Design and implementation of a power distribution network for control equipment for electric ...

38 Pages·2017·0.84 MB·English

LiU-ITN-TEK-A--17/008--SE
Design and implementation of a
power distribution network for
control equipment for electric
vehicle charging
Anton Lindström
2017-03-16
Department of Science and Technology Institutionen för teknik och naturvetenskap
Linköping University Linköpings universitet
SE-601 74 Norrköping, Sweden 601 74 Norrköping
LiU-ITN-TEK-A--17/008--SE
Design and implementation of a
power distribution network for
control equipment for electric
vehicle charging
Examensarbete utfört i Elektroteknik
vid Tekniska högskolan vid
Linköpings universitet
Anton Lindström
Handledare Lars Backström
Examinator Amir Baranzahi
Norrköping 2017-03-16
Upphovsrätt
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© Anton Lindström
Design and implementation of a power
distribution network for control
equipment for electric vehicle charging

Anton Lindström
2017-03-20
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Abstract
This thesis treats the design and implementation of a power distribution network for a controller PCB
for controlling charging of electric vehicles. The controller PCB is powered by mains power, and thus
needs both AC to DC conversion and DC to DC conversion in order to operate. The thesis focuses on
the design of an isolated flyback topology AC to DC converter, while also describing the design and
implementation of the DC to DC converters needed for the controller PCB to operate.
The work started with some theoretical study, and then progressed into designing the converters.
The AC to DC and the DC to DC converters where designed in parallel. After the design phase was
complete the converters where implemented on PCBs for evaluation. The evaluation of the AC to DC
converter involved evaluation of several different transformers from different suppliers, as well as
evaluation of the circuit design itself. All converters designed proved functional after evaluation.
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Acknowledgments
First I would thank my supervisor Erik at ChargeStorm for his guidance and support, as well as the
rest of the people at ChargeStorm who aided me during my thesis work.
Secondly I would also like to thank my supervisor Lars and my examiner Amir for their feedback
during my work.
I would also like to thank my family and my friends for supporting me through my studies. And a
special thanks to my partner Sofia for her endless patience and support.
Anton Lindström
Norrköping 2016

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TABLE OF CONTENTS
1 Introduction .......................................................................................................................................... 1
1.1 Purpose .................................................................................................................................... 1
1.2 The HCC ................................................................................................................................... 1
1.3 Methodology ........................................................................................................................... 1
1.4 Limitations and delimitations .................................................................................................. 2
2 Background theory .......................................................................................................................... 4
2.1 electric power conversion overview ....................................................................................... 4
2.1.1 Switched conversion ........................................................................................................ 4
2.1.2 Linear Conversion ............................................................................................................ 5
2.2 Switch Mode DCDC Conversion ............................................................................................... 5
2.2.1 Buck converter................................................................................................................. 5
2.2.2 Boost converter ............................................................................................................... 7
2.2.3 Buck-boost converter ...................................................................................................... 8
2.2.4 Continuous and Discontinuous Mode operation ............................................................ 9
2.3 Isolating Switch Mode ACDC Conversion ................................................................................ 9
2.4 Isolated Flyback converter basic operation .......................................................................... 10
2.5 AC/DC Flyback conversion theory ......................................................................................... 11
3 Implementation ............................................................................................................................. 12
3.1 DCDC Implementation ........................................................................................................... 12
3.1.1 +24V to 3.3V Design ...................................................................................................... 12
3.1.2 +24V to +12V Design ..................................................................................................... 14
3.1.3 +12 to -12 Design ........................................................................................................... 15
3.2 ACDC Implementation ........................................................................................................... 17
3.2.1 Requirements ................................................................................................................ 17
3.2.2 IC Selection .................................................................................................................... 17
3.2.3 Transformer Design. ...................................................................................................... 18
3.2.4 Input Capacitor Selection .............................................................................................. 20
3.2.5 Snubber Design .............................................................................................................. 21
3.2.6 Output Stages Design .................................................................................................... 21
3.2.7 Powering the Tinysitch-4 ............................................................................................... 21
3.2.8 Configuring the TinsySwitch-4 ....................................................................................... 22
3.2.9 Feedback circuit ............................................................................................................. 22
3.2.10 EMI considerations ........................................................................................................ 22
3.2.11 Schematic ...................................................................................................................... 23
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3.2.12 Layout Considerations ................................................................................................... 23
4 Results ........................................................................................................................................... 24
4.1 Results ................................................................................................................................... 24
5 Concluding Discussion and Future Work ....................................................................................... 26
References ............................................................................................................................................. 27

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Abbreviations
ACRONYM MEANING
PCB Printed Circuit Board
AC Alternating Current
DC Direct Current
AC/DC Alternating Current to Direct Current
DC/DC Direct Current to Direct Current
IC Integrated Circuit
PDN Power Distribution Network
AB AktieBolag
HCC Home Charge Controller
EV Electronic Vehicle
CCU Charge Controller Unit
NDA Non Disclosure Agreement
SMSP Switched-Mode Power Supply
EMI ElectroMagnetic Interference
EMC ElectroMagnetic Compliance
LDO Low DropOut regulator
DCM Discontinuous Conduction Mode
MOSFET Metal–Oxide–Semiconductor Field-Effect Transistor
MCU Micro Controller Unit
GND GrouND
RC Resistor Capacitor
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Figures and Tables:
Figure 2.1: Buck converter basic topology 5
Figure 2.2: Buck converter switch-closed current flow 6
Figure 2.3: Buck converter switch-open current flow 6
Figure 2.4: Boost converter basic topology 7
Figure 2.5: Boost converter switch-closed current flow 7
Figure 2.6: Boost converter switch-open current flow 7
Figure 2.7: Buck-boost converter basic topology 8
Figure 2.8: Buck-Boost converter switch-closed current flow 8
Figure 2.9: Buck-Boost converter switch-open current flow 9
Figure 2.10: Isolated Flyback converter basic topology and current flow 10
Figure 2.11: Isolated flyback circuit sections and associated waveforms 11
Figure 3.1: 24V to 3.3V converter with MC33063A 14
Figure 3.2: Schematic of +12V to -12V DC/DC converter with TPS54062 16
Figure 3.3: Isolation interface overview 18
Figure 3.4: Physical layout of the transformer 20
Figure 3.5: The finished schematic of the AC/DC converter 23
Figure 4.1: The +24V to +3.3V DC/DC layout (right) and implemented on a PCB (left) 25
Figure 4.2: The +12V to -12V DC/DC layout (right) and implemented on a PCB (left) 25
Figure 4.3: The AC/DC converter layout (right) and implemented on a PCB (left) 26

Table 3.1: Basic requirements for the 24V to 3.3V converter design 12
Table 3.2: MC33063A relevant performance parameters 13
Table 3.3: Basic requirements for the 24V to 12V converter design 14
Table 3.4. Basic requirements for the +12V to -12V converter design 15
Table 3.5: TPS54062 relevant performance parameters 15
Table 3.6: Requirements for the AC/DC converter 17
Table 3.7: Power requirements of the transformer 18
Table 3.8: Isolation specifications for the transformer 18
Table 3.9: Physical properties and requirements of the transformer 19
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