CN220857930U - Bidirectional DCDC battery formation power supply - Google Patents
Bidirectional DCDC battery formation power supply Download PDFInfo
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- CN220857930U CN220857930U CN202322620073.8U CN202322620073U CN220857930U CN 220857930 U CN220857930 U CN 220857930U CN 202322620073 U CN202322620073 U CN 202322620073U CN 220857930 U CN220857930 U CN 220857930U
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- HEZMWWAKWCSUCB-PHDIDXHHSA-N (3R,4R)-3,4-dihydroxycyclohexa-1,5-diene-1-carboxylic acid Chemical compound O[C@@H]1C=CC(C(O)=O)=C[C@H]1O HEZMWWAKWCSUCB-PHDIDXHHSA-N 0.000 title claims abstract description 43
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- 230000002457 bidirectional effect Effects 0.000 title abstract description 16
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 29
- 238000006243 chemical reaction Methods 0.000 claims abstract description 27
- 229910052802 copper Inorganic materials 0.000 claims abstract description 23
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- 229910052751 metal Inorganic materials 0.000 claims description 4
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- 238000003466 welding Methods 0.000 claims description 3
- 239000003990 capacitor Substances 0.000 abstract description 18
- 238000009423 ventilation Methods 0.000 abstract description 5
- 230000009286 beneficial effect Effects 0.000 abstract description 2
- 230000017525 heat dissipation Effects 0.000 description 6
- 238000010586 diagram Methods 0.000 description 4
- 230000002500 effect on skin Effects 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- 230000008602 contraction Effects 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 230000002035 prolonged effect Effects 0.000 description 2
- LAXBNTIAOJWAOP-UHFFFAOYSA-N 2-chlorobiphenyl Chemical compound ClC1=CC=CC=C1C1=CC=CC=C1 LAXBNTIAOJWAOP-UHFFFAOYSA-N 0.000 description 1
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- 230000007547 defect Effects 0.000 description 1
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- 238000010438 heat treatment Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
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- Dc-Dc Converters (AREA)
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Abstract
The utility model discloses a bidirectional DCDC battery formation power supply, which comprises a PCB (printed circuit board), wherein an isolated DCDC conversion circuit connected with the output end of a bidirectional PFC circuit is arranged on the PCB, the output end of the isolated DCDC conversion circuit is connected to an output terminal through a conductive bar, and the main circuit topology of the isolated DCDC conversion circuit is an upper 400V three-phase staggered half-bridge LLC circuit and a lower 400V three-phase staggered half-bridge LLC circuit; the electric conduction bars comprise positive electric conduction bars and negative electric conduction bars, the positive electric conduction bars and the negative electric conduction bars are made of copper bus plates with the thickness of 1mm and the width of 240mm, the copper bus plates are stamped with lead pins with the thickness of 2mm, are fixed on a PCB, and are welded with wiring copper foils for isolating the output ends of the DCDC conversion circuits. The bidirectional DCDC battery formation power supply can reduce ripple current of the filter electrolytic capacitor, has small ventilation wind resistance of the PCB and is beneficial to ventilation of the radiator; the output power part has fewer mechanical contacts, and reduces the conduction resistance loss.
Description
Technical Field
The utility model particularly relates to a bidirectional DCDC battery formation power supply, and belongs to the technical field of bidirectional DCDC battery formation power supplies.
Background
The whole machine output power of the existing battery formation power supply is 10KW, three-phase input voltage is 380V, output voltage is 15VDC, output current 667A, the internal part of the battery formation power supply is divided into a front stage and a rear stage, the front stage is a bidirectional PFC circuit, when the battery is charged in the forward direction, three-phase alternating current input voltage converts alternating current voltage into +/-400V bus voltage through the bidirectional PFC circuit to provide energy for a post-stage isolated DCDC conversion circuit, and +/-400V is converted into 15V output voltage through post-stage DCDC isolation and is supplied to the BMS part of the battery; the following two types of DCDC power circuit topologies are mainly adopted:
Scheme one: as shown in fig. 1, the voltage of the pre-stage rectified +/-400V bus is divided into upper and lower 2 paths of full-bridge LLC staggered control, the primary sides of transformers are connected in series, each resonant circuit is sampled by a current transformer to realize loop control and protection functions, and the upper and lower paths of the resonant circuits need to be added with power average control, so that the problem of large ripple current of electrolytic capacitors output by the +/-400V bus and the secondary side exists in the scheme;
Scheme II: as shown in fig. 2, the pre-stage rectification rear 800V three-phase interleaved half-bridge LLC control circuit has the advantages that the power MOS transistor of the circuit topology has high voltage stress requirement, 1200V SIC devices are needed, the number of the power devices is small, the circuit is simple, the efficiency is high, the power of the three-phase interleaved half-bridge LLC transformer is automatically divided equally, but the cost is high, and the software logic control wave generation strategy is relatively easy;
The two schemes have the common defects that when the output voltage is 15VDC, the output current 667A needs to reduce the conduction loss of a circuit, a plurality of bus copper bars with the height of 25 mm and the thickness of 2.5 mm are used for reducing the loss, the connection points are more, the connection points are fixedly connected by using screws with the height of more than M4, and the connection parts need to be coated with conductive mud to reduce the impedance and the temperature rise of contact points; secondly, the internal power device is in an air cooling heat dissipation mode, the bus bar is vertically arranged on the PCB, the height of the bus bar is generally 25 mm, the resistance of an air duct is increased, and the bus bar affects the effect of air cooling heat dissipation; the bus bar pins and the contacts are large in processing amount, more waste materials are generated in the stamping process, and the bus bar cost is high; the 3mm stamped lead-out pins of the vertical busbar are welded on the PCB copper foil to be electrically connected, the circumference of the sectional area of the busbar is long, the high-frequency current flows through the busbar to have skin effect so as to intensify heating, and the front ground potential and the rear ground potential have pressure difference; in addition, a high-current output lead of a secondary winding of the transformer is welded to the PCB by connecting a copper terminal and is connected with a vertical busbar, the drain electrode of the synchronous rectification MOS tube and the vertical busbar are directly locked to an aluminum profile radiator together, conductive adhesive is coated between the busbar and a metal radiator of the drain electrode of the output synchronous rectification MOS tube, impedance and thermal resistance are reduced, thermal resistance between the MOS tube and the radiator is large, and temperature rise is caused; the positive end of the output voltage of the power supply is connected with a winding lead terminal of the transformer through 2 vertical copper bus plates, circuit contact joints are arranged between the bus plates, the winding lead joint of the transformer is high in impedance and large in loss, the circuit contact joints are fastened by using 2M 4 screws, and conductive mud is added to reduce the conduction impedance; the negative end of the output voltage of the power supply is connected with the source pin of the synchronous rectification MOS tube through 3 vertical copper bus plates, circuit contact points are arranged between the bus plates, the bus plates are fastened by using 2M 4 screws, conductive mud is added to reduce conduction resistance, and the installation mode is complex.
Disclosure of utility model
In order to solve the problems, the utility model provides a bidirectional DCDC battery formation power supply which can reduce ripple current of a filter electrolytic capacitor, has small ventilation wind resistance of a PCB and is beneficial to ventilation of a radiator; the output power part has fewer mechanical contacts, and reduces the conduction resistance loss.
The utility model discloses a bidirectional DCDC battery formation power supply, which comprises a PCB (printed circuit board), wherein an isolated DCDC conversion circuit connected with an output end of a bidirectional PFC circuit is arranged on the PCB, the output end of the isolated DCDC conversion circuit is connected to an output terminal through a conductive bar, the conductive bar comprises a positive conductive bar and a negative conductive bar, the positive conductive bar and the negative conductive bar are both made of copper bus plates with the thickness of 1mm and the width of 240mm, the copper bus plates are stamped with lead-out pins with the thickness of 2mm and are fixed on the PCB, the lead-out pins are welded with wiring copper foils of the output end of the isolated DCDC conversion circuit, the expansion coefficients of the PCB and the copper bus plates are different, and the lead-out pins with the thickness of 2mm can buffer the deformation caused by heat expansion and cold contraction. The skin effect and impedance of the leads of the 6 branches are consistent, and the ground potential basically has no pressure difference.
Further, copper terminals are fixed on the large-current output leads of the 6 transformer secondary windings of the isolated DCDC conversion circuit and are fixedly connected with an aluminum profile radiator of an output synchronous rectification MOS tube of the isolated DCDC conversion circuit; the secondary winding of the transformer is connected with the drain electrode of the synchronous rectification MOS tube through the aluminum profile radiator, and the direct connection installation mode can reduce impedance and thermal resistance, so that the output current flow requirement is solved, and meanwhile, the heat dissipation problem of the synchronous rectification MOS tube can be guaranteed.
Further, conductive adhesive is coated between the aluminum profile radiator and the metal radiator of the drain electrode of the output synchronous rectification MOS tube.
Furthermore, the positive end of the output voltage of the isolated DCDC conversion circuit is connected with a direct copper busbar at the winding lead end of the transformer, no intermediate circuit contact exists, only 1 winding lead joint of the transformer has low impedance and small loss, and conductive mud is not needed to be added to reduce the conduction impedance; the negative end of the output voltage of the isolated DCDC conversion circuit is connected with a source pin of the synchronous rectification MOS tube through direct copper bus plate welding; the intermediate circuit contact is not needed, the impedance is low, the loss is small, and the conductive mud is not needed to be added to reduce the conduction impedance.
Compared with the prior art, the bidirectional DCDC battery formation power supply has the following advantages: the bidirectional formation power supply uses a three-phase interleaved LLC circuit, so that ripple current of the filter electrolytic capacitor is reduced, and service lives of the +/-400V busbar electrolytic capacitor and the output electrolytic capacitor are prolonged; each part of the three-phase staggered LLC circuit is laid out on a PCB, and a tiled busbar is adopted to reduce the difference of ground potential, reduce wind resistance and facilitate ventilation of a radiator; the output power part has fewer mechanical contacts, and reduces the conduction resistance loss.
Drawings
Fig. 1 is a schematic diagram of a positive and negative 400V upper and lower 2-way full-bridge LLC interleaved control topology.
Fig. 2 is a schematic diagram of a positive 800V three-phase interleaved half-bridge LLC control topology.
Fig. 3 is a schematic diagram of a positive-negative 400V up-down three-phase interleaved half-bridge LLC topology in accordance with the present utility model.
Fig. 4: the PCB board layout schematic diagram is provided.
Detailed Description
Example 1:
The bidirectional DCDC battery formation power supply shown in fig. 3 and 4 comprises a PCB board 1, wherein an isolated DCDC conversion circuit connected with the output end of a bidirectional PFC circuit is arranged on the PCB board 1, the output end of the isolated DCDC conversion circuit is connected to an output terminal 2 through a conductive bar 11, and the main circuit topology of the isolated DCDC conversion circuit is an upper 400V three-phase staggered half-bridge LLC circuit and a lower 400V three-phase staggered half-bridge LLC circuit as shown in fig. 3; the circuit is a traditional three-phase staggered half-bridge LLC circuit and comprises a driving circuit 3, a primary MOS tube circuit 4, a transformer circuit 5, a synchronous rectification MOS circuit 6 and an output capacitor 7 which are connected in sequence; a resonant inductor and a resonant capacitor are connected in series between the primary MOS tube circuit 4 and the transformer circuit 5 to form a resonant circuit, wherein the resonant inductor comprises an inductor in a circuit and a leakage inductance 8 of the transformer, and the resonant capacitor is a capacitor connected in series on the resonant circuit; a current transformer 9 is arranged on the resonance loop; the current transformer 9 is connected to a DSP controlled by the whole machine; the DSP can realize forward and reverse working mode switching, so that synchronous rectification driving is in a reverse working state; the circuit is an existing circuit, and the specific circuit structure and the working process thereof are not described in detail herein; the main circuit topology is an upper 400V three-phase staggered half-bridge LLC and a lower 400V three-phase staggered half-bridge LLC, the withstand voltage of the power MOS is COOLMOS of 600V grade, and the power MOS is a common device and has low cost; 6 transformers, small device size, easy heat dissipation and average temperature of the whole machine; three-phase LLC has three resonant tank, and every resonant tank is sampled through a mutual-inductor, and three-phase current sampling full-bridge rectification back, merges and obtains complete current signal, and wherein adopts three-phase LLC ripple current less, specifically does: the ripple current of the output electrolytic capacitor of the single-phase LLC topology is 0.5 times Io, the ripple current of the two-phase LLC is 0.15, the ripple current of the three-phase interleaved LLC is only 0.05, the ripple current is obviously reduced, the risk of exceeding the ripple current is reduced, and the service lives of the +/-400V bus electrolytic capacitor and the output electrolytic capacitor are prolonged;
Because the power supply outputs current 1000A and the PCB copper foil can generate high heat, a heat dissipation air flue is required to be laid out and optimized on the PCB, the conduction resistance of an output loop is reduced, the heat generation caused by large current is reduced, an isolated DCDC conversion circuit is arranged on a PCB board 1 and comprises a driving circuit 3, a primary MOS radiator 41, a current transformer 9, a resonant inductor 8, transformers of a transformer circuit 5, a synchronous rectification MOS radiator 61, a capacitor and an output terminal 2 which are arranged in parallel in sequence, wherein the capacitor comprises an output capacitor 7, a resonant capacitor and a driving circuit capacitor; the MOS tube of the primary MOS tube circuit 4 and the MOS tube of the synchronous rectification MOS circuit 6 are fixed on the primary MOS radiator 41 and the synchronous rectification MOS radiator 61; the fan 10 is fixed on the side of the output terminal, and the modules are arranged on the PCB, so that the smoothness of an air path can be ensured, and the wind resistance can be reduced; the fan 10 can meet the requirements by adopting air suction or blowing;
The conducting bars 11 comprise a positive conducting bar 111 and a negative conducting bar 112, the positive conducting bar 111 and the negative conducting bar 112 are both made of copper bus plates with the thickness of 1mm and the width of 240mm, the copper bus plates are stamped with lead pins with the thickness of 2mm and fixed on the PCB 1, and are welded with wiring copper foils for isolating the output ends of the DCDC conversion circuits, the expansion coefficients of the PCB and the copper bus plates are different, and the lead pins with the thickness of 2mm can buffer the deformation of heat expansion and cold contraction; the skin effect and impedance of the leads of the 6 branches are consistent, and the ground potential basically has no pressure difference.
Copper terminals are fixed on the high-current output leads of the secondary windings of the 6 transformers of the transformer circuit 5 and fixedly connected to the synchronous rectification MOS radiator 61; the secondary winding of the transformer is connected with the drain electrode of the synchronous rectification MOS tube through the synchronous rectification MOS radiator 61, and the direct connection installation mode can reduce impedance and thermal resistance, so that the output current flow requirement is solved, and meanwhile, the heat dissipation problem of the synchronous rectification MOS tube can be guaranteed.
And conductive adhesive is coated between the synchronous rectification MOS radiator 61 and the metal radiator of the drain electrode of the output synchronous rectification MOS tube.
The positive end of the output voltage of the isolated DCDC conversion circuit is connected with a direct copper busbar at the winding lead end of the transformer, no intermediate circuit contact exists, only 1 winding lead joint of the transformer has low impedance and small loss, and conductive mud is not needed to be added to reduce the conduction impedance; the negative end of the output voltage of the isolated DCDC conversion circuit is connected with a source pin of the synchronous rectification MOS tube through direct copper bus plate welding; the intermediate circuit contact is not needed, the impedance is low, the loss is small, and the conductive mud is not needed to be added to reduce the conduction impedance.
The above embodiments are merely preferred embodiments of the present utility model, and all changes and modifications that come within the meaning and range of equivalency of the structures, features and principles of the utility model are therefore intended to be embraced therein.
Claims (4)
1. The utility model provides a two-way DCDC battery formation power, includes the PCB board, be provided with the isolation DCDC conversion circuit who is connected with two-way PFC circuit output on the PCB board, isolation DCDC conversion circuit output is connected to output terminal through the conducting bar, its characterized in that: the main circuit topology of the isolated DCDC conversion circuit is an upper 400V three-phase staggered half-bridge LLC circuit and a lower 400V three-phase staggered half-bridge LLC circuit;
The electric conduction bars comprise positive electric conduction bars and negative electric conduction bars, the positive electric conduction bars and the negative electric conduction bars are made of copper bus plates with the thickness of 1mm and the width of 240mm, the copper bus plates are stamped with lead pins with the thickness of 2mm, are fixed on a PCB, and are welded with wiring copper foils for isolating the output ends of the DCDC conversion circuits.
2. The bi-directional DCDC battery-formed power supply of claim 1, wherein: copper terminals are fixed on the large-current output leads of the 6 transformer secondary windings of the isolated DCDC conversion circuit and are fixedly connected with an aluminum profile radiator of an output synchronous rectification MOS tube of the isolated DCDC conversion circuit; and the secondary winding of the transformer is connected with the drain electrode of the synchronous rectification MOS tube through an aluminum profile radiator.
3. The bi-directional DCDC battery-formed power supply of claim 2, wherein: and conductive adhesive is coated between the aluminum profile radiator and the metal radiator of the drain electrode of the output synchronous rectification MOS tube.
4. The bi-directional DCDC battery-formed power supply of claim 1, wherein: the positive end of the output voltage of the isolation DCDC conversion circuit is connected with a direct copper bus plate at the winding lead end of the transformer, and the negative end of the output voltage of the isolation DCDC conversion circuit is connected with a direct copper bus plate at the source electrode pin of the synchronous rectification MOS tube in a welding way.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202322620073.8U CN220857930U (en) | 2023-09-26 | 2023-09-26 | Bidirectional DCDC battery formation power supply |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202322620073.8U CN220857930U (en) | 2023-09-26 | 2023-09-26 | Bidirectional DCDC battery formation power supply |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN220857930U true CN220857930U (en) | 2024-04-26 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202322620073.8U Active CN220857930U (en) | 2023-09-26 | 2023-09-26 | Bidirectional DCDC battery formation power supply |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN220857930U (en) |
-
2023
- 2023-09-26 CN CN202322620073.8U patent/CN220857930U/en active Active
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