54-V, 1.5 kW, >99% Efficient, 70x69 mm2 power stage reference design for 3-phase BLDC drives
TIDA-010056
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Key Document
- 54-V, 1.5 kW, >99% Efficient, 70x69 mm^2 Power Stage Reference Design (Rev. A)
(PDF 8885 KB)
31 Jul 2019
Description
This reference design demonstrates a 1.5-kW power stage for driving a three-phase brushless DC motor in cordless tools operating from a 15-cell Li-ion battery with a voltage up to 63-V. The design is a 70mm x 69mm compact drive, bringing 25-ARMS continuous current at 20-kHz switching frequency without heat sink and with natural convection, implementing sensorbased trapezoidal control. The design achieves optimized MOSFET switching loss and EMI by using a smart gate driver with optimized MOSFET and PCB. The design shows MOSFET operation within the safe operating area using enhanced protections including MOSFET over current and shoot-through protection by VDS monitoring, gate protection, switching voltage spike optimization with slew rate control and over temperature protection.
Features
- Operates at voltage ranging from 9 V to 63 V (15s li-ion battery) delivering 25 ARMS continuous current, 400-A peak
- 54 V/1.5 kW, 25 ARMS support without heat sink in a small 70mm x 69mm PCB form factor
- More than 99% efficiency at 20 kHz trapezoidal control for 54 V/1.5 kW
- MOSFET over current protection by VDS sensing with response time less than 1-µs with additional 4-µs deglitch time to eliminate false trips
- Enhanced protection at MOSFET gate including VGS under-voltage, over-voltage, gate to source short circuit and open circuit protections
See the Important Notice and Disclaimer covering reference designs and other TI resources.