Integrated Transformer Module Technology For Higher Drive Time In EVs

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Engineers can now meet the need for smaller, lighter systems by cutting power solution size in half with new easy-to-use, bias-supply module

The rapid rise of the EV market has compelled automotive design engineers to improve efficiency and reliability while also reducing the weight of the heaviest part of the EV: the powertrain. To meet the need for smaller, more reliable systems that extend driving range, engineers are adopting a distributed power architecture in which every isolated gate driver has a dedicated bias supply, thus improving the system reaction to single-point failures. For instance, if one bias supply fails, then the other bias supplies will remain operational along with their paired gate drivers, helping to keep a vehicle safely on the road.

With the UCC14240-Q1, a small and accurate 1.5 W isolated DC-DC bias-supply module, the above requirements can be quickly addressed. The newly launched device’s integrated transformer technology by Texas Instruments (TI) enables designers to cut their power solution size in half for high-voltage applications in electric vehicles (EVs), hybrid EVs, motor-drive systems and grid-tied inverters.

Improved power density and system efficiency

The UCC14240-Q1 enables greater power density and system efficiency, which can allow vehicles to drive farther between charges. The 3.55 mm height and small footprint of the UCC14240-Q1 help reduce the power solution volume by as much as 50%, packing more power in half the size. The height reduction is also beneficial in terms of full flexibility for placing the module on either side of the printed circuit board.

This dual-output power module offers 60% efficiency – twice that of traditional bias supplies – doubling the power density for increased vehicle driving range. By delivering more than 1.5 W at ambient temperatures of 105°C, the UCC14240-Q1 enables engineers to drive isolated gate bipolar transistors (IGBTs), silicon carbide (SiC) and gallium nitride (GaN) switches at high frequencies.

Achieve high CMTI and ultra-low EMI to speed time to market

By leveraging TI’s integrated transformer technology with a 3.5-pF primary-to-secondary capacitance, the UCC14240-Q1 can mitigate EMI caused by high-speed switching and comfortably achieve common-mode transient immunity (CMTI) performance of more than 150 V/ns.

Featuring soft switching, spread-spectrum modulation, shielding and low parasitics, the UCC14240-Q1 enables more easy validation of designs to meet electromagnetic compatibility standards of Comité International Spécial des Perturbations Radioélectriques (CISPR) 25 and CISPR 32, speeding time to market.

Vehicle performance protection

The UCC14240-Q1’s integrated closed-loop control offers ±1.0% accuracy from -40°C to 150°C. The device’s tight tolerance enables the use of smaller power switches while also improving overcurrent protection, fault monitoring, overpower protection and overtemperature protection. The UCC14240-Q1 offers third-party-certified 3-kVrms isolation and delivers good vibration immunity due to its ultra-low weight and 3.55-mm height.

The UCC14240-Q1 is available in pre-production quantities from TI in a 36-pin, 12.8-mm-by-10.3-mm-by-3.55-mm shrink small-outline package. Engineers can evaluate this product with the UCC14240Q1EVM-052 evaluation module.


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