Saturday, June 15, 2024

84 W AC-DC Reference Design For E-bike Battery Charger

This highly versatile solution supports a wide output load range from 6 V to 42 V, making it suitable for various applications. 

Battery chargers for e-bikes play a pivotal role in the ever-expanding world of electric bicycles, reshaping urban transportation. These chargers are the lifeline of e-bikes, ensuring that riders can conveniently recharge their batteries, extending the range and functionality of these eco-friendly two-wheelers. As e-bikes continue to gain popularity as a sustainable and efficient mode of transportation, the importance of reliable and efficient battery chargers becomes increasingly evident. These chargers provide the convenience of recharging at home or on the go and contribute to reducing our carbon footprint by promoting the use of electric vehicles, thereby significantly impacting the environment and urban mobility. 

The REF_ICC80QSG_BPA2_84W by Infineon is an 84 W flyback-based reference design tailor-made for battery chargers for e-bikes.  It is based on the quasi-resonant flyback controller ICC80QSG and the renowned 700 V CoolMOS P7 technology in the small footprint and wave solderable SOT-223 package.  The secondary-side regulation system offers the flexibility of adjustable constant current (CC) output set points ranging from 0.2 A to 2 A, catering to various load requirements. Moreover, it boasts impressive energy efficiency, with a full-power efficiency exceeding 91 percent when operating at 230 VRMS_AC input. Even under heavy load conditions, the four-point average efficiency remains above 91 percent at the 42 V output. 

The design features of this system prioritise both efficiency and electromagnetic interference (EMI) reduction through the implementation of quasi-resonant (QR) valley switching. It offers configurable hysteresis for brown-in and brown-out events to enhance system stability and protection. The system incorporates an adaptive brown-out level mechanism based on monitoring bus voltage ripple, providing better protection for primary components against overheating and saturation by increasing the brown-out level during higher power transfer phases. A comprehensive array of safeguards is in place, including internal overtemperature protection (OTP), output overvoltage protection (OVP), VCC OVP, overcurrent protection (OCP), brown-in and brown-out protection, input OVP, and open-loop protection, ensuring the reliability and durability of the system in various operating conditions.

This product offers a maximum operating frequency of 60 kHz, an adjustable output current range from 0.2 A to 2 A, and a DC output mode. It is designed to work with an AC input voltage ranging from 176 V to 264 V, with a minimum input of 230 V. With a maximum output power of 84 W, it provides secondary side regulation with an adjustable constant current (CC) output set-point, allowing users to customise their power delivery needs. Potential applications for this technology encompass various areas, including battery chargers and light electric vehicles like e-bikes. It ensures high efficiency, with full-power efficiency consistently exceeding 91 per cent when connected to a 230 VRMS AC input, making it an ideal choice for various applications.

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Infineon has thoroughly tested this reference design, which includes a design guide, data sheets, application notes and more. Please visit the company’s website for further information on this reference design. To explore this design in greater detail, click here.

Akanksha Gaur
Akanksha Gaur
Akanksha Sondhi Gaur is a journalist at EFY. She has a German patent and brings a robust blend of 7 years of industrial & academic prowess to the table. Passionate about electronics, she has penned numerous research papers showcasing her expertise and keen insight.


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