Reference Design For 7 kW On-Board Charger


The on-board charger reference design of electrical autos provides excessive energy effectivity, revolutionary warmth administration, and modular adaptability.


An on-board charger (OBC) is an integral part of electrical autos (EVs) accountable for changing the alternating present (AC) from the electrical grid into direct present (DC) to cost the car’s battery. Because the identify implies, this charger is usually put in throughout the car itself. With the burgeoning progress of the EV business, the necessity for OBCs has turn out to be paramount. They permit EV homeowners to cost their autos conveniently at residence, workplaces, or public charging stations. The STDES-7KWOBC from STMicroelectronics is a reference design for an OBC that facilitates the charging of EV batteries. This charger lets customers energy their EVs utilizing a family AC mains plug or non-public and public AC charging stations.

The design is split into two fundamental segments. The primary section includes an interleaved totem pole Energy Issue Correction (PFC) stage that employs a 2-channel interleaved totem pole topology, working at a frequency of 70 kHz. The second section encompasses a twin galvanically-isolated full bridge Load-Inductor Load-Capacitor (LLC) Direct Present to Direct Present (DC-DC) Zero Voltage Switching (ZVS) resonant converter with a resonant frequency set at 140 kHz. This converter utilises MDmesh DM6 super-junction energy Metallic Oxide Semiconductor Area-Impact Transistors (MOSFETs). The ability framework of this reference design is spectacular. It has a 7 kW unit able to constantly delivering a present or voltage output. Moreover, it boasts the flexibility of working individually (1 PH+ N), along with different models, or a 3-phase mode (3Ph + N), probably rising its output to a considerable 21 kW.

One of many notable options of the OBC design is its warmth administration system. An insulated steel substrate (IMS) is strategically positioned on an aluminium base plate, guaranteeing optimum warmth dissipation. The incorporation of both compelled air or liquid cooling mechanisms additional enhances this. Each module throughout the reference design facilitates easy interlinking with different similar modules by way of wires or bus bar connections, enabling an amplified output energy. The standout characteristic of this reference design lies in its effectivity and excessive energy density. That is achieved by way of the incorporation of Silicon Carbide (SiC) and super-junction (SJ) energy MOSFETs, silicon and SiC diodes, gate drivers, the SPC58NN84E7RMHBR automotive-grade microcontroller for energy structure, and Silicon-Managed Rectifier (SCR) thyristors, which restrict inrush present. Notably, a 12 V enter provide voltage is galvanically remoted from the output voltage floor, which connects to the high-voltage battery. This design additionally helps each fixed present and fixed voltage modes. 

STMicroelectronics has examined this reference design. It comes with a Invoice of Supplies (BOM), schematics, and many others. You will discover further information in regards to the reference design on the corporate’s web site. To learn extra about this reference design, click on right here.


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