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TIDA-020031

Automotive 400-V battery to 12-V, 3.6-kW DC/DC converter reference design

TIDA-020031

Design files

Overview

This reference design is a 3.6-kW, automotive 400-V to 12-V unidirectional converter which converts the 200-V to 450-V DC input to 12-V, 300-A maximum output. Circuit breaker is applied for overcurrent and overvoltage protection. The converter is designed with SiC MOSFETs on the high voltage side and driven by 5.7-kVRMS, reinforced isolated dual-channel gate drivers. The enhanced phase-shifted full-bridge controller implements programmable delays which ensure zero voltage switching (ZVS) over a wide range of operating conditions. It offers multiple lightload management features including burst mode and dynamic SR on and off control when transitioning in and out of discontinuous current mode (DCM) operation. The output implements synchronous rectification, which enables fast transient response and a high-loop bandwidth.

Features
  • Phase-shifted full-bridge converter over 200- to 450-V DC input, 10- to 15-V output and power up to 3.6 kW
  • Scalable to 800-V input systems with tight regulation
  • Soft switching using phase-shifted full-bridge analog control loop
  • Soft switching with zero voltage switching (ZVS) on the primary and dynamic on and off control on the secondary to enable higher efficiency
  • Synchronization achievable for multiple phase operation

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.

TIDUEY2.PDF (1963 K)

Reference design overview and verified performance test data

TIDU186.PDF (3933 K)

Test results for the reference design, including efficiency graphs, test prerequisites and more

TIDM916.ZIP (674 K)

Detailed schematic diagram for design layout and components

TIDM917.ZIP (184 K)

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

TIDM918.ZIP (622 K)

Detailed overview of design layout for component placement

TIDM920.ZIP (6284 K)

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

TIDCG20.ZIP (2478 K)

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

TIDM919.ZIP (3349 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

PWM controllers

UCC28951-Q1Automotive green phase-shifted full-bridge controller with SR control for wide input voltage range

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

LMV393-Q1Automotive Catalog Dual General Purpose Low-Voltage Comparator

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Current sense amplifiers analog output

INA293-Q1AEC-Q100, -4-V to 110-V, 1.3-MHz, ultra-precise current sense amplifier

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D-type flip-flops

SN74LVC2G74-Q1Automotive Catalog Single Positive-Edge-Triggered D-Type Flip-Flop with Clear and Preset

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General-purpose op amps

TLC272Dual, 16-V, 2-MHz, In to V- operational amplifier

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Hall-effect current sensors

TMCS1100-Q1Automotive, precision isolated current sensor with external reference

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Ideal diode/ORing controllers

LM7480-Q13-V to 65-V, automotive ideal diode controller driving back to back NFETs

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Isolated gate drivers

UCC21530-Q1Automotive 4-A, 6-A, 5.7-kVRMS, isolated dual-channel gate driver with EN and DT pins for IGBT/SiC

Data sheet document-pdfAcrobat PDF open-in-new HTML
Linear & low-dropout (LDO) regulators

TL1963A-Q1Automotive 1.5-A, 20-V, adjustable low-dropout voltage regulator with reverse current protection

Data sheet document-pdfAcrobat PDF open-in-new HTML
Linear & low-dropout (LDO) regulators

TPS709-Q1Automotive 150-mA, 30-V, ultra-low-IQ, low-dropout voltage regulator with reverse current protection

Data sheet document-pdfAcrobat PDF open-in-new HTML
Low-side drivers

UCC27524A-Q1Automotive 5-A/5-A dual-channel gate driver with 5-V UVLO and negative input voltage handling

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
Transformer drivers

SN6505D-Q1Automotive, low-noise, 1-A, 420-kHz transformer driver for isolated power supplies

Data sheet document-pdfAcrobat PDF

Technical documentation

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Type Title Date
* Design guide Automotive 400-V Battery to 12 V, 3.6-kW DC/DC Converter Reference Design PDF | HTML Sep. 02, 2020
Application note UCC28950 600W Phase Shifted Full Bridge Design Review/Application Report (Rev. D) PDF | HTML Mar. 04, 2022
Test report PMP5568 Test Results Dec. 18, 2013

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