TIDA-010054

Bi-directional, dual active bridge reference design for level 3 electric vehicle charging stations

TIDA-010054

Design files

Overview

This reference design provides an overview on the implementation of a single-phase dual active bridge (DAB) DC/DC converter. DAB topology offers advantages like soft-switching commutations, a decreased number of devices and high efficiency. The design is beneficial where power density, cost, weight, galvanic isolation, high voltage conversion ratio and reliability are critical factors, making it ideal for EV charging stations and energy storage applications. Modularity and symmetrical structure in DAB allow for stacking converters to achieve high power throughput and facilitate a bidirectional mode of operation to support battery charging and discharging applications.

Features
  • Dual-channel UCC21530 with reinforced isolation used for driving SiC MOSFETs in the half-bridge configuration
  • TMS320F280049 controller for implementation of digital control
  • Isolated voltage and current sensing
  • Primary voltage of 700-800-V DC, secondary voltage of 380-500-V DC, maximum power output of 10 kW
  • Full load efficiency of 97.6% and a peak efficiency of 98.2% at 6 KW
  • High-power density of 2.32 KW/L

A fully assembled board has been developed for testing and performance validation only, and is not available for sale.

Design files & products

Design files

Download ready-to-use system files to speed your design process.

TIDUES0B.PDF (4260 K)

Reference design overview and verified performance test data

TIDRZW0B.ZIP (1118 K)

Detailed schematic diagram for design layout and components

TIDRZW1A.ZIP (270 K)

Complete listing of design components, reference designators, and manufacturers/part numbers

TIDRZW2B.ZIP (1281 K)

Detailed overview of design layout for component placement

TIDRZW4C.ZIP (14651 K)

Files used for 3D models or 2D drawings of IC components

TIDCFI5C.ZIP (2658 K)

Design file that contains information on physical board layer of design PCB

TIDRZW3B.ZIP (3654 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

N-channel MOSFETs

CSD17313Q230-V, N channel NexFET™ power MOSFET, single SON 2 mm x 2 mm, 32 mOhm

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N-channel MOSFETs

CSD18534Q5A60-V, N channel NexFET™ power MOSFET, single SON 5 mm x 6 mm, 9.8 mOhm

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Analog temperature sensors

LMT87±2°C 2.7V to 5.5V analog output temperature sensor with -13.6 mV/°C gain

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Analog temperature sensors

LMT87-Q1Automotive ±2.7°C 2.7V to 5.5V analog output temperature sensor with -13.6 mV/°C gain

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Analog temperature sensors

TMP2351C analog temperature sensor, 10 mV/C

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Buck modules (integrated inductor)

TPS8213017-V input 3-A step-down converter module with integrated inductor

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C2000 real-time microcontrollers

TMS320F280040-Q1Automotive C2000™ 32-bit MCU with 100 MHz, FPU, TMU, 128-KB flash, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280040C-Q1Automotive C2000™ 32-bit MCU with 100 MHz, FPU, TMU, 128-KB flash, InstaSPIN-FOC, CLB, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280041C2000™ 32-bit MCU with 100-MHz, FPU, TMU, 128-kb flash, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280041-Q1Automotive C2000™ 32-bit MCU with 100 MHz, FPU, TMU, 128 KB flash, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280041CC2000™ 32-bit MCU with 100-MHz, FPU, TMU, 128-kb flash, InstaSPIN-FOC, CLB, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280041C-Q1Automotive C2000™ 32-bit MCU with 100 MHz, FPU, TMU, 128 KB flash, InstaSPIN-FOC, CLB, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280045C2000™ 32-bit MCU with 100 MHz, FPU, TMU, 256 KB flash, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280048-Q1Automotive C2000™ 32-bit MCU with 100 MHz, FPU, TMU, 256 KB flash, CLA, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280048C-Q1Automotive C2000™ 32-bit MCU w/ 100 MHz, FPU, TMU, 256 KB flash, CLA, InstaSPIN-FOC, CLB, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280049C2000™ 32-bit MCU with 100-MHz, FPU, TMU, 256-kb Flash, CLA, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280049-Q1Automotive C2000™ 32-bit MCU with 100 MHz, FPU, TMU, 256 KB flash, CLA, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280049CC2000™ 32-bit MCU with 100-MHz, FPU, TMU, 256-kb Flash, CLA, InstaSPIN-FOC, CLB, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
C2000 real-time microcontrollers

TMS320F280049C-Q1Automotive C2000™ 32-bit MCU w/ 100 MHz, FPU, TMU, 256 KB flash, CLA, InstaSPIN-FOC, CLB, PGAs, SDFM

Data sheet document-pdfAcrobat PDF
Comparators

LMV762Dual, 120-ns, low-voltage, precision comparator

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Digital isolators

ISO7721Robust EMC, dual-channel, 1/1, reinforced digital isolator

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ESD & surge protection ICs

TVS140014V flat-clamp surge protection device

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Isolated ADCs

AMC1306M05Small Reinforced Isolated Modulator With ±50mV Input and CMOS Interface

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Isolated amplifiers

AMC1302±50-mV-input, high-precision, reinforced isolated amplifier for current sensing

Data sheet document-pdfAcrobat PDF
Isolated amplifiers

AMC13112-V input, reinforced isolated amplifier with high CMTI for voltage sensing

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Isolated gate drivers

UCC215305.7kVrms, 4A/6A dual-channel isolated gate driver with Enable & DT pins in DWK pkg for IGBT/S

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Linear & low-dropout (LDO) regulators

TLV713P150-mA, capacitor-free low-dropout voltage regulator with active output discharge & enable

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Linear & low-dropout (LDO) regulators

TPS763150-mA, 10-V, low-dropout voltage regulator with enable

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Linear & low-dropout (LDO) regulators

TPS7B69150-mA, 40-V, low-IQ, low-dropout voltage regulator

Data sheet document-pdfAcrobat PDF
Load switches

TPS229445.5-V, 0.1-A, 500-mΩ, load switch with current limit and active high enable

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Noninverting buffers & drivers

SN74LVC2G342-ch, 1.65-V to 5.5-V buffers

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Precision op amps (Vos<1mV)

OPA320Precision, Zero-Crossover, 20MHz, 0.9pA Ib, RRIO, CMOS Operational Amplifier ;

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Series voltage references

REF20333.3-V Vref, low-drift, low-power, dual-output Vref & Vref/2 voltage reference

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Shunt voltage references

TL431Adjustable precision shunt regulator

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Transformer drivers

SN6501Low-noise, 350-mA, 410-kHz transformer driver for isolated power supplies

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Transformer drivers

SN6505BLow-noise, 1-A, 420-kHz transformer driver with soft start for isolated power supplies

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Technical documentation

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Type Title Date
* Design guide Bidirectional, Dual Active Bridge Reference Des for Level 3 EV Charging Stations (Rev. B) Oct. 19, 2021
White paper Taking charge of electric vehicles – both in the vehicle and on the grid (Rev. A) Jun. 17, 2020
Technical article Designing highly efficient, powerful and fast EV charging stations Aug. 06, 2019

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