原标题：TI UCC25600 400W高效电池充电器电源设计方案

　　TI公司的ucc25600是高性能谐振模式控制器,开关频率40kHz到350kHz,提供完整的系统保护功能包括过流,UVLO,偏压电源OVP和超温保护,工作温度-40度C到125度C,主要用在AC/DC电源,电动自行车,LED照明,通信DC/DC模块,HDTV,低端洗衣机,有线调制解调器终端系统和太阳能系统.本文介绍了UCC25600主要特性和框图,300W LLC谐振半桥转换器应用电路以及400W高效电池充电器电源TIDA-00355主要特性和指标,框图,电路图,材料清单和PCB元件布局图和设计图.

　　The UCC25600 high performance, resonant mode controller is designed for dc-to-dc applications using resonant topologies, especially the LLC half-bridge resonant converter. This highly integrated controller implements frequency modulation control and complete system functions in only an 8-pin package. Switching to the UCC25600 will greatly simplify the system design and layout, and improve time to market, all at a price point lower than competitive 16-pin device offerings.

　　The internal oscillator supports the switching frequencies from 40 kHz to 350 kHz. This high-accuracy oscillator realizes the minimum switching frequency limiting with 4% tolerance, allowing the designer to avoid over-design of the power stage and, thus, further reducing overall system cost. The programmable dead time enables zero-voltage switching with minimum magnetizing current. This maximizes system efficiency across a variety of applications. The programmable soft-start timer maximizes design flexibility demanded by the varied requirements of end equipment using a half-bridge topology. By incorporating a 0.4-A source and 0.8-A sink driving capability, a low cost, reliable gate driver transformer is a real option.

　　The UCC25600 delivers complete system protection functions including overcurrent, UVLO, bias supply OVP, and overtemperature protection.

　　UCC25600主要特性:

　　Variable Switching Frequency Control

　　Programmable Minimum Switching Frequency With 4% Accuracy (3% Accuracy at Temperature Range: –20℃ to 105℃)

　　Programmable Maximum Switching Frequency

　　Programmable Dead Time for Best Efficiency

　　Programmable Soft-Start Time

　　Easy ON and OFF Control

　　Overcurrent Protection

　　Overtemperature Protection

　　Bias Voltage UVLO and Overvoltage Protection

　　Integrated Gate Driver With 0.4-A Source and 0.8- A Sink Capability

　　Operating Temperature Range: –40℃ to 125℃

　　SOIC 8-Pin Package

　　UCC25600应用:

　　AC/DC Power Supply - Dual Analog Controller

　　Industry-Specific Drives - E-Bikes & E-Scooters

　　Lighting: Multi String LED Driver

　　Power: Telecom DC/DC Module: Analog

　　TV: High-Definition (HDTV)

　　Washing Machine: Low-End

　　Cable Modem Termination System

　　Lighting: LCD Backlight

　　Ovens (Microwave, Other)

　　Solar Energy - String Inverters

　　TV: LCD/Digital

　　图1.UCC25600框图

　　图2.UCC25600应用电路:300W LLC谐振半桥转换器

　　400W高效电池充电器电源TIDA-00355

　　The design is a 400-W high efficiency battery charger power supply designed to charge wide range of batteries in the voltage range of 20V to 42V and ideal for 10-Cell Li-Ion battery pack used in cordless Power Tools and Garden Tools. The design has boost PFC pre-regulator stage opearting at an efficiency of 96%. It provides high Power Factor(PF) of >0.99 and meets PFC regulation as per IEC61000-3-2 class A. The main converter stage is realised using LLC configuration and operates at an efficiency of 96% at full load. The charger is designed for input voltage range of 175V – 265V AC. The design form factor (230mm x 80mm) is compact for the power level of 400W. The design has an operating overall system efficiency of 92% at full load, with voltage and current regulation within +/- 3%. The EMI filter at the front end of the circuit is designed to meet EN55011 class A conducted emission levels.

　　400W高效电池充电器电源TIDA-00355主要特性:

　　• 400 W Battery Charger with front-end PFC and half bridge LLC resonant converter

　　• Designed to charge wide range of batteries - Li-ion, Li-poly, Ni-Cd and Lead-acid, in the voltage range of 20V to 42V

　　• Ideal charger for 10-cell Li-ion battery pack used in industrial power tools

　　• Delivers up to 9 A of continuous charging current for fast charging of batteries

　　• Overall efficiency of 92% at full charging current of 9A and 230V input, eliminating need for external cooling

　　• High power factor > 0.99 and meets PFC Regulations & Current THD as per IEC 61000-3-2 Class A

　　• Very low standby power of < 200mW when battery is not connected

　　• Small PCB form factor of 230 x 80 mm offers portability in usage

　　• Provides flexibility for charge profiling through an additional external microcontroller

　　• Charger is protected for Over current & Short-circuit at Output terminals ensuring safety needs

　　• Meets the requirements of Conducted Emissions standard – EN55011 class A

　　图3.带PFC和LLC的400W电源TIDA-00355框图

　　图4.带PFC和LLC的400W电源TIDA-00355外形图

　　400W电源TIDA-00355主要指标:

　　400W电源TIDA-00355材料清单: