7kW On-Board Charger (OBC) Reference Design

The STDES-7KWOBC is an On-Board Charger (OBC) reference design that charges the battery of an Electric Vehicle (EV) from a household AC mains plug or a private/public outlet (AC charging station). The reference design embeds two parts: an interleaved totem-pole PFC with SiC and a dual galvanically isolated LLC DC-DC ZVS resonant converter based on MDmesh DM6 superjunction power MOSFETs. The power platform is a 7 kW module capable of providing constant current (CC) or constant voltage (CV) at the output, and can be used as standalone (1 PH+ N), parallel or three-phase mode (3Ph + N) to reach 21 kW. The underlying insulated metal substrate on an aluminum substrate allows very effective heat dissipation, forced or liquid cooling. Each module that makes up the reference design allows easy interconnection between modules of the same type through wires or busbar connections to reach higher output powers. The key factors of this reference design are efficiency and high power density, thanks to SiC and SJ power MOSFETs, silicon and SiC diodes, gate drivers, SPC58NN84E7 Power Architecture automotive-grade microcontroller, and SCR thyristors for inrush current limitation. The STDES-7KWOBC is a fully assembled kit developed for performance evaluation and is not for sale. All functionsFront-end PFC stage with 2-channel interleaved totem-pole topology, operating at 70 kHzDigital inrush current controlDC-DC stage with FB LLC resonant topology, resonant frequency 140 kHzConstant current and constant voltage modesControl stage based on SPC58NN84E712 V input supply voltageGalvanically isolated from output voltage GND (high voltage battery)Bus interconnection possibilityRoHS compliantPFC:Main products:TN3050H-12GY-TR SCR, STBR3012G2Y bypass diode, SCTH35N65G2V-7AG SiC power MOSFETInput: 85 to 265 VAC, 45 to 65 HzDigital inrush current limiterMaximum input current: 32 ArmsSwitching frequency: 70 kHzAverage current mode control in continuous conduction mode (CCM)PID or 2p2z 2x independent current loop regulatorPID or 2p2pz voltage regulatorSPC58NN84E7 MCU ControllerDC-DC:Main Products:STH47N60DM6-7AG power MOSFET,STPSC20065GY-TR output diode,A6387 gate driverOutput voltage:250 to 450 VDCSwitching frequency:92 to 250 kHz, start-up frequency is 350 kHzTwo independent current loops (CC)One voltage loop plus current balance (CV)PID regulatorSPC58NN84E7 MCU ControllerThe STDES-7KWOBC is an on-board charger (OBC) reference design which allows charging the battery of electric vehicles (EV) through your home AC mains plug or a private/public outlet (AC charging station).The reference design embeds two sections: an interleaved totem pole PFC with SiC and a dual galvanic isolated LLC DC-DC ZVS resonant converter, based on MDmesh DM6 super-junction power MOSFETs.The power platform is a 7 kW module able to deliver a constant current (CC) or constant voltage (CV) on the output to be used as standalone (1 PH+ N), in parallel or in 3-phase mode (3Ph + N) to reach 21 kW.The underlying insulated metal substrate on aluminum base plate enables very effective heat dissipation, forced or liquid cooling.Each module composing the reference design allows an easy interconnection among modules of the same type through wires or bus bar connection, reaching a higher output power.This reference design key factor is the efficiency and high-power density gained thanks to SiC and SJ power MOSFETs, silicon and SiC diodes, gate drivers, the SPC58NN84E7 power architecture automotive-grade microcontroller, and SCR thyristors for inrush current limitation. The STDES-7KWOBC is a fully assembled kit developed for performance evaluation only, not available for sale. All features Front end PFC stage using 2-channel interleaved totem pole topology operating at 70 kHzDigital inrush current controlDC-DC stage using FB LLC resonant topology with 140 kHz resonant frequencyConstant current and constant voltage modeControl stage based on SPC58NN84E712 V input supply voltage galvanically isolated from output voltage GND (high voltage battery)Bus bar interconnection possibilityRoHs compliantPFC:Key products: TN3050H-12GY-TR SCRs, STBR3012G2Y bypass diodes, SCTH35N65G2V-7AG SiC power MOSFETInput: 85 to 265 VAC, 45 to 65 HzDigital inrush current limiterMax. input current: 32 ArmsSwitching frequency:70 kHzAverage current mode control in continuous conduction mode (CCM)PID or 2p2z 2x independent current loop regulatorsPID or 2p2pz voltage regulatorSPC58NN84E7 MCU controllerDC-DC:Key products: STH47N60DM6-7AG power MOSFET, STPSC20065GY-TR output diodes, A6387 gate driverOutput voltage: 250 to 450 VDCSwitching frequency: 92 to 250 kHz with start-up at 350 kHzTwo independent current loops (CC)One voltage loop plus current balancing (CV)PID regulatorsSPC58NN84E7 MCU controller