Developing A 25-kW SiC-Based Fast DC Charger (Part 3): PFC Stage Simulation

Focus:

This 26-page, part 3 walks through the simulations of the fast EV charger’s ac-dc conversion stage, a.k.a. the PFC stage, with discussions of simulation goals, how the models were chosen, what operating and component parameters were selected, and takeaways from the simulation results presented here. These simulations were performed with Simetrix, a mixed-mode circuit simulator that offers enhanced SPICE for fast convergence. Goals of the simulation included verification of PFC stage functionality before designing hardware; confirming that dc output voltages, currents and power are delivered for all specified operating points; confirming that the efficiency target with the defined switching frequency is fulfilled and estimating power losses; establishing gate-drive gate resistor values as starting points for the prototypes; validating PFC chokes’ requirements/parameters (to be passed on to the inductor manufacturer) and selecting the dc link capacitor based on ripple current, ESR, capacitance and voltage rating.

What you’ll learn:

• How to model and simulate in Simetrix the ac-dc converter/PFC stage of a fast EV dc charger
• How to model the various components of a PFC stage including the mains and mains network, input filter, inrush current protection, PFC inductor, and the power stage include drivers and SiC power modules

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Author & Publication:

Oriol Filló, Karol Rendek, Stefan Kosterec, Daniel Pruna, Dionisis Voglitsis, Rachit Kumar and Ali Husain, ON Semiconductor, Phoenix, Ariz. , How2Power Today, Jun 15 2021

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