRD STEP: Current Sharing• Measurement Results• Board Image and Specifications• Measurement Results (PF, Efficiency, Input Current after Load Step)• IC Pinout Proposal• Conclusion
  • 10. COMPANY CONFIDENTIAL3kW PFC Demoboard block diagramL1COUTVORLOADL2IINS1S2I1I2ICOUTIOUTIR1155IR1155CURRENT SHARINGCLOCKINTERL.• Current sensing is implemented using four current transformers (CT)• Current sharing is implemented using a differential opamp• Clock interleaving is implemented using two comparators LM393Specs:• VIN: 120V/240V• Max IIN: 16A• VOUT: 385V• L: 250uH• COUT: 3mF• Freq: 50kHzCTCT
  • 11. COMPANY CONFIDENTIAL3kW PFC Demoboard ImageIGBT DiodeIGBT DiodeINDUCTORSBRIDGERECT1155AC IN OUTSpecs:• VIN: 120V/240V• Max IIN: 16A• VOUT: 385V• L: 250uH• COUT: 3mF• Freq: 50kHz• IGBT:AUIRGP65• DIODE:ETX150633cm27cmINTERL.CUR. SH.CTLOADVCC
  • 12. COMPANY CONFIDENTIALSummary of the Project• Oct : Study of PFC literature and IR products• Nov : Microcap model realization of the IR1155• Dec : Interleaving of two IRAC300 Demoboard + documentation• Jan : 3kW Demoboard Schematic and Layout realization• Feb : PCB assembly and measurements collecting• March : Demoboard second release (Schematic + Layout)• Apr :• Documentation (application note, user guide, patent)• Additional activities (Horn test software, LabView courses)

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