Developing A 25-kW SiC-Based Fast DC Charger (Part 8): Thermal Management

Focus:

This 8th part in the series discusses the techniques used to provide thermal management of the overall fast EV charger design to improve efficiency and reliability, and prevent premature failures. First, the authors describe the advantages of using SiC MOSFET modules rather than discrete SiC MOSFETs. Secondly, they describe the design of the cooling fan assemblies and control system used to air cool the SiC power modules and magnetic components. This includes how they leveraged the internal NTC of the SiC power module to automatically control fan cooling in the PFC and dc-dc stages. The design of the PWM-to- voltage converter, which is based on the NCV890100 buck regulator and is used to regulate fan speed, is discussed at length. Simulations are presented to demonstrate key aspects of this converter’s operation and the design of its compensator.

What you’ll learn:

• How to understand the thermal performance benefits of SiC MOSFET power modules versus discrete SiC MOSFETs in high power applications
• How to design a fan cooling system for high power application

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Author & Publication:

Karol Rendek, Stefan Kosterec, Didier Balocco, Aniruddha Kolarkar, Parthiv Pandya and Will Abdeh, onsemi, Phoenix, Arizona, How2Power Today, Feb 15 2022

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