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UCC28950: Feasibility of High Power(50kW or higher) Charger using off shelf Chips

Bharath Manogna
Prodigy 60 points
Part Number: UCC28950
Other Parts Discussed in Thread: UCC28070

Hi everyone,

I am conducting a feasibility study on designing high power chargers with below specs,

3 phase 415V 50Hz input  

110/220V DC output,

High efficiency >90%

The idea is to use a Front end interleaved PFC to generate intermediate 400VDC which shall be stepped down using Phase-shifted full bridge converter to 110/220V for batteries.

Some Challenges could be,

Finding high Current IGBTs.

Selecting an ideal switching frequency which may be limited to around 10kHz.

Designing Transformers(DC/DC)to handle high currents and with low leakage inductance to reduce ringing.

Designing Inductors to handle high currents(~400A).

Can UCC28070 and UCC28950 be used to achieve this.

Can anyone see any other significant challenges.

Any thoughts will be very much appreciated.

Thanks

  • 0
    TI__Mastermind 31580 points
    Hi Bharath,

    For three phase PFC I suggest you look at our digital solutions using the C2000 DSP, all our analogue controllers are targeted at single phase applications.

    4353.TI_3phasePFCandAPFapplicationwithTIC2000MCU[1].pdf
    www.ti.com/.../tidm-1000

    We have seen the UCC28950 designed into applications in the 3kW to 10kW region, but this design is much higher 40 to 80kW, which is beyond our normal application area.

    For magnetics design I suggest you talk to some of the magnetics vendors such as Wurth, Renco, and Pulse who may be able to give you some guidance on design of high current inductors.

    It may be better to look at implementing the design as a number of modules operating in parallel, 5kW each for example to reduce the output currents to a more manageable level.

    Regards

    Peter
  • 0 in reply to Peter Meaney
    Prodigy 60 points
    Hello Peter,
    Thank you for your insight , i too believe that paralleling low power High frequency systems is more manageable, but I was trying to assess the limits of high frequency systems, i will have a chat with magnetics vendors to get more info.
    I would like to ask, what according to you is the highest power rating you have seen in an stand alone high frequency system without any parallel systems. Would low frequency Thyristor based systems be a more attractive option at these powers. considering the fact that it would be less efficient but offer some advantages like isolation and relative ease of implementation.
    Regards,
    S.Bharath Manogna