First GREP Project

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

Published in: Automotive, Business
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First GREP Project

  1. 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. 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. 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. 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. 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. 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. 7. COMPANY CONFIDENTIALElectrolytic Capacitor lifetime PFCDual Phase PFCSingle Phase PFCEPCOS B43740Lifetime of the output capacitor is doubled in the interleaved PFC
  8. 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. 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. 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. 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. 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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