Charging System Analysis and Solutions by wuxiangyu

VIEWS: 114 PAGES: 38

									 High voltage charger solution
                            Li, Wang: wang-li@ti.com
                 MGambrill, Michael: mgambrill@ti.com
                       Liang, Roger: r-liang@ti.com




2010 Dallas BMS Deep Dive           TI Information – Selective Disclosure
Abstract

       •     A typical bq24610 Application
       •     A high voltage charger block diagram
       •     Test results
       •     More higher input voltage solution
       •     SMBus high voltage charger solution




2010 Dallas BMS Deep Dive   TI Information – Selective Disclosure
     A typical bq24610 Application




2010 Dallas BMS Deep Dive   TI Information – Selective Disclosure   3
A Typical standalone charger application circuit
                          Q1       Q2      RAC: 10m                                                                 SYSTEM LOAD
              R16                                                                                                              C3
Adapter       2Ω
                                                                                                         C2
                                                                                                       10µF                    10µF
                                              C11                                       10
               C1
                                             0.1µF ACN        VCC
               2.2µF                               ACP bq24610                           C7
                                                                                         0.1uF
                                                                                                                       Power
                                                   ACDRV
                                                   VREF
                                                                                                                       Source
                                                          BATDRV                                                      Q3
    R9       R3        R5         R7      C12
                                          1µF      CE
                                                                                     C5:1µF                            Selector
    9.31kΩ   100kΩ     100kΩ      100kΩ                     REGN
                                                   ISET1
                                                    ISET2             BTST                             C4
Pack                                                                                        Q4         10uF
                                                    ACSET
Thermistor                                                           HIDRV                                      RSR
                                                    TS                                             L: 6.8µH    10m    Battery Pack
    R10      R4        R6        R8                 TTC
                                           C17                            PH
    430kΩ    95.3kΩ    22.1kΩ    57.6kΩ    0.22µF                                                 Q5                      C8
                                                                    LODRV                                       C7        10µF
                                Adapter                               GND                                     10µF
                       R11:10kΩ                     STAT1                                                                             C9
                                                                                                                       R1
                                                                        SRP                                                           100pF
                                                                                    C10                                953kΩ
                        R12:10kΩ                    STAT2
                                                                        SRN         0.1µF                                         R2
                        R13:10kΩ                    PG                                                                            105kΩ
                                                                        VFB

bq24610: 600kHz, Li-Ion
4x4mm QFN-24                              Typical 1-6 Li-Ion Cells, VIN max: 28V

     2010 Dallas BMS Deep Dive                            TI Information – Selective Disclosure
Optional section divider or presentation
      slide
title High voltage charger block diagram




 2010 Dallas BMS Deep Dive   TI Information – Selective Disclosure   5
8-cell Li-ion battery charger

•Basic requirements:
 Output: if 4.2V/cell battery, the output
voltage setting needs 4.2Vx8=33.6V.

Input: Vin > 33.6V+few volt hysteresis

A typical bq24610/30 application circuit can
not accept the input voltage higher than 32V
(Input OVP setting).



2010 Dallas BMS Deep Dive   TI Information – Selective Disclosure
Modified Charger Block Diagram
                            The charger circuit have to do several modifications.
                                    The block diagram of HPA603 EVM:


                                      8~14V Vcc
  DC Input                Vcc Bias
                           Supply
  35~57V                  TPS54060
                                            ACN       VCC                                                         Pre-charge
                                            ACP                                                                Deeply discharged
                                                    BATDRV                                                          Battery
                                            ACDRV
                                 CE                                     BTST
                                            CE
                                                                       setting

                                                     REGN
                                            VREF
                                                                                  Vcc
                                                      BTST                                  Q1
                                            ISET1
                                                     HIDRV
            Pack                            ISET2                         Half Bridge                     L                          Battery Pack
                                                                                                                  Rsns
       Thermistor                                                            Gate
                                            ACSET      PH                   Drive
                                            TS                            UCC27201
                                                                                                     Q2
                                                    LODRV
                                            TTC                                                                 Current          C
                                                                                                                 Sense
                                                                                                                INA169

                    Vcc                               GND                Buffer
                                            STAT1                        LM358
                                                                                                                          VREF

                                            STAT2
                                                                                                          Rs           2~3V
                                                      SRP
                                            PG                                                                        Clamp
                                                      SRN

                                            bq24610/30
                                                    VFB




    2010 Dallas BMS Deep Dive                                TI Information – Selective Disclosure
VCC bias supply solution
         Function block: Vcc Bias supply
           It powers the charger IC-bq24610/30, external half
           bridge gate driver, current sense circuit and OMAMP
           buffer. And it is also used for charging up a deeply
           discharged battery. A switching Vcc bias power
           supply needs:
             • Operating from the maximum input voltage
             • An 8-14 V output voltage: It is set by the external
                half bridge gate driver requirement
             • At least 200mA: It is derived from the sum of the
                charging current for deeply discharged battery
                and the whole board current consumption.

         For 60V input, the TPS54060 is selected to meet these
           three requirements.



   2010 Dallas BMS Deep Dive     TI Information – Selective Disclosure
Modified Charger Block Diagram
                                     Half bridge gate drive solution

                                      8~14V Vcc
  DC Input                Vcc Bias
                           Supply
  35~57V                  TPS54060
                                            ACN       VCC                                                         Pre-charge
                                            ACP                                                                Deeply discharged
                                                    BATDRV                                                          Battery
                                            ACDRV
                                 CE                                     BTST
                                            CE
                                                                       setting
                                                     REGN
                                            VREF
                                                                                  Vcc
                                                      BTST                                  Q1
                                            ISET1
                                                     HIDRV
            Pack                            ISET2                         Half Bridge                     L                          Battery Pack
                                                                                                                  Rsns
       Thermistor                                                            Gate
                                            ACSET      PH                   Drive
                                            TS                            UCC27201
                                                                                                     Q2
                                                    LODRV
                                            TTC                                                                 Current          C
                                                                                                                 Sense
                                                                                                                INA169

                    Vcc                               GND                Buffer
                                            STAT1                        LM358
                                                                                                                          VREF

                                            STAT2
                                                                                                          Rs           2~3V
                                                      SRP
                                            PG                                                                        Clamp
                                                      SRN

                                            bq24610/30
                                                    VFB




    2010 Dallas BMS Deep Dive                                TI Information – Selective Disclosure
Half bridge gate drive solution
   Function block: Half Bridge Gate Drive
   It receives the charger IC HIDRV and LODRV signal and drive the buck FET
   Q5 and Q6. The half bridge gate drive needs:
        • 20% input voltage margin
        • Have two Complementary inputs to match HIDRV and LODRV output
        of bq24610.
        • Input logic high threshold need lower than 3V match the voltage level
        of bq24610/30’s HIDRV and LODRV output.
        • Reserve several resistors, caps and diode to adjust turn-on&off
        speed and dead time
   For 60V input, the UCC27201 is selected to meet these three requirements.


                      bq24610       R13                         Vcc                 Cin
                                     D3
                           HIDRV                      HI VDD HB               R25
                                                  C21 UCC HO
                                                                                    Q1
                                                       UCC
                               PH                      27201 HS
                                                       27201
                                                  C22 LI                            Q2
                                                         VSS LO
                          LODRV                                               R26
                                     R14
                                      D4
                           PGND



   2010 Dallas BMS Deep Dive          TI Information – Selective Disclosure
Modified Charger Block Diagram

Current sense solution
                                      8~14V Vcc
  DC Input                Vcc Bias
                           Supply
  35~57V                  TPS54060
                                            ACN       VCC                                                         Pre-charge
                                            ACP                                                                Deeply discharged
                                                    BATDRV                                                          Battery
                                            ACDRV
                                 CE                                     BTST
                                            CE
                                                                       setting
                                                     REGN
                                            VREF
                                                                                  Vcc
                                                      BTST                                  Q1
                                            ISET1
                                                     HIDRV
            Pack                            ISET2                         Half Bridge                     L                          Battery Pack
                                                                                                                  Rsns
       Thermistor                                                            Gate
                                            ACSET      PH                   Drive
                                            TS                            UCC27201
                                                                                                     Q2
                                                    LODRV
                                            TTC                                                                 Current          C
                                                                                                                 Sense
                                                                                                                INA169

                    Vcc                               GND                Buffer
                                            STAT1                        LM358
                                                                                                                          VREF

                                            STAT2
                                                                                                          Rs           2~3V
                                                      SRP
                                            PG                                                                        Clamp
                                                      SRN

                                            bq24610/30
                                                    VFB




    2010 Dallas BMS Deep Dive                                TI Information – Selective Disclosure
Current sense solution

        Function block: Current sense
          It is a high voltage bus current sensor or a current
          mirror circuit. It needs
        • Set 1:1 ratio between Rsns Voltage and Rs voltage.

        For battery voltage is upto 60V, the INA169 is selected
          to meet that requirement.
                                          Rsns



                    Current sense
                                            1k




                               Rs              1k
                               (R6)




   2010 Dallas BMS Deep Dive          TI Information – Selective Disclosure
Modified Charger Block Diagram

buffer solution
                                      8~14V Vcc
  DC Input                Vcc Bias
                           Supply
  35~57V                  TPS54060
                                            ACN       VCC                                                         Pre-charge
                                            ACP                                                                Deeply discharged
                                                    BATDRV                                                          Battery
                                            ACDRV
                                 CE                                     BTST
                                            CE
                                                                       setting
                                                     REGN
                                            VREF
                                                                                  Vcc
                                                      BTST                                  Q1
                                            ISET1
                                                     HIDRV
            Pack                            ISET2                         Half Bridge                     L                          Battery Pack
                                                                                                                  Rsns
       Thermistor                                                            Gate
                                            ACSET      PH                   Drive
                                            TS                            UCC27201
                                                                                                     Q2
                                                    LODRV
                                            TTC                                                                 Current          C
                                                                                                                 Sense
                                                                                                                INA169

                    Vcc                               GND                Buffer
                                            STAT1                        LM358
                                                                                                                          VREF

                                            STAT2
                                                                                                          Rs           2~3V
                                                      SRP
                                            PG                                                                        Clamp
                                                      SRN

                                            bq24610/30
                                                    VFB




    2010 Dallas BMS Deep Dive                                TI Information – Selective Disclosure
Current sense buffer solution
         Function block: Buffer
         The SRP/SRN pin of charge IC has few milliampere
           sink current. The current sense output may not
           have enough current capability. The buffer circuit
           needs:
         • Keep the output voltage on SRP/SRN pin is same
           as Rs voltage
         • Provides enough current (8mA) to drive SRP/SRN
           pin.

         The LM358 is selected to meet these two requirements.
                                                                      L          Rsns
                       U1             Buffer
                       bq24610       U5:LM358
                                                                       Rs      Current
                               SRP
                                                                      (R6)
                                                                                sense
                                      R3
                               SRN




   2010 Dallas BMS Deep Dive           TI Information – Selective Disclosure
Modified Charger Block Diagram

2~3V clamp circuit solution
                                      8~14V Vcc
  DC Input                Vcc Bias
                           Supply
  35~57V                  TPS54060
                                            ACN       VCC                                                         Pre-charge
                                            ACP                                                                Deeply discharged
                                                    BATDRV                                                          Battery
                                            ACDRV
                                 CE                                     BTST
                                            CE
                                                                       setting
                                                     REGN
                                            VREF
                                                                                  Vcc
                                                      BTST                                  Q1
                                            ISET1
                                                     HIDRV
            Pack                            ISET2                         Half Bridge                     L                          Battery Pack
                                                                                                                  Rsns
       Thermistor                                                            Gate
                                            ACSET      PH                   Drive
                                            TS                            UCC27201
                                                                                                     Q2
                                                    LODRV
                                            TTC                                                                 Current          C
                                                                                                                 Sense
                                                                                                                INA169

                    Vcc                               GND                Buffer
                                            STAT1                        LM358
                                                                                                                          VREF

                                            STAT2
                                                                                                          Rs           2~3V
                                                      SRP
                                            PG                                                                        Clamp
                                                      SRN

                                            bq24610/30
                                                    VFB




    2010 Dallas BMS Deep Dive                                TI Information – Selective Disclosure
2~3V clamp circuit solution
          Function block: 2~3v Clamp circuit
          If the SRP/SRN pin voltage is lower than 2V, the IC
              runs at a short protection mode. The low side
              MOSFET is held off at that mode. The clamp circuit
              needs:
          • Voltage is between 2~3V.
          • Can absorb the Rs current
          • Can support SRN pin sink current (8mA)

          A simple 2~3V clamp circuit can be created from the
            bq24610’s 3.3V VREF.      L   Rsns



                                           Rs               Current
                           bq24610        (R6)              sense
                                SRN
                                                                      VREF
                                          R27           C30
                                VREF




   2010 Dallas BMS Deep Dive           TI Information – Selective Disclosure
Modified Charger Block Diagram

BTST setting
                                      8~14V Vcc
  DC Input                Vcc Bias
                           Supply
  35~57V                  TPS54060
                                            ACN       VCC                                                         Pre-charge
                                            ACP                                                                Deeply discharged
                                                    BATDRV                                                          Battery
                                            ACDRV
                                 CE                                     BTST
                                            CE
                                                                       setting
                                                     REGN
                                            VREF
                                                                                  Vcc
                                                      BTST                                  Q1
                                            ISET1
                                                     HIDRV
            Pack                            ISET2                         Half Bridge                     L                          Battery Pack
                                                                                                                  Rsns
       Thermistor                                                            Gate
                                            ACSET      PH                   Drive
                                            TS                            UCC27201
                                                                                                     Q2
                                                    LODRV
                                            TTC                                                                 Current          C
                                                                                                                 Sense
                                                                                                                INA169

                    Vcc                               GND                Buffer
                                            STAT1                        LM358
                                                                                                                          VREF

                                            STAT2
                                                                                                          Rs           2~3V
                                                      SRP
                                            PG                                                                        Clamp
                                                      SRN

                                            bq24610/30
                                                    VFB




    2010 Dallas BMS Deep Dive                                TI Information – Selective Disclosure
BTST setting

     Function block: BTST setting
     To isolate PH, HIDRV and BTST pin. The PH pin is connected
        to ground. BTST voltage needs:
     • Higher than 3V to keep correct gate logic.
     • Lower than 4V to keep LODRV send refresh pulse every
        switching cycle. External half bridge gate will use that
        LODRV refresh pulse to charge its bootstrap cap.


A simply resistor divider from 6V REGN can set the BTST voltage easily.

                                bq24610
                                                  R22
                                    REGN

                                    BTST
                                                 R21             C16




    2010 Dallas BMS Deep Dive              TI Information – Selective Disclosure
Modified Charger Block Diagram

BTST setting
                                      8~14V Vcc
  DC Input                Vcc Bias
                           Supply
  35~57V                  TPS54060
                                            ACN       VCC                                                         Pre-charge
                                            ACP                                                                Deeply discharged
                                                    BATDRV                                                          Battery
                                            ACDRV
                                 CE                                     BTST
                                            CE
                                                                       setting
                                                     REGN
                                            VREF
                                                                                  Vcc
                                                      BTST                                  Q1
                                            ISET1
                                                     HIDRV
            Pack                            ISET2                         Half Bridge                     L                          Battery Pack
                                                                                                                  Rsns
       Thermistor                                                            Gate
                                            ACSET      PH                   Drive
                                            TS                            UCC27201
                                                                                                     Q2
                                                    LODRV
                                            TTC                                                                 Current          C
                                                                                                                 Sense
                                                                                                                INA169

                    Vcc                               GND                Buffer
                                            STAT1                        LM358
                                                                                                                          VREF

                                            STAT2
                                                                                                          Rs           2~3V
                                                      SRP
                                            PG                                                                        Clamp
                                                      SRN

                                            bq24610/30
                                                    VFB




    2010 Dallas BMS Deep Dive                                TI Information – Selective Disclosure
Pre-condition deeply discharge battery solution
  Function block: Pre-condition deeply discharge battery
     When battery voltage is deeply discharged lower than 3V, the current sense circuit
     can not work properly. The pre-condition circuit needs:
  • The pre-condition current can bring a deeply discharged battery
    voltage higher than 3V.
  • The pre-condition current is lower than bias supply output
    capability.
  A simply resistor (R46 and R47) and diode (D8) pre-charge path can pre-charge the
     battery voltage up to the 3V that is a minimum operating voltage range of the
     current sense circuit. A comparator compares the battery voltage with 3.3Vref. If
     the battery voltage is higher than 3.3V, the CE is pulled to high and charger is
     enabled.

                  TPS54060      R46

                  VCC bias                                    D8               BAT

                  supply
                                R47                                  R10
                                              VREF
                                                                               D7
                                              R31

                                      CE       LM2903
                                                                    VREF

   2010 Dallas BMS Deep Dive           TI Information – Selective Disclosure
The calculation tool of L, C value and other
parameters

        The calculation tool of L, C value and other
        parameters can be found in
        http://www.ti.com/litv/zip/sluc175c

                    Battery charge voltage setting
          Battery pre-charge/termination current setting
                   Battery fast-charge current setting

                          Iripple_Lout_Vripple
                 LC output filter resonant frequency
                               Fast charge timer

                           TS resistor network


   2010 Dallas BMS Deep Dive           TI Information – Selective Disclosure
EVM and Application note information




         The high voltage charge EVM (HPA603) and
         user’s guide (SLUU447) are available.



         Application notes (SLUA580) is released: A
         practical high voltage charger solution with
         existing bq24610 charger IC.




   2010 Dallas BMS Deep Dive   TI Information – Selective Disclosure
     Test Results on HPA603 EVM




2010 Dallas BMS Deep Dive   TI Information – Selective Disclosure   23
           Test result on HPA603 EVM
• 1 ISET1 control IBAT
    – 1.1 ISET1 vs IBAT waveform
    – 1.2 ISET1 transient
    – 1.3 ISET1 accuracy

• 2 Switching waveforms
• 3 Charger start-up or shut-down with CE control
• 4 Battery insertion and removal
• 5 soft start
• 6 efficiency




2010 Dallas BMS Deep Dive          TI Information – Selective Disclosure
Modified Charger Block Diagram
                            The charger circuit have to do several modifications.
                                    The block diagram of HPA603 EVM:


                                      8~14V Vcc
  DC Input                Vcc Bias
                           Supply
  35~57V                  TPS54060
                                            ACN       VCC                                                         Pre-charge
                                            ACP                                                                Deeply discharged
                                                    BATDRV                                                          Battery
                                            ACDRV
                                 CE                                     BTST
                                            CE
                                                                       setting

                                                     REGN
                                            VREF
                                                                                  Vcc
                                                      BTST                                  Q1
                                            ISET1
                                                     HIDRV
            Pack                            ISET2                         Half Bridge                     L                          Battery Pack
                                                                                                                  Rsns
       Thermistor                                                            Gate
                                            ACSET      PH                   Drive
                                            TS                            UCC27201
                                                                                                     Q2
                                                    LODRV
                                            TTC                                                                 Current          C
                                                                                                                 Sense
                                                                                                                INA169

                    Vcc                               GND                Buffer
                                            STAT1                        LM358
                                                                                                                          VREF

                                            STAT2
                                                                                                          Rs           2~3V
                                                      SRP
                                            PG                                                                        Clamp
                                                      SRN

                                            bq24610/30
                                                    VFB




    2010 Dallas BMS Deep Dive                                TI Information – Selective Disclosure
        1.1 ISET1 vs IBAT waveform




                                                                      IBAT
                                                                      ISET1




 • IBAT are proportional to ISET1. The ratio follows the
   datasheet equation.

2010 Dallas BMS Deep Dive     TI Information – Selective Disclosure
  1.2 ISET1 transient 2

• ISET1 from 1V to 2V (CCM)




                              IBAT


                              ISET1




 2010 Dallas BMS Deep Dive     TI Information – Selective Disclosure
1.3 ISET1 accuracy
                                              ISET1 vs Vsns


                               16

                               14

                               12
              Vsns error (%)




                               10

                               8

                               6                                            Series1


                               4

                               2

                               0
                                    0   0.5     1                1.5                  2   2.5
                                                    ISET1 (V)




2010 Dallas BMS Deep Dive                     TI Information – Selective Disclosure
   2 Switching waveforms



                               High side gate


                               High side gate
Switching node

Inductor current




   2010 Dallas BMS Deep Dive    TI Information – Selective Disclosure
3. Charger start-up or shut-down with CE control




       VBAT

       CE

                      Switching node

                Inductor current




    2010 Dallas BMS Deep Dive          TI Information – Selective Disclosure
4 Battery removal and insertion


                 VBAT

                  VIN
                            Switching node




                            Inductor current




                             Ch1 (yellow): Vin
                             Ch2 (blue): Vbat
                             Ch3 (pink): PH
                             4 (green): IL


2010 Dallas BMS Deep Dive       TI Information – Selective Disclosure
5 soft start


                     VBAT

                     VIN

                    Switching node



                    Inductor current




  Ch1 (yellow): Vin; Ch2 (blue): Vbat; Ch3 (pink): PH; ch4 (green): IL




2010 Dallas BMS Deep Dive          TI Information – Selective Disclosure
6 efficiency

                                        Efficiency and power dissipation

                       100.0%                                                                    8

                       90.0%
                                                                                                 7
                       80.0%
                                                                                                 6




                                                                                                     Power dissipation (W)
                       70.0%
                                                                                                 5
                       60.0%
          Efficiency




                       50.0%                                                                     4

                       40.0%
                                                                                                 3
                       30.0%                                     48Vin; 30Vbat
                                                                 power dissipation               2
                       20.0%
                                                                                                 1
                       10.0%

                        0.0%                                                                     0
                                0   1       2            3                4              5   6

                                                 Charging current (A)




  2010 Dallas BMS Deep Dive                      TI Information – Selective Disclosure
More Higher input voltage charger:
100Vin_max and 16-cell




2010 Dallas BMS Deep Dive   TI Information – Selective Disclosure   34
Higher input range solution
If need a even high voltage, for example: 16 cell battery charger with 80V input.
Please update those components and circuits:
                                       Output                                      Input
  Changer requirement

  bq24610EVM                           8-cell Li-ion battery                       Maximum 60V input
  (HPA603EVM)                          8x4.2=33.6V

  80Vin/16cell                         16-cell Li-ion battery                      Maximum 100V input
  Li-ion battery Charger               16x4.2=67.2V




                           VCC bias supply      Current sense            R23                L1 value    Power
  Change list:                                  circuit                  (Vbat              (Keep ΔI    FET
                                                                         setting)           constant)
  bq24610EVM               TPS54060             INA169                   R23:               22uH        80V FET
  (HPA603EVM)                                                            464k                           Si7852
  80Vin/16cell             Any 100V input;      Current mirror:          R23:               47uH        100V FET
  Li-ion battery Charger   10Vout@150mA bias    ZDS1009                  953k                           SiR846
                           supply




  2010 Dallas BMS Deep Dive                         TI Information – Selective Disclosure
   SMBus High voltage charger solution




2010 Dallas BMS Deep Dive   TI Information – Selective Disclosure   36
SMBus High Voltage Charger Solution

                                    8~14V Vcc
 DC Input               Vcc Bias
                         Supply
                        TPS54060
                                          CSSN        DCIN                                                        Pre-charge
                                          CSSP                                                                 Deeply discharged
                                                                                                                    Battery
                                          ACIN
                                          VDDSMB                      BTST
                                                                     setting
                                         VREF
                                         CE          PVCC

                                         ACOK        BOOT
    SMBUS                                                                       Vcc
                                                                                           Q4
                                          SCL
                                          SDA       UGATE
                                                                         Half Bridge                      L                          Battery Pack
                                                                                                                  Rsns
                                          VICM      PHASE                   Gate
                                                                           Drive
                                                                         UCC27201
                                                                                                     Q5
                                                     LGATE                                                      Current          C
                                          ICOUT
                                          ICREF                                                                  Sense
                                                                                                                INA169
                      R9 7.5k                         GND              Buffer
                                         EAO                           LM358
             C21                   C23                                                                                    VREF

             2000p                 51p    EAI        CSOP                                                 Rs           2~3V
            R10 20k                                  CSON
                                                                                                                      Clamp

                                         FBO
  C22                                                 VFB
              R11                          bq24747
  130p
              200k                                 1MΩ




     2010 Dallas BMS Deep Dive                               TI Information – Selective Disclosure
•Thank you


•Questions

2010 Dallas BMS Deep Dive   TI Information – Selective Disclosure

								
To top