Under the global trend of "carbon neutrality", the "green revolution" represented by electric vehicles is full of great opportunities. As the electric vehicle market grows rapidly, new demands are driving the adoption of high-voltage battery packs, while also drawing attention to high-power charger designs
The Renesas High Power Charger solution consists of a range of Renesas power components, including RAA214401 linear voltage regulator, RAA223021 AC/DC voltage regulator, R2A20114BFP Power factor correction (PFC) control IC, ISL6752 Zero voltage switch (ZVS) full bridge controller. Thanks to these devices, this charger solution can accept AC inputs up to 120V or 240V. And the power factor correction (PFC) controller can boost the signal up to 400VDC to overcome the input voltage variation. The PFC interleaving mode can also improve efficiency and reduce the footprint of the PFC controller.
System block diagram
RAA214401 Linear voltage regulator has a very wide input voltage range. And has an ultra-low static current, making it suitable for always-on and always-active applications. The device operates in the 5.4V-40V input voltage range with good line and load regulation. And with its integrated over temperature shutdown (OTSD), short circuit current limiting and other fault protection functions, can make the circuit design more secure.
RAA223021 Universal AC/DC switching regulator with ultra-low standby power with 700V integrated MOSFETs delivers up to 12W in step-down mode and flyback mode and supports output voltages as low as 3.3V with no additional LDO. When used, the RAA223021 combines constant-off time control with pulse frequency modulation (PFM) to provide excellent light load efficiency and ultra-low power consumption. In addition, the RAA223021 has input underpower protection to prevent overcurrent of the input circuit at low input voltages and burp protection under output fault conditions such as short circuit, overload, overvoltage and open circuit feedback.
The R2A20114BFP is a boost converter IC with PFC (power factor correction), which provides higher availability than the previous generation product. It is equipped with PFC boost control and differential input current detection amplifier, and integrated with various protection circuits, can greatly improve the reliability of the power while reducing the number of system components.
The ISL6752 Zero-voltage Switching (ZVS) full-bridge PWM controller implements ZVS operation by driving the upper bridge FET with a fixed 50% duty cycle, while the lower bridge FET uses trailing edge modulation with an adjustable resonant switching delay. Compared with common phase shift control methods, this algorithm can improve the performance of overcurrent and light load with the same efficiency, and the number of encapsulated pins is less and the complexity is lower. The ISL6752 has a complementary PWM output and can be used for synchronous rectifier (SR) control. The complementary output can be dynamically advanced or delayed. This advanced BiCMOS design has precision dead-time and resonant delay control.
Supported by these high-performance products, this solution has the following advantages:
● Staggered PFC control: reduce circuit area and improve efficiency
● ZVS controller
● Secondary control and feedback
● Pure hardware approach
● No programming
● Easy to configure
● Adjust the size of MOSFETs and passive components to determine the voltage, current and power of the charger
Renesas's successful portfolio of products provides customers across a wide range of industries with rich and simple solutions based on compatible and seamless components that help speed their products to market. The high-power charger solution introduced this time can not only adapt to the "20-28 series battery pack (up to 118V)" and "48V EV Solution" introduced in the previous successful product portfolio, but also provide more ideas for the charging design of AC/DC high-voltage, industrial power, light electric vehicle (LEV) and horticultural equipment applications.
