The DCDC Converter Circuit Design in Electrical Vehicle - LS Workshop
The DCDC Converter Circuit Design in Electrical Vehicle
The DCDC Converter Circuit Design in Electrical Vehicle

1.  DCDC  Converter Design- spec

Input voltage                                210Vdc~410Vdc
Output voltage                             14V1500W
Output voltage adjustable range:   12~16Vdc,  PWM signal control
Regulation:                                      ±1%
Start up overshoot:                        ± 5%
Transient response:                      1ms0%~50%~0%  1000A/s
                                                         0%~100%~0%  1000A/S
Ripple:                                          200mV
Efficiency:                                     92%
Protection function                     Input under voltage: Automatic recover
                                                         Input over voltage: Automatic recover
                                                         Output under voltage: Automatic recover
                                                         Output over voltage: Latch
                                                         Over load/short circuit: Automatic recover
                                                         Over temperature: Automatic recover
Remote control:                              TTL level voltage

Fault alarm:                                     OC alarm

Mechanical outline                      280mm×200mm×70mm
Weight:                                          3.6kg
Operation temperature:              -40~85 ℃
Cooling                                         Water cooling ( water temperature: 75℃)
                                                          ( water press is from 0.02Mpa)
EMC:                                              CISPR 25, Level 4

Vibration:                                       QC/T 413-2002 3.12,   Not on the Engine in engine  
Protection:                                    IP66

2. DCDC  Converter Design- Circuit 

(1).             EMI stage:
                   Four common mode inductor: 2.1mH, R7K, T25X15X10, 1.2mm, 23T

(2). Buck+ open loop interleaved LLC
   Buck: Mosfet: 20N60,  Diode:R1560
  Inductor: 2X56uH, CS234090, FeSiAl, 1.0mmX3, 20T
  UC2843  IRS21834
  Switching frequency:   100KHz

(3). Open loop Interleaved LLC
    Primary Mosfet: IRF38N20,  Synchronous Rectifier: IRF3805
    Lm: 18uH,  Lr: 2.6uH,  Cr:39nF
    Lr:  2.6uH, PQ26, PC95, 0.25X3.5X4, 3T
    Transformer: ER30, PC95, Primary 4OZ PCBX2, 5T
    Secondary 0.2X4.5mm copperX6, 1T
    Output Capacitor: 10uFx17
    Switch frequency: 300kHz  

(4). Auxiliary Power Supply
      Transformer: EFD20, PC40
      Mosfet:          9R1K20
     Control IC:    UC2844
     Switching frequency: 130KHz


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