TIDA-01505

Automotive 40-V to 1-kV input flyback reference design supporting regenerative braking test

TIDA-01505

Design files

Overview

This power supply reference design for automotive auxiliary circuits generates a 15-V, 4-A output from a wide input range of 40 V to 1 kV and up to a 1.2-kV transient. The design fits ideally into an 800-V batterydriven hybrid-electric vehicle (HEV) or electric vehicle(EV) traction inverter system. The 40-V minimum input voltage supports the functional safety test for the regenerative braking from the traction motor. This reference design implements a silicon carbide (SiC) MOSFET with high blocking voltage and low gate charge to reduce switching losses. A non-isolated level shifter enables driving the SiC MOSFET from the Si MOSFET driver embedded in the flyback controller. The board includes two flyback converter variants: primary-side regulation (PSR) and optocoupler feedback to make comparisons and address different needs. The transformer design meets qualifications for Automotive AEC-Q200 Grade 1 with reinforced isolation.

Features
  • 40V to 1kV input, 15-V output flyback auxiliary power supply with output power up to 60W
  • Regulated 15V with active start-up circuit for reduced standby power
  • Extendable to higher voltage and higher power range to utilize high voltage capability of SiC MOSFET
  • Two converter variants with PSR and optocoupler feedback included on board
  • Constant switching frequency type of controller with maximum switching frequency of 1MHz and duty cycle range from 0% to 96%

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.

TIDUDT5B.PDF (3669 K)

Reference design overview and verified performance test data

TIDRVN8A.PDF (963 K)

Detailed schematic diagram for design layout and components

TIDRVN9.PDF (77 K)

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

TIDRVO0.PDF (395 K)

Detailed overview of design layout for component placement

TIDRVO2A.ZIP (1705 K)

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

TIDCEI4.ZIP (283 K)

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

TIDRVO1.PDF (1570 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

PWM controllers

UCC28C43-Q11-A, automotive single ended 1MHz current mode PWM controller with 8.4V/7.6V UVLO 100% duty cycle

Data sheet document-pdfAcrobat PDF open-in-new HTML
Shunt voltage references

TL431-Q1Automotive adjustable precision shunt regulator (pin layout: KRA)

Data sheet document-pdfAcrobat PDF open-in-new HTML

Technical documentation

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Type Title Date
* Design guide Automotive 40-V to 1-kV Input Flyback Reference Design (Rev. B) Aug. 13, 2019
Application note Modeling, Analysis and Compensation of the Current-Mode Converter Sep. 05, 1999
Application note U-111, Practical Considerations in Current Mode Power Supplies Sep. 05, 1999

Related design resources

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TIDA-01179 Automotive Wide Vin Front-End Power Reference Design w/Cold Crank Operation & Transient Protection

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