On-board charger control circuit

Abstract

This utility model belongs to the technical field of on-board chargers, specifically relating to on-board charger control circuits. The on-board charger control circuit includes a power input module, an inductive energy storage module, an output capacitor / load module, a feedback acquisition module, and a control module; the power input module, inductive energy storage module, output capacitor / load module, feedback acquisition module, and control module are sequentially electrically connected; the control module is electrically connected to the inductive energy storage module; the inductive energy storage module is controlled by a high-frequency switching transistor. This utility model effectively improves the power of the on-board charger while reducing component heat generation.

Description

Technical Field

[0001] This utility model belongs to the field of vehicle-mounted charger technology, specifically relating to vehicle-mounted charger control circuits. Background Technology

[0002] With the increasing popularity of electric vehicles, the performance of on-board chargers, as key components, has attracted much attention. Current technologies for on-board chargers face numerous challenges in power enhancement and component heat management. On the one hand, to meet the demands of fast charging for electric vehicles, the charger's power needs to be increased, but this often leads to increased component heat generation. For example, in traditional on-board chargers using higher charging power, the bridge arm switches in the power factor correction (PFC) circuit generate significant heat due to high-frequency operation, increasing switching losses and reducing circuit stability and reliability. On the other hand, the subsequent resonant converter, operating over a wide output voltage range, often experiences resonant current overcurrent due to the use of frequency conversion modulation (PFM) and other methods. This not only increases losses but also makes it difficult to simultaneously achieve high efficiency and wide voltage gain.

[0003] Therefore, how to design an on-board charger control circuit that can effectively improve the power of the on-board charger while reducing the heat generation of the components has become a technical problem that urgently needs to be solved in this field. Utility Model Content

[0004] This invention aims to overcome the problem that existing on-board charger control circuits in the prior art struggle to balance power enhancement and component heat generation, and provides an on-board charger control circuit that can effectively improve the power of the on-board charger while reducing component heat generation.

[0005] To achieve the above-mentioned objectives, this utility model adopts the following technical solution: The on-board charger control circuit includes a power input module, an inductive energy storage module, an output capacitor / load module, a feedback acquisition module, and a control module; the power input module, inductive energy storage module, output capacitor / load module, feedback acquisition module, and control module are electrically connected in sequence; the control module is electrically connected to the inductive energy storage module; the inductive energy storage module is controlled by a high-frequency switching transistor.

[0006] Preferably, the power input module includes a relay board K201; the relay board K201 is externally connected to a 12V DC power supply.

[0007] Preferably, the inductive energy storage module includes MOSFET S200, MOSFET S203, IGBT elements S201 and S202, capacitors C207, C208, C212, C213, C256, C257, and inductor L200; the source of MOSFET S200 is electrically connected to one end of inductor L200 and the drain of MOSFET S203; the drain of MOSFET S200 is electrically connected to capacitor C207, C208, C212, C213, C256, C257, and inductor L200. 207. The collector of capacitor C208 and IGBT element S201 are electrically connected; the source of MOSFET S203 is electrically connected to capacitors C212 and C213 and the emitter of IGBT element S202; capacitor C207 is connected in parallel with capacitor C208; capacitor C212 is connected in parallel with capacitor C213; capacitor C207 is electrically connected to capacitors C212 and C213; the emitter of IGBT element S201 is electrically connected to the collector of IGBT element S202.

[0008] Preferably, the feedback module includes operational amplifier U400A, operational amplifier U400B, resistors R400, R401, R402, R403, R404, R405, R406, R407, R408, R409, R410, R411, R412, R413, and capacitors C400, C401, and C402. Capacitors C403, C404, C405, C406, and C407; Schottky diodes D400 and D403; resistors R402, R403, and R404 connected in series; resistor R404 is electrically connected to the gate of Schottky diode D400, resistor R401, capacitor C401, and the negative input terminal of operational amplifier U400A; resistors R407, R408, and... R409 is connected in series; resistor R409 is electrically connected to the gate of Schottky diode D403, resistor R410, capacitor C404, and the positive input terminal of operational amplifier U400A; capacitor C408 is electrically connected to resistor R410 and capacitor C404; the output terminal of operational amplifier U400A is electrically connected to resistor R401, resistor R405, and capacitor C401; resistor R406 is electrically connected to resistor R405, capacitor C402, capacitor C403, and resistor R412; resistor R413 is electrically connected to capacitor C405, capacitor C406, and the positive input terminal of operational amplifier U400B; the negative input terminal of operational amplifier U400B is electrically connected to the output terminal of operational amplifier U400B and resistor R411; resistor R411 is electrically connected to capacitor C407; the positive power supply terminal of operational amplifier U400A is electrically connected to resistor R400 and capacitor C400.

[0009] Preferably, the control module includes an isolated gate driver U301, resistors R306, R307, R316, R317, R320, R321, capacitors C304, C310, C311, C315, and C317; the isolated gate driver U301 is model SI8233BB-D-IS1; the first pin of the isolated gate driver U301 is electrically connected to resistor R316, capacitor C311, and resistor R307 respectively; the second pin of the isolated gate driver U301 is electrically connected to resistor R306, capacitor C310, and resistor R321 respectively. 317 Electrical connection; Pin 3 of the isolated gate driver U301 is electrically connected to capacitor C304 and the 5V DC power supply respectively; Pin 4 of the isolated gate driver U301 is electrically connected to capacitors C310, C311, resistors R306, R307, C315, R321, and C317 respectively; Pin 5 of the isolated gate driver U301 is electrically connected to capacitor C315 and resistor R320 respectively; Pin 6 of the isolated gate driver U301 is electrically connected to resistor R321; Pin 8 of the isolated gate driver U301 is electrically connected to capacitor C317 and the 5V DC power supply respectively.

[0010] Preferably, the control module further includes an inductor L301, resistors R302, R303, R309, R311, and R313, capacitors C302, C305, C309, and C314, transistors Q301 and Q303, and a Zener diode D301; pin 16 of the isolated gate driver U301 is electrically connected to inductor L301, capacitor C302, resistors R302, R303, and capacitor C305; pin 15 of the isolated gate driver U301 is electrically connected to resistor R311; resistor R311 is electrically connected to transistors... The base of Q301 is electrically connected to the base of transistor Q303; the collector of transistor Q301 is electrically connected to resistor R302; the emitter of transistor Q301 is electrically connected to resistor R309 and the emitter of transistor Q303, respectively; pin 14 of isolated gate driver U301 is electrically connected to the collector of transistor Q303, the anode of Zener diode D301, and capacitor C314, respectively; resistor R303 is electrically connected to the cathode of Zener diode D301, capacitors C314 and C305, resistor R313, and capacitor C309, respectively; resistor R309 is electrically connected to resistor R313 and capacitor C309, respectively.

[0011] Preferably, the control module further includes an inductor L303, resistors R324, R325, R327, R329, and R331, capacitors C319, C321, C323, and C325, transistors Q305 and Q307, and a Zener diode D303; pin 11 of the isolated gate driver U301 is electrically connected to inductor L303, capacitor C319, resistors R324, R325, and capacitor C321; pin 10 of the isolated gate driver U301 is electrically connected to resistor R329; resistor R329 is electrically connected to transistors... The base of transistor Q305 is electrically connected to the base of transistor Q307; the collector of transistor Q305 is electrically connected to resistor R324; the emitter of transistor Q305 is electrically connected to resistor R327 and the emitter of transistor Q307, respectively; pin 9 of isolated gate driver U301 is electrically connected to the collector of transistor Q307, the anode of Zener diode D303, and capacitor C325, respectively; resistor R325 is electrically connected to the cathode of Zener diode D303, capacitors C321 and C325, resistor R331, and capacitor C323, respectively; resistor R327 is electrically connected to resistor R331 and capacitor C323, respectively.

[0012] Preferably, the output capacitor / load module includes resistors R200, R201, R203, R204, R206, and R207, and capacitors C203, C204, C205, C221, C222, and C223; capacitors C203, C204, and C205 are connected in parallel; capacitors C221, C222, and C223 are connected in parallel; capacitor C204 is electrically connected to capacitors C221, C222, and C223, resistors R200 and R201 respectively; capacitor C221 is electrically connected to capacitors C203, C204, and C205, resistors R206 and R207 respectively; resistors R200, R203, and R206 are connected in series; and resistors R201, R204, and R207 are connected in series.

[0013] Compared with the prior art, the advantages of this utility model are: (1) This utility model improves the power while reducing the heat generation of the device through a unique circuit design, thereby improving the overall performance and reliability of the on-board charger. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the principle of this utility model; Figure 2 This is a circuit diagram of the power input module in this utility model; Figure 3This is a circuit diagram of an inductive energy storage module in this utility model; Figure 4 This is a circuit diagram of a feedback module in this utility model; Figure 5 This is a circuit diagram of the control module in this utility model; Figure 6 This is a circuit diagram of the output capacitor / load module in this utility model. Detailed Implementation

[0015] To more clearly illustrate the embodiments of this utility model, the specific implementation methods of this utility model will be described below with reference to the accompanying drawings. Obviously, the drawings described below are merely some embodiments of this utility model. For those skilled in the art, other drawings and other implementation methods can be obtained based on these drawings without any creative effort.

[0016] Example: like Figure 1 As shown, this utility model provides a vehicle-mounted charger control circuit, including a power input module, an inductive energy storage module, an output capacitor / load module, a feedback acquisition module, and a control module; the power input module, inductive energy storage module, output capacitor / load module, feedback acquisition module, and control module are electrically connected in sequence; the control module is electrically connected to the inductive energy storage module; the inductive energy storage module is controlled by a high-frequency switching transistor.

[0017] Furthermore, such as Figure 2 As shown, the power input module includes a relay board K201; the relay board K201 is externally connected to a 12V DC power supply. Pin 6 on the right side of the relay board K201 is electrically connected to the inductor energy storage module.

[0018] Furthermore, such as Figure 3As shown, the inductor energy storage module includes MOSFET S200, MOSFET S203, IGBT elements S201 and S202, capacitors C207, C208, C212, C213, C256, C257, and inductor L200; the source of MOSFET S200 is electrically connected to one end of inductor L200 and the drain of MOSFET S203; the drain of MOSFET S200 is electrically connected to capacitor C207. 07. The collector of capacitor C208 and IGBT element S201 are electrically connected; the source of MOSFET S203 is electrically connected to capacitors C212 and C213 and the emitter of IGBT element S202 respectively; capacitor C207 is connected in parallel with capacitor C208; capacitor C212 is connected in parallel with capacitor C213; capacitor C207 is electrically connected to capacitors C212 and C213 respectively; the emitter of IGBT element S201 is electrically connected to the collector of IGBT element S202. Figure 3 In this context, J200 represents a PCB jumper wire, which shorts two different signal networks.

[0019] Furthermore, such as Figure 4As shown, the feedback module includes operational amplifier U400A, operational amplifier U400B, resistors R400, R401, R402, R403, R404, R405, R406, R407, R408, R409, R410, R411, R412, R413, capacitors C400, C401, and C402, and capacitors... Capacitors C403, C404, C405, C406, and C407; Schottky diodes D400 and D403; resistors R402, R403, and R404 are connected in series; resistor R404 is electrically connected to the gate of Schottky diode D400, resistor R401, capacitor C401, and the negative input terminal of operational amplifier U400A; resistors R407, R408, and R... 409 are connected in series; resistor R409 is electrically connected to the gate of Schottky diode D403, resistor R410, capacitor C404, and the positive input terminal of operational amplifier U400A; capacitor C408 is electrically connected to resistor R410 and capacitor C404; the output terminal of operational amplifier U400A is electrically connected to resistor R401, resistor R405, and capacitor C401; resistor R406 is electrically connected to resistor R405, capacitor C402, capacitor C403, and resistor R412; resistor R413 is electrically connected to capacitor C405, capacitor C406, and the positive input terminal of operational amplifier U400B; the negative input terminal of operational amplifier U400B is electrically connected to the output terminal of operational amplifier U400B and resistor R411; resistor R411 is electrically connected to capacitor C407; the positive power supply terminal of operational amplifier U400A is electrically connected to resistor R400 and capacitor C400.

[0020] Furthermore, such as Figure 5As shown, the control module includes an isolated gate driver U301, resistors R306, R307, R316, R317, R320, and R321, and capacitors C304, C310, C311, C315, and C317. The isolated gate driver U301 is model SI8233BB-D-IS1. Pin 1 of the isolated gate driver U301 is electrically connected to resistors R316, C311, and R307. Pin 2 of the isolated gate driver U301 is connected to resistors R306, C310, and R317. 7. Electrical Connections: Pin 3 of the isolated gate driver U301 is electrically connected to capacitor C304 and the 5V DC power supply, respectively; Pin 4 of the isolated gate driver U301 is electrically connected to capacitors C310, C311, resistors R306, R307, C315, R321, and C317, respectively; Pin 5 of the isolated gate driver U301 is electrically connected to capacitor C315 and resistor R320, respectively; Pin 6 of the isolated gate driver U301 is electrically connected to resistor R321; Pin 8 of the isolated gate driver U301 is electrically connected to capacitor C317 and the 5V DC power supply, respectively.

[0021] The control module also includes inductor L301, resistors R302, R303, R309, R311, and R313, capacitors C302, C305, C309, and C314, transistors Q301 and Q303, and Zener diode D301. Pin 16 of the isolated gate driver U301 is electrically connected to inductor L301, capacitor C302, resistors R302, R303, and capacitor C305. Pin 15 of the isolated gate driver U301 is electrically connected to resistor R311. Resistor R311 is also electrically connected to transistor Q301. The base of transistor Q301 is electrically connected to the base of transistor Q303; the collector of transistor Q301 is electrically connected to resistor R302; the emitter of transistor Q301 is electrically connected to resistor R309 and the emitter of transistor Q303, respectively; pin 14 of isolated gate driver U301 is electrically connected to the collector of transistor Q303, the anode of Zener diode D301, and capacitor C314, respectively; resistor R303 is electrically connected to the cathode of Zener diode D301, capacitors C314 and C305, resistor R313, and capacitor C309, respectively; resistor R309 is electrically connected to resistor R313 and capacitor C309, respectively.

[0022] The control module also includes inductor L303, resistors R324, R325, R327, R329, R331, capacitors C319, C321, C323, C325, transistors Q305 and Q307, and Zener diode D303. Pin 11 of the isolated gate driver U301 is electrically connected to inductor L303, capacitor C319, resistors R324, R325, and capacitor C321. Pin 10 of the isolated gate driver U301 is electrically connected to resistor R329. Resistor R329 is electrically connected to transistor Q305. The base of transistor Q305 is electrically connected to the base of transistor Q307; the collector of transistor Q305 is electrically connected to resistor R324; the emitter of transistor Q305 is electrically connected to resistor R327 and the emitter of transistor Q307, respectively; pin 9 of isolated gate driver U301 is electrically connected to the collector of transistor Q307, the anode of Zener diode D303, and capacitor C325, respectively; resistor R325 is electrically connected to the cathode of Zener diode D303, capacitor C321, capacitor C325, resistor R331, and capacitor C323, respectively; resistor R327 is electrically connected to resistor R331 and capacitor C323, respectively.

[0023] Furthermore, such as Figure 6 As shown, the output capacitor / load module includes resistors R200, R201, R203, R204, R206, and R207, and capacitors C203, C204, C205, C221, C222, and C223; capacitors C203, C204, and C205 are connected in parallel; capacitors C221, C222, and C223 are connected in parallel; capacitor C204 is electrically connected to capacitors C221, C222, and C223, resistors R200 and R201 respectively; capacitor C221 is electrically connected to capacitors C203, C204, and C205, resistors R206 and R207 respectively; resistors R200, R203, and R206 are connected in series; and resistors R201, R204, and R207 are connected in series.

[0024] The core logic of the energy path in this invention is as follows: 1. AC input (power input module) → inductor energy storage module controlled by high-frequency switching transistor → output capacitor / load module 2. The direction of energy flow is dynamically switched by the state of the switching transistor, with different switching transistors dominating the positive and negative half-cycles respectively.

[0025] Its essence is the boost capability achieved through inductor energy storage and switching control. For example, in an onboard OBC, the typical input voltage is 220V AC, and the output voltage needs to reach 400V DC, with a gain of about 1.82.

[0026] This energy path design is central to achieving efficient power factor correction, and its key lies in the synergistic effect of switch control, inductor energy storage and release, and output capacitor buffering. The totem-pole topology, with its low conduction loss and high power density, improves power efficiency while reducing power loss due to device heat generation. Wide bandgap devices and soft-switching technology further enhance energy efficiency. By optimizing the topology, control strategy, and component selection, a balance between high performance and high reliability is achieved.

[0027] The working principle of this utility model is as follows: The power input module performs EMC processing such as filtering, common-mode rejection, and differential-mode rejection on the mains power before supplying it to the inductor energy storage module. The inductor energy storage module stores part of the mains energy in the inductor and, after rectification by a bridgeless PFC, converts the AC power into DC power to supply the output capacitor / load module. The output capacitor / load module filters and utilizes the DC power. The feedback sampling module samples data such as the DC voltage obtained by the load module and sends this sampled data to the control module. The control module adjusts the control frequency and waveform based on the obtained sampled data, thereby regulating the DC voltage output after PFC rectification, ensuring that the load module always receives a fixed DC voltage value. The bridgeless PFC eliminates the bridge rectifier circuit, directly converting AC to DC. This simplified structure reduces rectification losses, while achieving high-efficiency energy conversion through high-frequency switching of the switching transistors. Many existing bridgeless PFC switching devices use IGBTs or even gallium nitride. Compared to traditional bridge rectifier devices, this invention, at the same power, has lower thermal resistance, higher heat dissipation efficiency, and relatively lower heat generation, resulting in reduced device heat generation and higher energy conversion efficiency.

[0028] The above description is only a detailed explanation of the preferred embodiments and principles of this utility model. For those skilled in the art, there may be changes in the specific implementation methods based on the ideas provided by this utility model, and these changes should also be considered within the protection scope of this utility model.

Claims

1. An on-board charger control circuit, characterized in that, It includes a power input module, an inductor energy storage module, an output capacitor / load module, a feedback acquisition module, and a control module; the power input module, inductor energy storage module, output capacitor / load module, feedback acquisition module, and control module are electrically connected in sequence; the control module is electrically connected to the inductor energy storage module; the inductor energy storage module is controlled by a high-frequency switching transistor.

2. The on-board charger control circuit according to claim 1, characterized in that, The power input module includes a relay board K201; the relay board K201 is externally connected to 12V DC power.

3. The on-board charger control circuit according to claim 1, characterized in that, The inductor energy storage module includes MOSFETs S200 and S203, IGBT elements S201 and S202, capacitors C207, C208, C212, C213, C256, C257, and an inductor L200. The source of MOSFET S200 is electrically connected to one end of inductor L200 and the drain of MOSFET S203, respectively. The drain of MOSFET S200 is connected to capacitor C207. The collector of capacitor C208 and IGBT element S201 are electrically connected; the source of MOSFET S203 is electrically connected to capacitors C212 and C213 and the emitter of IGBT element S202; capacitor C207 is connected in parallel with capacitor C208; capacitors C212 and C213 are connected in parallel; capacitor C207 is electrically connected to capacitors C212 and C213; the emitter of IGBT element S201 is electrically connected to the collector of IGBT element S202.

4. The on-board charger control circuit according to claim 1, characterized in that, The feedback module includes operational amplifier U400A, operational amplifier U400B, resistors R400, R401, R402, R403, R404, R405, R406, R407, R408, R409, R410, R411, R412, R413, and capacitors C400, C401, C402, and C403. 403, capacitors C404, C405, C406, C407, Schottky diodes D400 and D403; resistors R402, R403, and R404 are connected in series; resistor R404 is electrically connected to the gate of Schottky diode D400, resistor R401, capacitor C401, and the negative input terminal of operational amplifier U400A; resistors R407, R408, and R4... 09 are connected in series; resistor R409 is electrically connected to the gate of Schottky diode D403, resistor R410, capacitor C404, and the positive input terminal of operational amplifier U400A; capacitor C408 is electrically connected to resistor R410 and capacitor C404; the output terminal of operational amplifier U400A is electrically connected to resistor R401, resistor R405, and capacitor C401; resistor R406 is electrically connected to resistor R405, capacitor C402, capacitor C403, and resistor R412; resistor R413 is electrically connected to capacitor C405, capacitor C406, and the positive input terminal of operational amplifier U400B; the negative input terminal of operational amplifier U400B is electrically connected to the output terminal of operational amplifier U400B and resistor R411; resistor R411 is electrically connected to capacitor C407; the positive power supply terminal of operational amplifier U400A is electrically connected to resistor R400 and capacitor C400.

5. The on-board charger control circuit according to claim 1, characterized in that, The control module includes an isolated gate driver U301, resistors R306, R307, R316, R317, R320, and R321, and capacitors C304, C310, C311, C315, and C317. The isolated gate driver U301 is model SI8233BB-D-IS1. Pin 1 of the isolated gate driver U301 is electrically connected to resistors R316, C311, and R307. Pin 2 of the isolated gate driver U301 is connected to resistors R306, C310, and R317. Electrical connections: Pin 3 of the isolated gate driver U301 is electrically connected to capacitor C304 and the 5V DC power supply; Pin 4 of the isolated gate driver U301 is electrically connected to capacitors C310, C311, resistors R306, R307, C315, R321, and C317; Pin 5 of the isolated gate driver U301 is electrically connected to capacitor C315 and resistor R320; Pin 6 of the isolated gate driver U301 is electrically connected to resistor R321; Pin 8 of the isolated gate driver U301 is electrically connected to capacitor C317 and the 5V DC power supply.

6. The on-board charger control circuit according to claim 5, characterized in that, The control module also includes an inductor L301, resistors R302, R303, R309, R311, R313, capacitors C302, C305, C309, C314, transistors Q301 and Q303, and a Zener diode D301. Pin 16 of the isolated gate driver U301 is electrically connected to inductor L301, capacitor C302, resistors R302, R303, and capacitor C305. Pin 15 of the isolated gate driver U301 is electrically connected to resistor R311. Resistor R311 is electrically connected to transistor Q301. The base of transistor Q1 is electrically connected to the base of transistor Q303; the collector of transistor Q301 is electrically connected to resistor R302; the emitter of transistor Q301 is electrically connected to resistor R309 and the emitter of transistor Q303, respectively; pin 14 of isolated gate driver U301 is electrically connected to the collector of transistor Q303, the anode of Zener diode D301, and capacitor C314, respectively; resistor R303 is electrically connected to the cathode of Zener diode D301, capacitors C314 and C305, resistor R313, and capacitor C309, respectively; resistor R309 is electrically connected to resistor R313 and capacitor C309, respectively.

7. The on-board charger control circuit according to claim 6, characterized in that, The control module also includes inductor L303, resistors R324, R325, R327, R329, R331, capacitors C319, C321, C323, C325, transistors Q305 and Q307, and Zener diode D303; pin 11 of the isolated gate driver U301 is electrically connected to inductor L303, capacitor C319, resistors R324, R325, and capacitor C321; pin 10 of the isolated gate driver U301 is electrically connected to resistor R329; resistor R329 is electrically connected to transistor Q305... The base of transistor Q5 is electrically connected to the base of transistor Q307; the collector of transistor Q305 is electrically connected to resistor R324; the emitter of transistor Q305 is electrically connected to resistor R327 and the emitter of transistor Q307, respectively; pin 9 of isolated gate driver U301 is electrically connected to the collector of transistor Q307, the anode of Zener diode D303, and capacitor C325, respectively; resistor R325 is electrically connected to the cathode of Zener diode D303, capacitor C321, capacitor C325, resistor R331, and capacitor C323, respectively; resistor R327 is electrically connected to resistor R331 and capacitor C323, respectively.

8. The on-board charger control circuit according to claim 1, characterized in that, The output capacitor / load module includes resistors R200, R201, R203, R204, R206, and R207, and capacitors C203, C204, C205, C221, C222, and C223. Capacitors C203, C204, and C205 are connected in parallel; capacitors C221, C222, and C223 are connected in parallel; capacitor C204 is electrically connected to capacitors C221, C222, and C223, as well as resistors R200 and R201; capacitor C221 is electrically connected to capacitors C203, C204, and C205, as well as resistors R206 and R207; resistors R200, R203, and R206 are connected in series; and resistors R201, R204, and R207 are connected in series.

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