3.6KW Bi-directional energy storage converter

Release time:

2023-05-24 14:18

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PROJECT INTRODUCTION
In this design, input range is 90Vac-264Vac and output is 39-55Vdc/55A. A singleSpintrol ARM4 MCU is used as system controller, Totem-pole PFC and synchronousLLC is designed in the system, to realize bi-directional charge & discharge energyflow.The forward charging uses CC&CV dual control loop and the reverse inverter usesSPWM design. The inverter outputs pure sine wave, and the resistive load outputUTHD is less than 2%; The RC and RL load output UTHD is less than 3%: The RCD loadoutput UTHD is less than 5%.
 
DESIGN SPECIFICATION
Input Voltage 90Vac~264Vac
Output Voltage 39Vdc~55Vdc
Rated Power 3600W
System Efficiency PFC: 45KHz;LLC: 80-350KHz
PF >0.99
Switching Frequency PFC: 45KHz: LLC: 80-350KHZ

 

⽅案特点

· Single ARM4 MCU is designed to control bi-directional PFC and LLC with fullprotection, including input UVLO/OVP/OCP, output OVP/OCP. Compared with thetraditional DSP design, the system cost is greatly reduced;

· Forward charging uses CC&CV dual loop design; Reverse inverter uses SPWMdesign, smaller UTHD:

· PFC frequency is set to 45KHz. Compared with the traditional 20KHz design, theinductor volume is halved. Small volume and high power density:

· Novosense isolated half-bridge driver and amplifier are used to meet reinforcedinsulation requirements

 

MAIN TOPOLOGY

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MAIN DEVICES
 
Function Part Number Brand
MCU SPC1168 Spintrol
Input Fuse 0215020.MXEP Littelfuse
Input Relay CHFN-V-112HA2F(35A) Churod
PFC IGBT AUS65N65FP Lu-semi
PFC Driver NSI6602B Novosense
PFC Current Detection MCA1101-50-5 Aceinna
LLC Primary MoS CPW60R09OFD3 Coolsemi
LLc Secondly Mos SRTION043HTC-E Sanrise
LLC Primary Driver NSI6602B-DSPNR Novosense
LLC Secondly Driver MD18201A Meraki

 

 MEASUREMENT RESULTS AND WAVEFORMS

 

pic92.4%@ 220Vac output, full load

pic99.68 @230Vac input, full load

 

 

pic92.4%@ 220Vac output, full load

pic0.728%@220Vac output, full load

 

 

picPFC working wavefrom

picPFC full load start-up

 

 

picInverter start-up

picInverter working waveform--resistive full load

 

 

picRC Load 3KVA PF=0.8

picRL Load 3KVA PF=0.8

 

 

picRCD Load 3KVA

picInverter short circuit protection 1S

 

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3.6KW Bi-directional energy storage converter

2023-05-24