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OBC 1KW-Automotive

Muthuraj M
Prodigy 20 points
Other Parts Discussed in Thread: UCC28180, UCC28070A, UCC28070-Q1, PMP22220, UCD3138, PMP8740

Hello TI Team,

We are planning for an OBC for small vehicles in automotive grade.

Kindly share some reference desing for below requirements.

Output Power -    1000W

Ouptut Votage -    300 to 450 VDC

Input voltage -      110 to 265 VAc - 50Hz

Input current -       7.5 Amps Max 

Efficiency      -       >95%

PF                -        0.99

Regards,
Muthuraj M

  • 0
    TI__Expert 8680 points

    Hello Muthuraj,

    Thank you for your interest in TI products.

    • We have an abundance of reference designs that you can search for using our TI Reference Design Library: https://www.ti.com/reference-designs/index.html.
    • You can also generate custom circuits based on your parameters using Webench Power Designer: https://webench.ti.com/power-designer/

    Webench power designer recommends UCC28180 (https://www.ti.com/product/UCC28180) or UCC28070A (https://www.ti.com/product/UCC28070A), which are good choices based on your power level. For an automotive grade part, consider the UCC28070-Q1 (https://www.ti.com/product/UCC28070-Q1).

    For a reference design, you can view the PMP22220 (https://www.ti.com/tool/PMP22220). This uses the UCD3138 (https://www.ti.com/product/UCD3138), which is our digital controller. With high power level, high efficiency and high PF requirements, it may be worth considering a digital controller. The UCD3138 excels in this space since it provides the benefits of digital control while also being easy to program. 

    You can also view the PMP8740 (https://www.ti.com/tool/PMP8740). This reference design uses the UCC28180 and matches your output power, although the efficiency is not as high.

    As a heads up with your requirements, the low end of your output voltage is 300V. PFC circuits will almost always be some form of a boost converter (especially at that power level). In order to use a boost converter, you MUST boost the output voltage. Since your input voltage is the universal AC input, the minimum output voltage required from your PFC stage is 265V*sqrt(2) =  375V. This is why most PFC circuits have an output voltage of 390V, to account for the peak universal AC input voltage. 

    If the 300VDC output voltage is required, you may need to consider a second DC/DC stage after the PFC. A second DC/DC stage is also recommended since, at a high power, isolation is important. Something like an LLC, a Full-bridge, or a PSFB may be useful. The UCD3138 will also be a good choice since it can control both the PFC circuit and your DC/DC circuit. Or, you can use an analog PFC controller and an analog DC/DC controller.

    We have a new LLC controller that will be released soon that you may consider: https://www.ti.com/product/UCC25660 

    Please let me know if you have any more questions.

    Regards,

    Jonathan Wong

  • 0 in reply to Jonathan Wong
    Prodigy 20 points

    Thankyou Jonathan, Will allign and connect further.

    Regards,

    Muthuraj M