98.6% Efficiency, 6.6-kW Totem-Pole PFC Reference Design for HEV/EV Onboard Charger

(ACTIVE) TIDA-01604

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Key Document

Description

This reference design functions from a base of silicon carbide (SiC) MOSFETs that are driven by a C2000 microcontroller (MCU) with SiC-isolated gate drivers. The design implements three-phase interleaving and operates in continuous conduction mode (CCM) to achieve a 98.46% efficiency at a 240-V input voltage and 6.6-kW full power. The C2000 controller enables phase shedding and adaptive dead-time control to improve the power factor at light load. The gate driver board (see TIDA-01605) is capable of delivering a 4-A source and 6-A sink peak current. The gate driver board implements a reinforced isolation and can withstand more than 100-V/ns common-mode transient immunity (CMTI). The gate driver board also contains the two-level turnoff circuit, which protects the MOSFET from voltage overshoot during the short-circuit scenario.

Features
  • High-power-density, high-efficiency PFC design to power systems up to 6.6 kW
  • Half-bridge- and compact isolated gate driver with reinforced isolation and two-level turnoff protection                                             
  • Full digital control with high-performance C2000™ controller to enable advanced control scheme
  • 98.46% peak efficiency, greater than 0.99 power factor and less than 2% total harmonic distortion (THD)
  • Three-phase interleaved operation with phase shedding control

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Schematic/Block Diagram

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Design Files

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Bill of Materials (BOM)

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TI Devices (8)

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Part Number Name Product Family Sample & Buy Design Kits & Evaluation Modules
ISO7731-Q1  High Speed, Robust EMC Triple-Channel Digital Isolators  Isolation  Sample & Buy View Design Kits & Evaluation Modules
OPA2376-Q1  Low Noise, Low Quiescent Current, Precision Operational Amplifier e-trim/trade  Operational amplifiers (op amps)  Sample & Buy View Design Kits & Evaluation Modules
SN74LVC1G3157  1-channel, 2:1 analog switch  Switches & multiplexers  Sample & Buy View Design Kits & Evaluation Modules
TL1963A-Q1  Auto Catalog Single Output LDO, 1.5A, Adj. (1.21V to 20V), Fast Transient Response  Power management  Sample & Buy View Design Kits & Evaluation Modules
TLV713P-Q1  Automotive Capacitor-Free 150mA Low-Dropout (LDO) Regulator With Foldback Current Limit  Power management  Sample & Buy Not Available
TMS320F280049  Piccolo™ 32-bit MCU with 100 MHz, FPU, TMU, 256 KB Flash, CLA, PGAs, SDFM  C2000 real-time control MCUs  Not Available View Design Kits & Evaluation Modules
UCC21520-Q1  Automotive 4A/6A, 5.7 kVrms Isolated Dual Channel Gate Driver  Gate drivers  Sample & Buy View Design Kits & Evaluation Modules
UCC28700-Q1  Compact Primary-side Regulation PWM Controller with Automotive Grade  Offline & isolated DC/DC controllers & converters  Sample & Buy View Design Kits & Evaluation Modules

CAD/CAE symbols

Part # Package | Pins CAD File (.bxl) STEP Model (.stp)
ISO7731-Q1 Download
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OPA2376-Q1 Download
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SN74LVC1G3157 Download Download
Download Download
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TL1963A-Q1 Download Download
TLV713P-Q1 Download
TMS320F280049 Download -
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UCC21520-Q1 Download
UCC28700-Q1 Download Download

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Technical Documents

View the Important Notice for TI Designs covering authorized use, intellectual property matters and disclaimers.

Application notes (1)
Title Abstract Type Size (KB) Date Views
PDF 100 26 Apr 2017 0
User guides (1)
Title Abstract Type Size (KB) Date Views TI Recommends
PDF 4892 27 Aug 2018 0
White papers (1)
Title Abstract Type Size (KB) Date Views
PDF 1217 27 Jul 2018 0
Design files (6)
Title Abstract Type Size (KB) Date Views
PDF 421 27 Aug 2018 0
ZIP 2820 27 Aug 2018 0
PDF 73 27 Aug 2018 0
ZIP 890 01 Mar 2018 0
PDF 2654 01 Mar 2018 0
PDF 335 01 Mar 2018 0
Related Tools & Software

Reference Designs  ( 1 )

Design Kits & Evaluation Modules  ( 1 )

Name Part Number Tool Type
F280049M Experimenter Kit for C2000 Real-Time Control Development Kits  TMDXDOCK280049M  Evaluation Modules & Boards 

Software (1)

Name Part Number Software Type
DigitalPower Software Development Kit (SDK) for C2000 MCUs  C2000WARE-DIGITALPOWER-SDK  Software Development Kits (SDK) 


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