【经验】解析如何有效并联两个48V/12V汽车评估电源模块
EPC推出的48V/12V汽车评估电源模块(EPC9137、EPC9163、EPC9165等)采用两相同步降压/升压拓扑。边缘连接器和控制器卡还被设计用于在一个控制器上并联控制两个模块,有效地实现四相,从而使额定电流和功率翻倍。图1展示了使用EPC9137模块的示例。
图 1. 两个 EPC9137 并联连接,使用一个 EPC9528 控制器实现3kW (12V 250A) 输出。
连接
这种并联两个模块的方法和四相转换器之间的区别在于12V连接阻抗。理想情况下,该阻抗应极低,以消除电感电流纹波。因此,应使用母线或8AWG短线连接12V(低电压)以确保低阻抗,如图2所示。48V(高电压)总线的连接不太重要,但仍然首选低阻抗以避免寄生谐振。地线 (GND) 也应与相应的总线配对,并避免形成接地环路。
图 2. 两个EPC9137与一个EPC9528控制器并联,显示 48V总线和12V总线连接。
12V总线需要两模块之间的低阻抗。
测量和PWM
测量和PWM信号通过边缘连接器路由,如图3所示。务必确保移除两块板上J800上的任何跳线。控制器的3.3V电压仅由板1提供。每个板产生自己的5V电源。由于边缘连接器的引脚限制,仅支持2板并行。请修改PWM信号的相移以确保适当的纹波消除:PWM1和2与PWM3和4的相位相差180度,而PWM1和3之间的相移应为90度。
图 3. 与一个控制器连接的两块板的框图。
控制
本技术使用带外电流平衡的平均电流模式控制。图4显示了一个简化的控制图。外部电压环路为相位1电感器平均电流IL1生成电流参考IREF。剩余的相电感电流IL2、IL3、IL4被检测并与IL1比较。如果存在任何不平衡,则为每个相位生成一个占空比偏移Δd,以最小化不平衡。与主控制回路相比,这发生在低得多的频率上,例如10kHz左右。
图 4. 平均电流模式控制回路的控制图
散热
由于散热器散热片的方向不同,板下风侧的冷却气流会减少。接近额定功率运行时,至少需要2000 LFM。由于冷却不足,实际输出功率可能小于两块单板的总和。
实验结果
图5显示了在48V输入和12V输出下工作的两块EPC9137板的测量效率和损耗。图6显示了满载(12V,250A输出)下的相应热成像。由于气流方向,下风位置的电路板温度更高。
图 5. 两个EPC9137并联的测量效率和损耗。VIN=48V,VOUT=12V,f=250kHz。
图 6. 两个EPC9137的示例热图像。VIN=48V,VOUT=12V,IOUT=250A,f=250kHz。可以看出下风板更热
总结
48V/12V汽车评估电源模块设计为并联,在适当冷却时可实现额定功率的两倍。本文给出了详细的接线图、控制方法和电流平衡。此外,本文还展示了一个测试结果:在将48V转换为12V时,在3kW输出下测试了带有两个EPC9137和一个EPC9528的示例系统。
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