HEV/EV OBC & DC/DC converter

Decrease charging time and design smaller, more efficient and safety-compliant onboard charging systems and DC/DC converters

As electric vehicle (EV) architectures evolve, the onboard charger and DC/DC converter are moving from discrete electronic control unit (ECU) designs toward either mechanically or electrically integrated combo box designs.  These advanced architectures require real-time digital controllers for sophisticated power topologies. Our real-time microcontrollers (MCUs) work with our isolated gate driver, bias supply and sensing technologies to enable fast and efficient EV charging and high-voltage to low-voltage DC/DC conversion.

Why choose TI for your onboard charger and DC/DC converter systems?

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Enable advanced features and architectures

Move to higher power levels by enabling advanced features such as bidirectional power flow and integrated powertrain systems with our broad portfolio of real-time MCUs and analog technology.

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Improve power density while reducing system size

Our power management devices enable switching at higher frequencies, even for the most advanced state-of-the-art topologies, resulting in increased power density.

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Enhance safety and reliability

Efficiently achieve ISO 26262 certification with help from TI Functional Safety-Compliant and TI Functional Safety-Capable devices, available documentation, and advice from our safety experts.

Enabling technologies

Real-time control MCUs

Advances in real-time control have increased processing capabilities and expanded sensing and actuation performance, resulting in higher precision and efficiency to make vehicles more affordable.

Benefits include: 

  • Reduced size and weight: low latency control loops and high resolution PWMs enable higher switching frequencies which reduce the physical size and weight of passives and magnetics.
  • Improved power density and efficiency: unlock the benefits of wide band-gap (WBG) gallium nitride and silicon carbide semiconductors that require 100-kHz to 1-MHz switching frequencies.
  • System integration to reduce cost: cores and peripherals enable advanced power topologies and support the integration of multiple power conversions on a single MCU.
Resource
7.4-kW on-board charger reference design with CCM totem pole PFC and CLLLC DC/DC reference design
This bidirectional OBC reference design consists of an interleaved continuous conduction mode totem-pole bridgeless power-factor correction power stage followed by a CLLLC DC/DC power stage controlled by a real-time control MCU.
White paper
Achieving High Efficiency and Enabling Integration in EV Powertrain Subsystems (Rev. A)
This paper discusses the common control challenges of onboard chargers and high-voltage to low-voltage DC/DC converters, along with the benefits of C2000™ real-time MCUs in these subsystems. 
PDF | HTML
Technical article
How MCUs can unlock the full potential of electrification designs
Read how high-performance real-time MCUs can help reduce the size and weight of the motor to increase driving ranges and help make electric vehicles (EVs) more affordable.
PDF | HTML
Featured products for MCUs
TMS320F280039C-Q1 ACTIVE Automotive C2000™ 32-bit MCU 120-MHz 384-KB flash, FPU, TMU with CLA, CLB, AES and CAN-FD
TMS320F28386D-Q1 ACTIVE Automotive C2000™ 32-bit MCU w/ connectivity manager, 2x C28x+CLA CPU, 1.5MB flash, FPU64, CLB, Eth
AM2634-Q1 ACTIVE Automotive quad-core Arm® Cortex®-R5F MCU up to 400 MHz with real-time control and security

Isolated gate drivers

A gate driver provides galvanic isolation between the input and output and drives the insulated-gate bipolar transistor-, silicon- or silicon carbide-based power factor correction stage.

Benefits include:

  • Improved system-level efficiency: minimized switching and conduction losses that include turnon and turnoff energy.
  • Reduced overall system size and weight: increased switching frequencies enable a significant reduction in overall system magnetics and weight, while a dual-channel driver implementation reduces overall printed circuit board area and bill of materials compared to single-channel options.
  • System reliability: galvanic isolation and high common-mode transient immunity increase system resilience to transients and noise.
Application note
Optimizing On-Board and Wireless Charger Systems Using Logic and Translation (Rev. A)
This application note provides example solutions for common design challenges to achieve efficient power conversion in on-board charger systems that can be resolved using logic and translation.
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White paper
A High-Performance, Integrated Powertrain Solution: The Key to EV Adoption (Rev. A)
This paper examines the benefits of using an integrated powertrain solution to speed adoption of EVs through power electronics, with the focus on implementation of wide band-gap semiconductor switches and isolated gate drivers.
PDF
White paper
Meeting the demand for more efficient and powerful onboard chargers (Rev. A)
This white paper discusses advanced topologies to support high power with improved power density and efficiency.
PDF
Featured products for isolated gate drivers
UCC21530-Q1 ACTIVE Automotive 4-A, 6-A, 5.7-kVRMS, isolated dual-channel gate driver with EN and DT pins for IGBT/SiC
UCC5350-Q1 ACTIVE Automotive, ±5-A single-channel isolated gate driver with miller clamp or split outputs for IGBT/SiC
UCC21222-Q1 ACTIVE Automotive 3.0kVrms, 4A/6A 2-channel isolated gate driver w/ disable, programmable deadtime, 8V UVLO

The right bias power supply solution

Optimize costs while improving power density and efficiency to meet your system requirements. Choose from a portfolio of bias power supplies with integrated field-effect transistors (FETs) and magnetics, integrated FETs and external magnetics, or external FETs and external magnetics.

Benefits include:

  • Improved power density and efficiency in a small footprint, with >150-V/ns common-mode transient immunity and mitigated electromagnetic interference.
  • Streamlined functional safety, with International Organization for Standardization 26262 compliance and system-level diagnostics and protection.
  • Protected power modules, with high load regulation accuracy and thermal performance.
White paper
Power Through the Isolation Barrier: The Landscape of Isolated DC/DC Bias Power (Rev. A)
This paper examines various isolated DC/DC bias power supplies to move signals and power across the isolation barrier.
PDF
Application note
UCC14240-Q1 Simplifies HEV, EV, Bias Supply Design for Isolated Gate Drivers
This application report introduces the benefits of using UCC14240-Q1 for isolated gate driver bias applications. The focus of this document is automotive applications and ease of use of fully integrated bias supply solution.
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White paper
Addressing High-Volt Design Challenges w/ Reliable and Affordable Isolation Tech (Rev. C)
This document provides an overview of galvanic isolation, explains common isolation methods for high-voltage systems and shows how our isolation integrated circuits can help designers meet isolation needs reliably.
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Featured products for bias power supply
SN6501-Q1 ACTIVE Automotive low-noise, 350-mA, 410-kHz transformer driver for isolated power supplies
UCC25800-Q1 ACTIVE Ultra-low EMI transformer driver for isolated bias supplies
LM25118-Q1 ACTIVE 3-42-V wide VIN, current mode non-synchronous buck-boost controller, AEC-Q100 qualified

Voltage and current sensing

Achieve accurate, low-latency current and voltage measurements with high common-mode transient immunity and working voltages, thereby improving the system efficiency, reliability and performance of onboard charging systems.

Benefits include:

  • Capacitive isolation, which enhances safety and lowers system costs.
  • High bandwidth for faster control and reaction times, enabling higher system reliability and better performance.
  • Easier design complexity, which eliminates the need for external protection.
Analog Design Journal
Design considerations for isolated current sensing (Rev. A)
This article covers design considerations while selecting an isolated amplifier, such as isolation specifications, how to power the high side, and selection of the input voltage range.
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Application brief
Accuracy Comparison of Isolated Shunt and Closed-Loop Current Sensing
This document compares isolated shunt- and magnetic-based sensing to accomplish isolated current sensing for applications such as onboard chargers, DC charging (pile) stations, power conversion systems and motor drives.
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Featured products for sensing
AMC3302-Q1 ACTIVE Automotive, ±50-mV input, precision current sensing reinforced isolated amplifier with int. DC/DC
TMCS1100-Q1 ACTIVE AEC-Q100, ±600-V, precision, isolated current sensor with external reference
INA225-Q1 ACTIVE AEC-Q100, 36V, bi-directional current sense amplifier w/ four pin-selectable gain settings

Design efficiency

A compact and efficient design of the electromagnetic interference (EMI) input filter is critical to achieving the full benefits of electrification.  Active EMI filter ICs reduce magnetic component and overall filter size relative to a passive-only design.

Benefits include:

  • Easier system integration: due to a more compact size and smaller packaging.
  • Reduced component power losses: enables better thermal management, higher efficiency, longer component lifetime and increased system-level reliability.
  • Lower component weight: provides better mechanical robustness and improved performance.
  • Improved high-frequency: the smaller-sized chokes have lower parasitic interwinding capacitance, which improves filter attenuation at the high frequencies.
White paper
How Active EMI Power-Supply Filter ICs Mitigate Common-Mode Emissions
This technical white paper discusses measured results from a 3.3-kW power factor correction (PFC) AC/DC regulator to illustrate the benefits of EMI mitigation and board space savings.
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Technical article
How a standalone active EMI filter IC shrinks common-mode filter size
This article discusses how space-constrained applications can use active power-supply filter integrated circuits to reduce the size of magnetic components and the overall filter.
Video
Single- and three-phase active EMI filter ICs mitigate common-mode EMI, save space and reduce cost
Learn how our portfolio of stand-alone AEF products for CM noise cancellation effectively reduces size, weight and cost in single-phase and three-phase systems compared to a traditional passive filter design.
Featured products for active EMI filters
TPSF12C1-Q1 ACTIVE Automotive common-mode active EMI filter (AEF) for single-phase systems
TPSF12C3-Q1 ACTIVE Automotive common-mode active EMI filter (AEF) for three-phase systems

Reference designs related to HEV/EV OBC & DC/DC converter

Use our reference design selection tool to find designs that best match your application and parameters.

Featured products

C2000 real-time microcontrollers TMS320F280037C-Q1 ACTIVE Automotive C2000™ 32-bit MCU 120-MHz 256-KB flash, FPU, TMU with CLA, CLB, AES and CAN-FD
Isolated gate drivers UCC21530-Q1 ACTIVE Automotive 4-A, 6-A, 5.7-kVRMS, isolated dual-channel gate driver with EN and DT pins for IGBT/SiC
NEW Hall-effect current sensors TMCS1123 ACTIVE ±1300V reinforced isolation, 80Arms 250kHz Hall-effect current sensor with AFR, reference and ALERT
Isolated amplifiers AMC1311-Q1 ACTIVE Automotive, 2-V input, precision voltage sensing reinforced isolated amplifier
Isolated power modules (integrated transformer) UCC14240-Q1 ACTIVE Automotive, 2.0-W, 24-Vin, 25-Vout high-density > 3-kVRMS isolated DC/DC module
Power-supply filter ICs TPSF12C3-Q1 ACTIVE Automotive common-mode active EMI filter (AEF) for three-phase systems
28 APR 2021 | COMPANY BLOG
Integrating powertrain systems into a compact mechanical enclosure can lead to more affordable, more efficient electric vehicles (EVs)
Read more

Technical resources

White paper
White paper
Meeting the demand for more efficient and powerful onboard chargers (Rev. A)
This white paper discusses advanced topologies to support high power with improved power density and efficiency. 
document-pdfAcrobat PDF
White paper
White paper
Achieving High Efficiency and Enabling Integration in EV Powertrain Subsystems (Rev. A)
This document discusses the common control challenges of on-board chargers and high- to low-voltage  DC/DC converters, and the benefits of  C2000™ real-time microcontrollers in these subsystems. 
document-pdfAcrobat PDF
White paper
White paper
Taking charge of electric vehicles – both in the vehicle and on the grid (Rev. A)
This document discusses on-board chargers, how they work and how charging stations interact with on-board charger and EV BMS, along with various power-architecture implementations.
document-pdfAcrobat PDF