TI3交错图腾柱无桥PFC资料，高频管使用碳化硅，有数字控制环路介绍

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本参考设计聚焦于TI的6.6千瓦无桥图腾柱功率因数校正（PFC）解决方案，特别适用于混合电动汽车（HEV）/电动汽车（EV）的车载充电器。该设计采用了碳化硅（SiC）MOSFET，并由C2000微控制器（MCU）驱动，以实现高效率和高功率密度。无桥PFC技术减少了损耗，提高了整体系统性能。在电路结构中，三个相位的交错工作确保了连续导通模式（CCM），在240伏输入电压下达到98.60%的高效率。C2000控制器通过实现相位卸载和自适应死区时间控制，优化了轻负载条件下的功率因数。这种智能控制策略有助于在各种负载条件下保持高效运行。门驱动板（TIDA-01605）采用增强隔离设计，具有超过100V/ns的共模瞬态抗扰度（CMTI），确保了系统的稳定性。此外，它还包括二级关断电路，以防止在短路情况下MOSFET出现电压过冲，增强了器件保护。关键组件包括： 1. **C28004x C2000TM MCU**：作为核心控制器，执行数字控制算法，管理整个系统的运行。 2. **UCC21520-Q1**：隔离式门驱动器，用于驱动SiC MOSFET，提供强化隔离并保护系统免受高瞬态电压的影响。 3. **UCC28700-Q1**：可能是一个电源管理IC，负责监控和调节电源轨电压。 4. **TLV71333-Q1**：可能是一个低压差线性稳压器，为系统提供稳定的工作电压。 5. **SN6501-Q1**：隔离器，用于在高压和低压部分之间提供电气隔离。 6. **ISO7721-Q1**：可能是数字隔离器，用于在不同电压域之间安全地传递信号。 7. **TIDA-01605**：门驱动板，包含了上述的隔离和保护功能。 8. **TMS320F280049**：C2000系列的微控制器，用于实现数字控制环路，包括相位控制和死区时间调整。该设计还利用了SiC技术的优势，如更高的开关频率、更低的开关损耗和更高的热效率，从而提高了整个PFC转换器的能效和功率密度。通过采用这些先进技术，该参考设计为HEV/EV车载充电器提供了高效的解决方案，同时也为其他高功率应用提供了有价值的参考。为了进一步了解和应用此设计，可以访问TI Designs的TIDA-01604设计文件夹，以及相关产品的详细资料，例如UCC21520-Q1、TMS320F280049等。同时，C2000WARE-DIGITALPOWER-SDK工具文件夹提供了软件开发套件，帮助用户进行定制化开发。在遇到问题时，TI的E2E专家支持服务可以提供在线的技术咨询和解答。

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Driver

Vdc

Vdc Sense

Line

Voltage

Sense

Neutral

Voltage

Sense

SiC MOSFET

(High Frequency)

Si/SiC (Low

Frequency)

Power Grid

V_N

Ineu

Vdc Sense

F28004x

C2000

MCU

V_L

UCC28700-Q1

TLV71333-Q1

Vdc

5 V

3.3 V

F28004x Control Card

SN6501-Q1

Ineu

15 V & -4 V

PFC Vout

Hall

Sensor

Hall Sensor

x 3

ISO7721-Q

Fault

Reset

5 V

15 V & -4 V

UCC21520-Q1

4 × TIDA-01605

G1 G2 G3 G4 G5 G6 G7 G8

TIDUE54B–March 2018–Revised April 2020

Submit Documentation Feedback

98.6% Efficiency, 6.6-kW Totem-Pole PFC Reference Design for HEV/EV

Onboard Charger

TI Designs: TIDA-01604

98.6% Efficiency, 6.6-kW Totem-Pole PFC Reference

Design for HEV/EV Onboard Charger

Description

This reference design presents a 6.6-kW totem-pole

(TTPL) bridgeless power factor correction (PFC)

solution for Onboard Charger. The power stage

implements silicon carbide (SiC) MOSFETs driven by

a C2000™ microcontroller (MCU) with SiC-isolated

gate drivers. The design implements three-phase

interleaving and operates in continuous conduction

mode (CCM) to achieve a 98.60% efficiency at a 240-

V input voltage and 6.6-kW full power. The C2000

controller enables phase shedding and adaptive dead-

time control to improve the power factor at light load.

The gate driver board (see TIDA-01605) implements

reinforced isolation and can withstand more than 100-

V/ns common-mode transient immunity (CMTI). The

gate driver board also contains the two-level turnoff

circuit, which protects the MOSFET from voltage

overshoot during the short-circuit scenario.

Resources

TIDA-01604 Design Folder

UCC21520-Q1 Product Folder

TMS320F280049 Product Folder

UCC28700-Q1 Product Folder

TL1963A-Q1 Product Folder

ISO7731-Q1 Product Folder

C2000WARE-

DIGITALPOWER-SDK

Tool Folder

ASK Our E2E™ Experts

Features

• High-power-density, high-efficiency PFC design to

power systems up to 6.6 kW

• SiC MOSFETs with TI drivers offers higher

integration for customers

• Half-bridge- and compact isolated gate driver with

reinforced isolation and two-level turnoff protection

• Full digital control with high-performance C2000™

controller to enable advanced control scheme

• 98.86% peak efficiency, greater than 0.99 power

factor and less than 2% total harmonic distortion

(THD)

• Three-phase interleaved operation with phase

shedding control

• Programmable output voltage of 400 V to 600 V

Applications

• HEV/EV Traction Inverter

• HEV/EV Onboard Charger

• Electronic Control Units

• HEV/EV DC/DC Converters

System Description

www.ti.com

TIDUE54B–March 2018–Revised April 2020

Submit Documentation Feedback

98.6% Efficiency, 6.6-kW Totem-Pole PFC Reference Design for HEV/EV

Onboard Charger

An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and other

important disclaimers and information.

1 System Description

WARNING

Do not leave the device powered when unattended.

High voltage! There are accessible high voltages present

on the board. Electric shock is possible. The board operates at

voltages and currents that may cause shock, fire, or injury if not

properly handled. Use the equipment with necessary caution and

appropriate safeguards to avoid injury or damage to property. For

safety, use of isolated equipment with overvoltage and overcurrent

is highly recommended. TI considers it the user's responsibility to

confirm that the voltages and isolation requirements are identified

and understood before energizing the board or simulation. When

energized, do not touch the design or components connected to

the design.

Hot surface! Contact may cause burns. Do not touch!

Some components may reach high temperatures > 55°C when the

board is powered on. The user must not touch the board at any

point during operation or immediately after operating, as high

temperatures may be present.

1.1 Benefits of Totem-Pole Bridgeless PFC

All plug-in hybrid electric vehicles (PHEVs) require an onboard charger (OBC) between the power grid and

the high-voltage battery pack located inside the vehicle. Implementing a power factor correction (PFC)

converter is mandatory to connect directly to the power grid for AC/DC power conversion and maximize

the real power that flows to the downstream DC/DC converters.

Conventional PFC converters implement a passive diode bridge for rectification, which is now known as a

passive PFC technique. The advantages of such a scheme are: simple design, reliability, slow-system

control loop, and low cost. However, the disadvantages are also very obvious: the passive components

are heavy with a low-power factor and generate significant power losses, which results in bulky heat sinks

and a lot of heat dissipation. Further investigation into the matter shows that an input bridge consumes

approximately 2% of the input power at the low line of a wide mains application. If the designer can

suppress one of the series diodes, then they can save 1% of the input power, which allows the efficiency

to rise from 94% to 95% (Turchi; Dalal; Wang; Lenck 2014). Due to previously-mentioned drawbacks, the

power rating of bridged traditional PFCs is limited under hundreds of watts, especially in a hybrid-electric

vehicle (HEV) or electric vehicle (EV) where reduced space and weight are the key design parameters.

Power Grid

Load

SiC

(b)

Power Grid

Load

SiC

(a)

www.ti.com

System Description

TIDUE54B–March 2018–Revised April 2020

Submit Documentation Feedback

98.6% Efficiency, 6.6-kW Totem-Pole PFC Reference Design for HEV/EV

Onboard Charger

As a result, the trend continues to move toward a bridgeless architecture with the elimination of the

traditional diode bridge. The OBC is based on a silicon power device and has limitations such as low

efficiency, low power density, and high weight. With the advantages of the SiC MOSFET, the designer can

greatly improve these limitations by utilizing the superior performance of fast switching, low reverse

recovery charge, and a low R

DS(ON).

Figure 1 shows the basic structure of the totem-pole bridgeless PFC boost rectifier. The component

consists of a boost inductor, two high-frequency boost SiC switches (SiC

and SiC

), and two components

for conducting current at the line frequency. The line frequency components can be two slow diodes, as

Figure 1 shows. Side (A) shows two silicon MOSFETs (Si

and Si

). Side (B) shows that the use of Si

and

further increases the efficiency.

Figure 1. Totem-Pole Bridgeless PFC Boost Converter Topology:

(A) Diode for Line Rectification (B) MOSFET for Line Rectification

The inherent issue in the totem-pole PFC is the operation mode transition at the AC voltage zero-crossing.

When the AC input changes from the positive half line to the negative half line at the zero-crossing, the

duty ratio of the low-side high-frequency switch SiC

changes from 100% to 0%, and the duty cycle of SiC

changes from 0% to 100%. Because of the slow reverse recovery of the high-side diode (or body diode of

the MOSFET), the voltage at the cathode of D

cannot jump from ground to DC+ voltage instantly (this

causes a large current spike). Because of this issue, the designer cannot use an Si MOSFET in a

continuous-conduction mode (CCM) totem-pole PFC. Therefore SiC

and SiC

must be either SiC

MOSFET or gallium nitride (GaN) field-effect transistors (FETs), which have a low reverse recovery.

The biggest advantage of the totem-pole PFC is the reduced power losses in the conduction path. Table 1

shows the device comparison between a conventional PFC and a totem-pole PFC.

Table 1. Device Comparison of Conventional Bridged PFC and Totem-Pole Bridgeless PFC

PARAMETER

LOW-FREQUENCY

DIODES

HIGH-FREQUENCY

DIODES

HIGH-FREQUENCY

SWITCHES

CONDUCTION PATHS

Conventional bridged

PFC

Four One One

Two low-speed diodes + one

switch or (two low-speed diodes +

one high-speed diode)

Totem-pole bridgeless

PFC

Two Zero Two

One high-speed SiC switch + one

low-speed Si (or SiC) MOSFET

Power Grid

Load

(b)

Power Grid

Load

(a)

System Description

www.ti.com

TIDUE54B–March 2018–Revised April 2020

Submit Documentation Feedback

98.6% Efficiency, 6.6-kW Totem-Pole PFC Reference Design for HEV/EV

Onboard Charger

The following list summarizes the benefits of the totem-pole PFC:

• Although the conventional PFC boost converter is the most popular topology, its efficiency suffers from

the conduction losses of the front-end diode bridge rectifier and it is not bidirectional. A totem-pole PFC

is inherently capable of bidirectional operation.

• Bridgeless PFC boost converters greatly reduce the number of diodes, increase the power density, and

increase the efficiency.

• This PFC is superior in terms of: high efficiency, small common mode noise, small AC current ripple,

small reverse recovery current, and fewer components.

• The low reverse recovery charge of the SiC body diode and the low turnon resistance of the SiC

MOSFET make the converter an efficient and cost-effective solution for bidirectional onboard chargers.

1.2 Totem-Pole Bridgeless PFC Operation

The totem-pole PFC operates in the positive and negative cycles of the AC mains input, respectively, and

determines the current flow depending on how the high frequency SiC MOSFETs are switched (see

Figure 2 and Figure 3, respectively).

The high-frequency SiC MOSFETs together with the inductor create a synchronous mode boost converter.

During the positive half cycle, S

is the boost switch which is driven with duty cycle D and S

is driven with

a complementary pulse-width modulation (PWM) signal (1-D). Figure 2 (A) shows the direction in which

the current flows. Similarly, during the period when S

is switched with 1-D, S

is switched with D; Figure 2

(B) shows the direction in which the current flows. Note that, during this cycle, S

conducts continuously.

During the negative half cycle, the operation is similar except that the role of the high-side- and low-side,

high-frequency switches are swapped. Figure 3 shows the direction in which the current flows. Note that,

during this cycle, S

conducts continuously.

Figure 2. Totem-Pole Bridgeless PFC Operation During Positive Half Cycle:

(A) While S

is Switched ON (B) While S

is Switched OFF

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