Friday, March 1, 2024

High-Power-Density Battery Charger For eBikes Reference Design

By Nidhi Agarwal

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The design integrates three PowiGaN-based ICs for a 180W battery charger, suitable for power tools and eBikes, focusing on efficiency and power density, with safety and performance features.

e-bike charger

High-power-density battery chargers are becoming increasingly vital in the realm of electronic mobility and professional tooling, particularly for power tools and eBikes. These advanced chargers offer a host of benefits that greatly enhance the user experience and operational efficiency. Characterized by their ability to charge batteries quickly, they ensure minimal downtime and maximize productivity, especially crucial for professionals dependent on power tools for their work. Furthermore, their efficiency and compact design make them environmentally friendly and convenient to use, while also extending the overall life of the batteries they charge. This technology represents a significant leap forward in how we power and maintain devices critical to both transportation and various professional fields.

The DER-930 – 180 W High-Power-Density Battery Charger for Power Tools and eBikes reference design from Power Integrations uses three PowiGaN-based ICs InnoSwitch4-CZ active clamp flyback switcher IC (INN4177C-H189), ClampZero active clamp IC (CPZ1076M) and HiperPFS-5 Power Factor Correction IC (PFS5177F). This design demonstrates the remarkable potential for high power density and efficiency achievable through the advanced integration of the InnoSwitch4-CZ active clamp flyback controller, which delivers exceptional performance. 

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The input fuse plays a crucial role in the circuit by isolating it and providing protection against component failure. Additionally, the metal oxide varistor RV1 is instrumental in safeguarding the system during line surge events by clamping the input voltage seen by the power supply effectively. In this context, the HiperPFS-5 family emerges as a noteworthy innovation, featuring a quasi-resonant DCM PFC controller integrated with a 750 V PowiGaN. This integration includes X-capacitor discharge capabilities and a high-voltage self-start-up mechanism, all encompassed within a compact, low-profile power package. A key advantage of the HiperPFS-5 devices is their elimination of the need for external current sense resistors, thus reducing associated power loss. Furthermore, these devices employ an advanced control technique that dynamically adjusts the switching frequency based on variations in output load, input line voltage, and the input line cycle, enhancing overall efficiency and performance.

This device boasts a versatile input range of 90 VAC to 265 VAC and delivers an output of 20 V at 9 A. It is highly efficient, achieving 95% full-load efficiency at 230 VAC. When operating under no-load conditions, it consumes just 100 mW at 230 VAC. The device operates using quasi-resonant DCM control, ensuring optimized performance. Additionally, it complies with the CISPR22 / EN55022 Class B standards for conducted electromagnetic interference (EMI), highlighting its reliability and safety in various environments.

Power Integrations has tested this reference design. It comes with a Bill of Material (BOM), schematics, printed circuit board (PCB) layout, etc. You can find additional data about the reference design on the company’s website. To read more about this reference design, click here.

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