3kW Power Supply for Electric Scooter Fast Chargers Using SiC MOSFET

In recent years, the growing focus on carbon neutrality has led to increased popularity of electric scooters, driving demand for fast battery charging. This reference design presents a 3kW power supply tailored for fast chargers used with electric scooters.
Design tips on each portion of the circuit, method of operation, and design information such as circuit diagrams and PCB patterns are available, please use them for your design.

Board Appearance
TW092V65C TW092V65C TW092V65C TRS12V65H TRS12V65H TRS12V65H TW027U65C TW027U65C TW027U65C TW027U65C TW027U65C TPW2900ENH TPW2900ENH TPM1R908QM TPW2900ENH TPM1R908QM DCL540C01

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Features

  • Provides appropriate power devices (MOSFET and SiC diode) and digital Isolator totally.
  • Achieving high power density through the adoption of surface-mounted devices (34% improvement compared to our existing design).
  • Total efficiency 94.8% (Vin = 230V at 100% load condition)

Description

Input Power Supply Voltage AC 180V to 264V
Output voltage DC 50V
Output power 3kW
Circuit topology Semi-Bridgeless PFC, Phase-Shift Full-Bridge + Synchronous Rectification, ORing Circuit for Output
Efficiency Curve

Design Documents

Materials for designers, such as an overview of circuit operation and explanations of design considerations. Please click on each tab to view the contents.

Design Data

Provides circuit data that can be loaded into EDA tools, PCB layout data, and data used in PCB manufacturing. Available in formats from multiple tool vendors. You can freely edit it with your preferred tool.

*1:Actual PCB was designed on CR5000BD. The other files were made from CR5000BD file.

*2:The data was generated on CR5000BD.

Used Toshiba Items

Part Number Device Category Portion Usage Description
Power SiC MOSFETs PFC Circuit・2 N-ch SiC MOSFET, 650 V, 0.092 Ω(typ.)@18 V, DFN 8×8, 3rd Gen.
SiC Schottky barrier diode PFC Circuit・2 650 V/12 A SiC Schottky Barrier Diode, DFN8×8
Power SiC MOSFETs PSFB Circuit・4 N-ch SiC MOSFET, 650 V, 0.027 Ω(typ.)@18 V, TOLL, 3rd Gen.
Power MOSFET (N-ch 150V<VDSS≤250V) PSFB Circuit・12 N-ch MOSFET, 200 V, 0.029 Ω@10V, DSOP Advance, U-MOSⅧ-H
Power MOSFET (N-ch single 60V<VDSS≤150V) ORing Circuit・6 N-ch MOSFET, 80 V, 0.0019 Ω@10V, SOP Advance(E), U-MOSⅩ-H
Standard Digital Isolators PSFB Circuit・1 HIGH SPEED QUAD CHANNEL DIGITAL ISOLATORS, High-speed, 150 Mbps, 5000 Vrms, 16pin SOIC Wide body

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