TIDM-02002

Bidirectional CLLLC resonant dual active bridge (DAB) reference design for HEV/EV onboard charger

TIDM-02002

Design files

Overview

CLLLC resonant DAB with bidirectional power flow capability and soft switching characteristics is an ideal candidate for Hybrid Electric Vehicle/Electric Vehicle (HEV/EV) on-board chargers and energy storage applications. This design illustrates control of this power topology using a C2000™ MCU in closed voltage and closed current-loop mode. The hardware and software available with this design help accelerate
your time to market.

Features
  • Vprim: 380–600 V DC; Vsec: 280–450 V DC; Power Max: 6.6 kW; 98% peak efficiency
  • CLLLC resonant tank with 500-kHz nominal PWM switching (300 kHz–700 kHz range) enables higher power density
  • Soft switching with zero voltage switching (ZVS) on the primary; zero current switching (ZCS) and ZVS on the secondary enable higher efficiency
  • Active synchronous rectification scheme implementation using on chip resources on C2000 MCU and Rogowski coil sensor implementation using Rogowski coil sensor enables higher efficiency
  • Software frequency response analyzer (SFRA) and compensation designer for ease of tuning of control loops
  • Software support for TMS320F28004x device with the control law accelerator (CLA), which enables integrated OBC design with AC-DC and DC-DC controlled using a single C2000 MCU

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.

TIDUEG2C.PDF (13510 K)

Reference design overview and verified performance test data

TIDRZ84A.PDF (492 K)

Detailed schematic diagram for design layout and components

TIDRXR2B.PDF (154 K)

Detailed schematic diagram for design layout and components

TIDRXR7A.PDF (150 K)

Detailed schematic diagram for design layout and components

TIDRZ85.PDF (109 K)

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

TIDRXR3A.PDF (94 K)

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

TIDRXR8A.PDF (94 K)

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

TIDRZ86.PDF (898 K)

Detailed overview of design layout for component placement

TIDRXR4.PDF (110 K)

Detailed overview of design layout for component placement

TIDRXR9.PDF (110 K)

Detailed overview of design layout for component placement

TIDRXR6B.ZIP (592 K)

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

TIDRZ88.ZIP (3137 K)

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

TIDRXS1A.ZIP (592 K)

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

TIDCFC5.ZIP (3381 K)

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

TIDCF13.ZIP (1804 K)

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

TIDCF14.ZIP (1795 K)

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

TIDRZ87.PDF (2843 K)

PCB layer plot file used for generating PCB design layout

TIDRXR5.PDF (475 K)

PCB layer plot file used for generating PCB design layout

TIDRXS0.PDF (472 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

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
Digital isolators

ISO7820Highest isolation rating, dual-channel, 2/0, reinforced digital isolator

Data sheet document-pdfAcrobat PDF open-in-new HTML
General-purpose op amps

LMV116Single, 12-V, 45-MHz operational amplifier

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

AMC1302-Q1Automotive ±50-mV-input, high-precision, reinforced isolated amplifier for current sensing

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

AMC1311-Q1Automotive 2-V input, reinforced isolated amplifier with high CMTI for voltage sensing

Data sheet document-pdfAcrobat PDF open-in-new HTML
Isolated gate drivers

UCC21530-Q1Automotive 5.7kVrms, 4A/6A dual-channel isolated gate driver w/ EN & DT pins in DWK pkg for I

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

TLV713P-Q1Automotive 150-mA, low-dropout voltage regulator with enable

Data sheet document-pdfAcrobat PDF open-in-new HTML
Precision op amps (Vos<1mV)

OPA320Precision, zero-crossover, 20-MHz, 0.9-pA Ib, RRIO, CMOS operational amplifier

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

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

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

Technical documentation

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Type Title Date
* Design guide Bidirectional CLLLC Resonant Dual Active Bridge Ref Design HEV/EV Onboard (Rev. C) Mar. 12, 2020
Application note The Essential Guide for Developing With C2000 Real-Time Microcontrollers (Rev. D) Sep. 14, 2021
White paper Taking charge of electric vehicles – both in the vehicle and on the grid (Rev. A) Jun. 17, 2020

Related design resources

Hardware development

DAUGHTER CARD
TMDSCNCD280049C F280049C controlCARD Evaluation Module

Software development

SOFTWARE DEVELOPMENT KIT (SDK)
C2000WARE-DIGITALPOWER-SDK DigitalPower software development kit (SDK) for C2000™ MCUs
DRIVER OR LIBRARY
SFRA powerSUITE Digital Power Supply Software Frequency Response Analyzer Tool for C2000™ MCUs

Reference designs

REFERENCE DESIGN
PMP21495 6.6 kW, bi-directional, dual-active-bridge CLLLC resonant converter reference design PMP21553 Safety isolated primary SiC MOSFET driver reference design PMP21561 Safety isolated secondary SiC MOSFET driver reference design

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