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First GREP Project
- 1. COMPANY CONFIDENTIAL 1 3kW PFC for Electrical Car Charger Alex Lollio, Global Rotation Engineer Automotive Products Business Unit Pavia Design Centre, Italy October, 2012 - April, 2013 Project Manager : Davide Giacomini Program Mentor : Massimo Grasso
- 2. COMPANY CONFIDENTIAL Outline • Introduction • Electrical Car Charger • PFC Topologies • IR Portfolio • Overview of the IR115x PFC Controller • 3kW Interleaved PFC Demoboard Realization Steps: • FIRST STEP: Current Sense Transformers • SECOND STEP: Clock Synchronization and Interleaving • THIRD STEP: Current Sharing • Measurement Results • Board Image and Specifications • Measurement Results (PF, Efficiency, Input Current after Load Step) • IC Pinout Proposal • Conclusion
- 3. COMPANY CONFIDENTIAL Level 1: OnBoard Charger Level 3: Charger Station 1.5kW < Power < 3.5kW 16h < Charge Time < 7h Level 2: External Charger 3.5kW < Power < 10kW 7h < Charge Time < 2.5h 10kW < Power < 25kW 2.5h < Charge Time < 1h Electrical Vehicle Charger Classification http://avt.inl.gov/pdf/phev/phevInfrastructureReport08.pdf Charge Time for 25kWh battery
- 4. COMPANY CONFIDENTIAL Level 1 AC/DC Onboard Charger Each Electrical Vehicle has an Onboard charger : • High volume addressable market • The target power is between 1.5kW and 3.5kW • AC input : 16A@140V/240V → 2.2kW/3.8kW (www.imsresearch.com) • DC Output: 200 - 450V AC SOURCE AC/DC PFC DC/DC High Voltage Battery AC/DC PFC IS THE FOCUS OF THIS WORK ONBOARD CHARGER 140V - 240V 200V - 450V + -
- 5. COMPANY CONFIDENTIAL Power Factor Correction: Working Principle The goal of the PFC is to obtain a phase alignment between the input voltage and input current AC INPUT 140V/240V 385V DC OUT 385V 0V CONTROLLER • PFC Figure of Merit → PF = P/(VRMS x IRMS) = Watts/V.A. • The switch is the mayor contributor of switching loss (20kHz<FS<150kHz) • The diode works in hard switching mode (reversed current when turning OFF) Current Voltage LEGEND
- 6. COMPANY CONFIDENTIAL Interleaved PFC: Working Principle VIN L1 COUT VO RLOAD L2 IIN S1 S2 I1 I2 ICOUT IOUT Benefit of interleaving: • Input Ripple Current reduction • Output Ripple Current reduction • Better thermal management • Core Magnetic size halved ESINGLE = ½LIIN² EINTERLEAVED = ½L(IIN/2)² + ½L(IIN/2)² = ¼LIIN² S1 S2 ΔIL1 ΔIL2 IIN=IL1+IL2 I1 I2 ICOUT IIN/2
- 7. COMPANY CONFIDENTIAL Electrolytic Capacitor lifetime PFC Dual Phase PFC Single Phase PFC EPCOS B43740 Lifetime of the output capacitor is doubled in the interleaved PFC
- 8. COMPANY CONFIDENTIAL IR Portfolio IR products for Interleaved PFC Application: L1 COUT VO RLOAD L2 IIN S1 S2 I1 I2 ICOUT IOUT CONTROLLER CONTROLLER • IGBT • Controller IR115x Family Single Phase PFC The Goal of this work is to adapt the IR115x Single Phase PFC Controller to a Dual-Phase Interleaved PFC Implementation
- 9. COMPANY CONFIDENTIAL Outline • Introduction • Electrical Car Charger • PFC Topologies • IR Portfolio • Overview of the IR115x PFC Controller • 3kW Interleaved PFC Demoboard Realization Steps: • FIRST STEP: Current Sense Transformers • SECOND STEP: Clock Synchronization and Interleaving • THIRD STEP: Current Sharing • Measurement Results • Board Image and Specifications • Measurement Results (PF, Efficiency, Input Current after Load Step) • IC Pinout Proposal • Conclusion
- 10. COMPANY CONFIDENTIAL 3kW PFC Demoboard block diagram L1 COUT VO RLOAD L2 IIN S1 S2 I1 I2 ICOUT IOUT IR1155 IR1155 CURRENT SHARINGCLOCK INTERL. • Current sensing is implemented using four current transformers (CT) • Current sharing is implemented using a differential opamp • Clock interleaving is implemented using two comparators LM393 Specs: • VIN: 120V/240V • Max IIN: 16A • VOUT: 385V • L: 250uH • COUT: 3mF • Freq: 50kHz CT CT
- 11. COMPANY CONFIDENTIAL 3kW PFC Demoboard Image IGBT Diode IGBT Diode INDUCTORS BRIDGE RECT 1155 AC IN OUT Specs: • VIN: 120V/240V • Max IIN: 16A • VOUT: 385V • L: 250uH • COUT: 3mF • Freq: 50kHz • IGBT: AUIRGP65 • DIODE: ETX1506 33cm 27cm INTERL. CUR. SH. CT LOAD VCC
- 12. COMPANY CONFIDENTIAL Summary of the Project • Oct : Study of PFC literature and IR products • Nov : Microcap model realization of the IR1155 • Dec : Interleaving of two IRAC300 Demoboard + documentation • Jan : 3kW Demoboard Schematic and Layout realization • Feb : PCB assembly and measurements collecting • March : Demoboard second release (Schematic + Layout) • Apr : • Documentation (application note, user guide, patent) • Additional activities (Horn test software, LabView courses)