[introduction]Inside global limits from internal-combustion engine car (ICE) turns to electric car (the condition of EV) is corresponding charge infrastructure obtains significant progress. Although low power (<15 KW) car carries charger to be able to support a family to charge during car is unused, but long-distance journey and service industry need are faster charge speed, with gas station of current to mark gas cheer speed. Charge to rise speed, need improves batteries at the same time technology and charge infrastructure.

Inside global limits from internal-combustion engine car (ICE) turns to electric car (the condition of EV) is corresponding charge infrastructure obtains significant progress. Although low power (<15 KW) car carries charger to be able to support a family to charge during car is unused, but long-distance journey and service industry need are faster charge speed, with gas station of current to mark gas cheer speed. Charge to rise speed, need improves batteries at the same time technology and charge infrastructure.

This guideline discussed bridge of 60 KW double active (the design of DAB) converter, development and test, this converter can satisfy electric car to keep apart and adjust of fast charger at the same time demand. In addition, this develop that devises an alternative attacks the structure makes its can shunt-wound, be as high as the output power of 300 KW in order to come true.

1.Foreword

As the market from internal-combustion engine (ICE) car turns to electric car (EV) , the whole world grows continuously to the demand of electric car. The maturity of batteries and technology of electric power electron makes electric car is in all sorts of function index respects can be rivalled with photograph of internal-combustion engine car, even car of excel internal-combustion engine. However, large-scale promotion is dynamoelectric the limitative element of the car is remained charge suitably infrastructure, with solution of current to mark internal-combustion engine car, cheer namely. The low power of electric car (<15 KW) car carries charger (during OBC) support car is unused charge for long, for example inside the garage nightly charge. But, this kind of charger does not suit long-distance journey and commercial vehicle team, to latter, charge the internal-combustion engine fuel with time current to mark need cheers time.

Lead to satisfy afore-mentioned charging that time asks and raise the whole of electric car to use further, the electric car that needs independence is fast charger (> 50 KW) . Independent charger can bypass car vehicle carries charger, direct link communicates electrified wire netting and car batteries, what build high power thereby is straight even. Output of this kind of high power comes true normally through heightening tension, use cable of big electric current in order to avoid. Although fast charger is likely,carry charger than the car big, but still need to increase efficiency and power density, so that large-scale promotion.

compositive carborundum (fast charger design can satisfy the electric car of SiC) power electronic parts all these demand (namely high output voltage, efficient with high power density) . The bridge of 60 KW double active that this white paper introduced a kind to be used at electric car to charge quickly (DAB) converter compose builds module, bat around its develop attacks to the structure chooses and be designed decision-making. The emulation of this design and archetypal hardware got test and verify. Notable is, this converter design is with an active front (AFE) conjugate is used, in order to form a complete electric car fast charger, next can its paralell connection, be as high as the output power of 300 KW in order to offer.

2.Develop attacks choice

As a result of electric car direct link is in fast charger between alternating current net and car batteries, move for ground of on the safe side, charger must can keep apart user and alternating current net, can output voltage to charger / electric current undertakes modulatory. Segregation can pass the labour frequency transformer that receives alternating current source repeatedly directly to come true. However, charge quickly to electric car requires power level, corresponding transformer can be gotten greatly not actual. Carborundum power electronic parts can work below tall switch frequency, because this can use tall frequency transformer. Lead transformer photograph to compare with the low frequency that is the same as rated power, the advantage of tall frequency transformer is dimension apparent smaller. Accordingly, tall frequency transformer was used in the design.

Successful design asks to be commutate of alternating voltage of electrified wire netting dc generatrix voltage, ability receives batteries repeatedly. This can come true through diode passive commutate, perhaps attack through using the develop such as converter of such as AFE active commutate of the structure will come true. AFE and passive commutate photograph are showing an advantage than having, can offer for example adjustable output voltage, can realize two-way power to transmit. The join of design hypothesis input that this white paper place narrates adjusts to AFE- dc generatrix voltage, but incorrect in this white paper this undertakes treatise.

A variety of develop attack the structure is OK with conjugate of tall frequency transformer, in order to offer the segregation of electric car charger that place needs. Establish ties for example syntonic converter (SRC) , LLC and CLLC (with its the component in syntonic chamfer names) , move complete bridge (PSFB) and double active bridge (DAB)[1] . Stem from the reason of many sided, this design chooses to use DAB develop to attack structure. Above all, DAB can fall to realize 0 voltage switch in side of transformer and 2 side in all sorts of work requirements (ZVS) operation, reduced integral loss of the system from this, improved efficiency thereby and reduced heat government demand. Next, this design supports two-way move, this is OK to electric car charger the car network of electrified wire netting of retrorse feed communication is interactive (Vehicle-to-grid) application is crucial. The 3rd, keep apart and adjust what DAB can satisfy fast charger at the same time requirement. With AFE conjugate when, whole charger includes two form only, if pursue,1 is shown. Because this does not need,include 3 form to undertake be outputtinged finally (3 class charger) . The 4th, DAB develop attacks easy paralell connection offers the structure higher cumulative output power. Under photograph comparing, the shunt-wound moving likelihood that completely syntonic develop attacks is more difficult, because this kind of develop often asks the switch frequency between shunt-wound class is accurate pit-a-pat,match. Design of DAB of shunt-wound carry exercise can serve as module to use, the rating of power of the biggest output that differs through add or reducing shunt-wound unit to come true.

Graph 1: 2 class are dynamoelectric car charger framework

3.Double active bridge (way of DAB) converter work

DAB converter all uses complete bridge circuit in side of transformer and 2 side, if pursue,2 are shown. Ask an attention, this graph still includes other component, will undertake treatise to this later. The working way of two complete bridges is same, because this discusses side parts of an apparatus in detail only, the working way of 2 side parts of an apparatus and this is identical. All switch position uses wide modulation of arteries and veins (PWM) means works, occupy sky comparing to be 50% (the effect that does not include dead band time) . The diagonally switch position of complete bridge moves in phase; Namely . But turn over between two groups of diagonal; Namely:

Graph 2: CRD60DD12N-GMA block diagram

Side of transformer and 2 side are means of this kind of switch. The power of DAB is transmitted is through be in side mixes transformer 2 times phase shift introduces to come true between side, if pursue,3 are shown. Through controlling side and 2 phase shift between side, can adjust output power, following place are shown

Among them the output power that POUT is DAB [W] , n is transformer changes than [without unit] , VP is side volts d.c. [V] , VS is side 2 volts d.c. [V] , It is phase shift [radian] , fsw is switch frequency [Hz] , llk is feeling of circuit leakage of electricity [H] . When = When, achieve peak value to output power. Notable is, this control program is mixed 2 times in side only individual phase shift introduces between side. Through be in the complementary diagonal of side is opposite between be opposite with the complementary diagonal of 2 side between the phase shift that introduces independence (call ternary phase shift normally (TPS) work way) , can improve DAB further. However, these improve the range that exceeded the article.

Graph 3: Sequential chart of simple phase shift (dead band time omits)

Inside the dead band time between complementary switch event, the energy half-and-half conductor that DAB circuit stores in leakage feeling outputs capacitance to undertake discharging. Hypothesis circuit design is appropriate, this process can guide in parts of an apparatus before connecting, semiconductor discharge of output electric capacity reachs 0 V. Because parts of an apparatus guides below 0 V voltage,connect, because this is in,guide in passing Cheng won’t because of voltage / electric current overlaps and produce switch loss. This process calls 0 voltage switch (ZVS) , it is an advantage that DAB develop attacks, can improve circuit efficiency through reducing systematic switch loss. Should be in below rated load when the job, side of circuit and 2 side all can use ZVS job means.

4.Hardware

The hardware of this design with CAB006A12GM3T module of half bridge power is a center, if pursue,4 are shown. This module uses crimp technology, operate through be being pressed simply can relaxed module compositive in the design, need not pass bolt join terminal or solder large Copper Foil. In addition, this module is used design without motherboard, omited an original in module hot stack, because this can improve hot performance. This module uses SiC MOSFET entirely, the circuit level that brings in order to realize the SiC power electronic parts that above paragraphs place narrates is improved. Finally, this module is used besmear beforehand hot interface material (TIM) , have multinomial advantage, include: TIM passes special option, with a lot of off-the-peg TIM photograph comparing has taller property; Besmear beforehand mean TIM even from beginning to end and firm; And Wolfspeed was reflected adequately use the hot property of the module of this TIM.

Graph 4: CAB006A12GM3T power module

The design hardware of implementation is shown 5 times like the graph. This design uses 4 CAB006A12GM3T side in transformer and 2 side form module of half bridge power complete bridge circuit. Direct installation is in afore-mentioned module liquid cooling is cold board on, this board receives the two side of transformer repeatedly, also offer refrigeration for transformer. Use v/LIT all over the ground number than be 1:1, the tall frequency transformer that magnetization inductance is inductance of H of 248 μ , leakage to be H of 5 μ undertakes keeping apart. This design relies on the leakage inductance of transformer to realize ZVS only, do not need to add appropriative leakage inductor in circuit.

Introduce drive of driver of grid of high-powered Wolfspeed CGD1700HB2M-UNA module of every half bridge, although be in,bus line voltage also can realize fast operation below elevatory circumstance. Every position of grid driver all is passed board carry integrated circuit of driver of power source of segregation type DC-DC and grid of type of segregation of Texas Instruments UCC21710 to undertake keeping apart. Use current controller of Texas Instruments TMDSCNCD28379D to undertake controlling, can realize firmware easily custom-built, this design includes compositive controller local area network (CAN) interface, can undertake with controller dovish and reliable real time corresponds, update in order to realize feedback and control. This design still includes to be used at monitoring to input / the voltage feedback that outputs voltage is measured and use at monitoring transformer to slant the transformer electric current of buy electric current is measured.

Graph 5: CRD60DD12N-GMA hardware

5.Experimental test and verify

This system undertook experimental test and verify below a variety of work requirements, in order to demonstrate systematic operation. The performance below all sorts of laden conditions was evaluated below the target switch frequency of 100 KHz. If the complete parameter of experimental test and verify expresses 1 to show. This system uses open loop of simple phase shift to move. All sorts of function features of the DAB circuit that experimental measured value uses at place of test and verify to come true. Above all, running control of phase shift of the test and verify below power actually. User interface of use Wolfspeed graph (GUI) hand moves control phase shift, if pursue,6(a) place is shown. Side that graph 6(b) and graph 6(c) showed position of a switch respectively and voltage of source of 2 side bar (VGS) and leakage source voltage (the measured value of VDS) . No less than anticipates in that way, in be being measured with VDS in VGS, the phase shift that can configure was measured between side and position of 2 side switch.

Graph 6: (User interface of A) DAB graph, (B) VGS measures medium phase shift test and verify, (C) VDS measures medium phase shift test and verify

Next, use resistor group output adjustment and transformer are evaluated to move below high power as systematic load. Graph 7 showed in ?  = 11.6 ° The time domain that leaves the system that run with condition of POUT = 40 KW measures give typical examples. If the graph is shown 6 times, VGS and VDS phase shift are measured in circuit in apparent also. In addition, measure a result to show circuit will output voltage adjustment normally to arrive stable 800 V (the target outputs voltage) . Finally, transformer electric current measures what accord with circuit of double active bridge as a result to anticipate echelon feature, show circuit job is regular.

Graph 7: = 11.6 ° and the time domain when POUT = 40 KW measures give typical examples

The 3rd, inspection system realizes ZVS operation whether successfully. Graph 8 indication circuit are in= 18.9 ° and POUT = 60 KW (rated power) side of position of a switch when come off work is made and 2 side VGS and VDS. In grid signal command parts of an apparatus guides before connecting, the leakage source voltage of two side achieves 0 V, affirm the system moves successfully below ZVS.

Graph 8: Test and verify 0 voltage switch guides

The 4th, through changing output load evaluates the systematic efficiency below level of different output power. Actual measurement efficiency is shown 9 times like the graph. Because this system uses SiC parts of an apparatus to move, accordingly this circuit can be in wider output keeps efficient inside power level limits (when 20 KW of POUT ≥ , efficiency>98.7% ) , and the peak value efficiency of circuit is achieved 99.2% . It is under 20 KW, the system cannot move with ZVS means again, because of this loss of efficiency, this also is accorded with anticipate.

Graph 9: Actual measurement efficiency

6.Emulate

Does Wolfspeed offer the Plexim PLECS of all power module in Wolfspeed product combination? Model, include this DAB to design medium CAB006A12GM3T. These models but herein is gotten. Be based on the model that these can get publicly, developed complete PLECS to emulate (if the graph is shown 10 times) will capture the behavior that this DAB designs. To check the validity of the model, head preexistence and the experimental result that above paragraphs narrates undertake emulation below same operation condition, emulation result and be identical of experimental result height. For example, graph 11 during showing 60 KW moves emulate and the experiment measures side and electric current of 2 side transformer. Emulated accurate ground to capture basic circuit behavior measures extent with what observe in experimental result.

Graph 10: CRD60DD12N-GMA is emulated

Graph 11: Emulation test and verify

If classics proof is OK,general circuit operates imitate, should emulate the property that can be used at studying all sorts of control are politic, understand the sensitivity of includes circuit parameter. For example, graph 12 showed change leakage of electricity feels right transformer the influence of side electric current. Emulate make clear, the transformer in increasing leakage inductance to be able to add a system electric current of side peak value. Reduce leakage inductance to be able to reduce peak value electric current. Emulate can use at optimizing package and controller strategy further.

, graph 12: Feeling of transformer leakage of electricity emulates sensitivity to analyse

7.Conclusion

This white paper introduced converter of bridge-type of double active of a 60 KW, the compose that its can regard electric car as fast charger builds module. This design with Wolfspeed CAB006A12GM3T module of half bridge power is a center. Module of complete SiC power is used high-powered besmear beforehand hot interface material, can raise those who heat up function not to have substrate design and but relaxed and compositive crimp cites a base. What discuss in the article is modular when DAB and active front conjugate are used, realize much compose easily to establish module parallel connection, come with expanding cumulative output power be as high as 300 KW. This white paper includes to design implementation of operation ABC, hardware to discuss, experimental test and verify and emulation sensitivity analysis.

Bibliographical reference

[1] B. W. Nelson, “Wolfspeed WolfPACK? Power Module Platform: Accelerating Fast-Charger Development, “Wolfspeed, 1 March 2021. [Online] . Available:&Nbsp;Https://www.wolfspeed.com/knowledge-center/article/wolfspeed-wolfpack-power-module-platform-accelerating-fast-charger-development/ . [Accessed 7 May 2024] .

(article origin: WOLFSPEED, author: Chris New)

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