System Solutions For Hybrid and Electric Vehicles

System Solutions for Hybrid and Electric Vehicles
www.ti.com/hev
2Q 2010

Texas Instruments Automotive Commitment
Texas Instruments Automotive Commitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction to Electric Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Why TI? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 System Architecture of HEV/EV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Start/Stop Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Power Management for Start/Stop Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Start/Stop Function Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TPS40210: Boost Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TPIC74100: Buck-Boost-Converter Integrated Switches . . . . . . . . . . . . . . . . . . . . . . . 5 TPS40090: Four-Channel Multiphase Buck DC/DC Controller (or Boost) . . . . . . . . . . . 5 Start/Stop Function Using the C2000 DSP Piccolo MCU. . . . . . . . . . . . . . . . . . . . 6 Introduction to Battery Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Battery Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Battery Management: bq76PL536 and bq76PL537. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Battery Management: Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 bq76PL536: Battery Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 bq76PL536: Evaluation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Introduction to DC/DC Converter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DC/DC Converter: Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 UCC2895: Advanced Phase-Shift Resonant Controller. . . . . . . . . . . . . . . . . . . . . . . . 12 DC/DC Converter Using C2000 DSO Piccolo MCUs . . . . . . . . . . . . . . . . . . . . . . 12 C2000 DSPs Piccolo TMS320F280x Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 C2000 DSP Digital Power DC/DC Developer Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 On-Board Charger AC/DC with PFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 AC/DC Developers Kit with TMS320F280x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 AC/DC Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Piccolo MCUs F2802x vs. F2803x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 UCC28070: Two-Phase Interleaved Constant Current Mode (CCM) Power Factor Correction (PFC) Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Texas Instruments (TI ) is committed to providing superior cost-efficient solutions to the transportation market, along with excellent product documentation, on-time delivery and conformance to specifications. TI supports transportation industry requirements and continues to add to our transportation portfolio. With more than 30 years of experience serving customers with demanding requirements, TI can help you achieve the quality, reliability and cost goals to succeed in todays marketplace. TI is fully committed to automotive quality; we have a dedicated quality organization and a zero-defect strategy in place. We are TS16949 certified and a preferred supplier to major car manufacturers. Introduction to Electric Transportation Electric transportation is not a new phenomena; in fact, the concept has been around for more than 100 years. However, given growing environmental sensitivities, long-term supply concerns, fossil fuel prices and improved technology, there is a strong motivation to further accelerate this market segment. Government regulations like the 130-g/km (and future planned 95-g/km) CO2 average emission limits for car manufacturers in Europe are also catalysts behind new electrified transportation alternatives. With the adoption of more electronics, vehicles become safer, exhibit higher performance, and are more efficient. Electric transportation is a key element within the overall renewable energy landscape. Energy for charging is expected to come from renewable sources like wind-, solar- or waterpowered plants. Home and public charging stations will also become more prevalent and can take advantage of off-peak charging (nighttime) and other green energy sources such as wind. With a full range of analog and embedded processing products, TI is at the forefront of helping to bring safer, affordable and more efficient electric transportation solutions to market. TIs solutions for this industry range from optimized and dedicated integrated
Start/Stop Function (Micro Hybrid)
Battery Management, Power Conversion (DC/DC) and Charging (AC/DC)
Motor Control
Introduction to DC/AC for Inverter Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 TMS570: The Safe TI Microcontroller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TMS570: Evaluation Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
The Analog Foundation
Analog Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ISO1050: Isolated CAN Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ISO72x Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ISO7221Cxx: Dual-Channel, 1/1, 25-Mbps Digital Isolator . . . . . . . . . . . . . . . . . . . . . 21 ISO55xx: Isolated Gate Driver Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 AMC1203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Charging Infrastructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Charging Infrastructure Connecting the Car to the Smart Power Grid . . . . . . . . . . . 23 PLC Kit Using the TMS320F28335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ZigBee RF Using the CC2530 System-on-Chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 bq78PL114: Integrated Gas Gauge, Protection and Active Cell Balancing. . . . . . . . . 26 bq77PL900: Standalone and Host-Controlled Battery Protection. . . . . . . . . . . . . . . . 26 Digital Motor Control for E-bikes, Scooters and STOVs . . . . . . . . . . . . . . . . . . . . . . . 27 High-Voltage PFC and Motor Control Developers Kit . . . . . . . . . . . . . . . . . . . . . . . . . 27 controlSuite Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
E-Bike, Scooter and Small Task-Oriented Vehicles (STOVs) . . . . . . . . 25
TI Worldwide Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

circuits to full system-level solutions to help our customers optimize and accelerate product development. TIs experience in diverse markets such as industrial control, industrial motor drives, digital power supplies, smart metering and grids, wired and wireless communications, consumer electronics, and energy efficiency enables engineers to meet increasing needs for higher speeds, higher precision, lower power and more robust equipment all while maintaining the high standards of quality and reliability that the automotive and transportation market demands.
Texas Instruments 2Q 2010

Introduction to Electric Transportation
Why TI?
Innovated semiconductor solutions Making advanced automotive and transportation devices more flexible, affordable and accessible. Addressing growing needs in energy efficiency, power and battery management, wired and wireless connectivity, and performance and precision. Complete portfolio Amplifiers, data converters, interfaces, power management, isolation, logic, DSPs, MCUs, wireless connectivity. Catalog, application-specific, enhanced and custom IC options. Experienced automotive and transportation sector supplier with a full range of AEC Q-100-certified analog and embedded processing technologies and products. Quality and reliability Experience in serving the automotive market for more than 30 years. Ability to serve customers of all sizes with a variety of supplier chains and needs. Long product lifetimes and flexible product obsolescence policy, ensuring continuity of supply. Worldwide manufacturing and R&D capabilities. Member of industry-standard organizations and alliances. Commitment Design support Tools Training Distribution This Hybrid and Electric Vehicle Solutions Guide is intended to help you explore TIs IC solutions as the various transportation sectors become increasingly electrified on a path toward energy efficiency and sustainability. This guide features several system block diagrams, followed by details about key devices and support functions. Within this guide, you will find solutions and support for your hybrid and electric vehicle applications designs in the following categories:
Different types of hybrid and electric vehicles Start/ Stop a Micro Hybrid a a Mild Hybrid a a a Full Hybrid (Parallel) a a a a a a a a a a a Full Hybrid (Serial) Full Electric
Feature Start/stop alternator Regenerative breaking Electric torque assist Electric and combustion drive Only electric drive possible Plug-in capability
Different types of hybrid and electric vehicle concepts exist in the market. Texas Instruments offers leading-edge solutions for all systems, from a basic start/stop function to a fully integrated plug-in electric vehicle. This guide will give an overview of the various functions and also cover product highlights from various areas. For the latest information, see TIs Web site, www.ti.com.
Battery Monitoring
Battery Management
Electrical Motor/ Generator
DC/AC Inverter Motor Control
DC/DC Converter (Reversible) Energy Conversion
HighVoltage Li-Ion Battery
AC/DC Converter (PFC + PLC) Charger
The hybrid and electric vehicle system is built of several modules to form the drive train and energy storage system. The battery block (typically a Li-ion chemistry in the range of 400 V) is managed and monitored by the battery management system (BMS) and charged via an on-board AC/DC converter module, with voltages ranging from 110-V single phase to 380-V three-phase systems. The DC/ AC inverter uses the high voltage of the battery to drive the electric motor, but also is used for regenerative breaking, storing energy back into the battery. To connect the high-voltage battery to the conventional 12-V board net requires a DC/DC converter. The connection of a high-voltage battery to the inverter also requires a reversible DC/DC converter in most cases. The complete HEV system has to meet specific safety requirements
DC/DC Converter (Full Bridge)
12-V Board Net
LowVoltage 12-V Battery
(up to ASIL-D) that are specifically relevant for managing the potentially explosive high-voltage battery pack, as well as the drive train used for breaking. TI is very active in the industrial control segment and can combine extensive application experience with a strong background in the automotive space. Several evaluation modules with hardware and software support will speed up development, while the product roadmap addresses future requirements.
System Architecture of HEV/EV
Infrastructure/Charging Spot

Start/Stop Function
This feature is present in hybrid electric vehicles, but has also appeared in vehicles that lack a hybrid electric powertrain. For non-electric vehicles (called micro hybrids), fuel economy gains from this technology are typically in the range of 5 to 10 percent. But because automobile accessories like air conditioners and water pumps have typically been designed to run off a serpentine belt on the engine, these systems must be redesigned to function properly when the engine is turned off. Typically, an electric motor is used to power these devices instead.
A start/stop system automatically shuts down and restarts an automobiles internal combustion engine to reduce the amount of time the engine spends idling, thereby improving fuel economy. This is most advantageous for vehicles that spend significant amounts of time waiting at traffic lights or that frequently come to a stop in traffic jams.
Power Management for Start/Stop Function

TIs solution
Supply
VBAT Power Management Buck/Boost
Vdriver AIN Vlogic Rmod GND Enable
Cboot1 L1 L2 Cboot2 VOUT PGND 5Vg AOUT
Cold crank, crank down to 2 V-4 V

VS
Constant 5-V output at supply voltage from 1.5 V to 40 V Aux 5-V Output
2 V-4 V
5Vg_Enable RESET REST CLP
VBAT VOUT VOUT High-Power Booster PWM Controller Phase 1 Gate Driver VOUT
Start-stop crank, crank down to 6 V-7 V

VS
6 V-7 V
Phase n +1 Gate Driver
More and more modules inside a car have to be defended from voltage drop during cranking. This problem has increased with the implementation of
start/stop (micro hybrid) systems, a trend seen in the automotive industry to improve fuel efficiency.
TI offers a variety of products in the power management area that can solve this system/customer problem.

Start/Stop Function Applications
Boost Converter TPS40210
Get samples, datasheets, EVMs and app reports at: www.ti.com/sc/device/TPS40210 Key Features Wide-input voltage range: 4.5 V to 52 V Current-mode controller TPS40210: internal reference voltage: 0.70 V Internal undervoltage lockout Programmable frequency 35 kHz to 500 kHz Frequency synchronization Closed-loop soft start Overcurrent protection Integrated NMOS-FET driver Small package size 10-pin MSOP Benefits Suitable for any type of boost application Boost, flyback and SEPIC topologies possible
RC SS DIS/EN
VDD VBP GDRV ISNS RSENSE
TPS40210 controller configured as a high-efficiency constant-current LED driver.
COMP
FB
GND
EVM available
Buck-Boost-Converter Integrated Switches TPIC74100-Q1

Get samples, datasheets, EVMs and app reports at: www.ti.com/sc/device/TPIC74100-Q1 Key Features Wide-input voltage range: 1.5 V to 40 V Max. load current: 1 A (TPIC74100-Q1) 500 mA (TPS55065-Q1) Max. load current: 200 mA @ VIN = 2.0 V Max. load current: 120 mA @ VIN = 1.5 V Fixed output voltage: 5 V Enable function, shutdown current < 20 A Switching frequency 440 kHz (nom) Slew rate control and frequency modulation for EMI reduction Alarm function for undervoltage detection Switched 5-V output with current limit Thermally enhanced 20-pin PowerPAD package Benefits Stable 5-V line, also during cranking pulse Wideinput voltage range, no external protection required Reset integrated, additional alarm threshold integrated Output voltage switched to second pin (auxiliary 5-V output) Designed for harsh automotive environments (protections for over temperature, overvoltage)
EVM available
Vdriver
Supply
Cboot1
AIN
L1
L
Vlogic
L2
Rmod
Cboot2
GND
Vout
Main 5-V output
GNDP Enable 5Vg 5Vg_Enable Aout CLP RESET

Aux 5-V output
Four-Channel Multiphase Buck DC/DC Controller (or Boost) TPS40090

Get samples, datasheets, EVMs and app reports at: www.ti.com/sc/device/TPS40090 Key Features Qualified for automotive applications Two-, three- or four-phase operation 5-V to 15-V operating range Programmable switching frequency up to 1 MHz/phase Current-mode control with forced current sharing (1) 1% internal 0.7-V reference Resistive divider set output voltage True remote sensing differential amp
2 CS2 4 CS4
CBP5
TPS40090
CS3 3
CCS3 RCS3
14 PGQOD 22 BP5 6 ILIM
CSCN 5
CCS1 RCS1
Resistive or DCR current sensing Current-sense fault protection Programmable load line Compatible with TIs UCC37222 Predictive Gate Drive technology drivers 24-pin space-saving TSSOP package Binary outputs
CS1 1 VIN 23
VIN (4.5 V to 15 V) CIN TI Synchronous Buck Driver L1
CSS RILIM2 RRT RDROOP
17 GND 15 SS 16 RT 7 DROOP 8 REF
RILIM1 CREF
PWM1 21
BP5
RFB3
CFB1
24 EN/SYNC 9 COMP 10 FB
PWM2 20 PWM4 18
TI Synchronous Buck Driver L2 VOUT(0.7 V to 3.5 V) COUT
RFB2
RFB1
11 DIFFO 13 GNDS 12 VOUT
PWM3 18
EVM available

Start/Stop Function Using the C2000 DSP Piccolo MCU
VIN-12 V
VIN
V-BOOST
VOUT
+ Piccolo CPU
32-bit DSP 60 MHz
+
1A
CS Gain
1-phx1
ADC
12-bit 4.6 MSPS
1-phs 1 1-phs 2 1-phs 3 1-phs 4 V-boost V-IN TempSense 1A
VREF I2C SPI UART CAN

PWM 1 (HR) PWM 2 (HR) PWM 3 (HR) PWM 4 (HR)
+
2A
CS Gain
1-phx2
LS DRV
2A 3A 4A
+
3A
CAN bus
CS Gain
1-phx3
+
4A
CS Gain
1-phx4
Using a C2000 DSP with enhanced real-time features brings both highspeed loop control and system management capabilities in a single device. The Piccolo MCUs math-efficient CPU, closely coupled with high-performance PWMs and ADCs, can control multiphase boost stages over a wide range of operating points. Digital control schemes with feed-forward, 3-pole/ 3-zero compensators, PID, etc., allows power designers to realize complex and
flexible loop control strategies that can be adaptive and managed for efficiency, transient performance, light-load operation, fault-handling and rich diagnostics. Independent control of each phase allows for current balancing within each phase, spreading the load evenly and improving reliability. This also adds phase-shedding capability, where at light loads one or two phases are used, hence increasing efficiency.
Under these conditions, intelligent management software can re-tune control loops by dynamically changing compensator coefficients. The above diagram shows a four-phase boost implementation where each MOSFET is controlled with a highresolution PWM capable of 150-pS edgeplacement accuracy, ensuring smooth PWM switching speeds from 100 KHz to beyond 500 KHz without the undesirable limit-cycle oscillations often associated with low-resolution pulse-width modulators.
Contact local sales office for more information.

Introduction to Battery Management
High-Voltage Battery Pack Current Sense AC Line 83-265 VAC Rectied AC Boosted DC Output 385 V-400 V Protection Isolation Boundary BMS
+ I + I + I + I + I + I + I + I + I + I + I + I + I
Temp Sensor
MOSFET Driver BMS Relay Driver
Current Sense
Current Sense
BMS
Digital Power Controller

Current Sense
Digital Power Controller
Power Line Communication
Interface Option
Isolation Auxiliary Power
Isolation Interface Option Temp Sensor
Legend Other Interface Power Amplier
Plug-in hybrid electric vehicles (PHEVs) and battery electric vehicles (BEVs) are two quickly emerging technologies that use powerful electric motors as the propulsion source. In order to power these electric motors, large battery packs are made up of hundreds of cells, totaling 300-400 volts installed in the vehicle. Because batteries have a finite energy capacity, PHEVs and BEVs must be recharged on a periodic basis, typically by connecting to the power grid. The charging system for these vehicles consists of an AC/DC rectifier to generate a DC voltage from the AC line, followed by a DC/DC converter to generate the DC voltage required by
the battery pack. Additionally, advanced charging systems might also communicate with the power grid using PLC modems to adjust charging based on power grid conditions. The battery pack must also be carefully monitored during operation and charging in order to maximize energy usage and prolong battery life. High-performance analog parts are also available to provide critical system functions and features such as sensor feedback, isolation, chip power supplies and communication transceivers. The bq76PL5xx device families are designed for high-cell-count battery
packs. They can handle the voltages and currents found in higher power applications like power tools and electronic mobility. The more cells a pack has in series, the greater the difference in state of charge, impedance, and capacitance affecting the health and energy delivery of the pack. The bq76PL5xx devices include circuitry for bringing the cells back into balance. This increases the lifetime of the pack and can help deliver as much energy to the application as possible. Each bq76PL5xx device protects from overcharge, over discharge, over temperature and high-current events for pack and system safety.

Battery Management System
ISENSE Shunt
+ + + + +
Safety Disconnect
Battery/Ultra Capacitor Stack

+ + + + + + + + + +
e.g. 400 V
+
Cell Balancing Parts
Cell Monitoring
Cell Monitoring Isolation
Cell Monitoring
Power Supply
MCU ADC Digital Isolator Reference Isolated DC/DC Converter
Supervisor
CAN
Temp Sensor
The battery management system (BMS) is a key element in the overall HEV architecture. Not only will an intelligent implementation extend the batterys lifetime, but also extend the possible range of the vehicle in fully electric drive mode, which is a key selling point to end users. The battery system is often divided into several submodules that can be placed in various positions of the vehicle. All of these modules require battery supervision and battery cellbalancing features, often connected through different communication paths to ensure system redundancy. Built-in temperature management is also a crucial element for the system lifetime, and for safety. The complete battery system represents a highly safety-critical function; therefore, the microcontroller needs to meet specific safety requirements.
+
Module 1
+
Module 2
+
Module 3 Private CAN
Safety Line BMS Main C TMS570 Family Dual Core Lockstep SIL3-Compliant
Public CAN

Preview
Building on the broad experience in battery-management solutions for consumer and industrial applications, the new battery-management devices
for high-cell-count applications offer highly integrated solutions for the HEV/ EV space. They are available in different setups with passive and active cell
balancing as well as with and without a secondary protector function and are the start of a bigger family of devices for the HEV/EV space.
HEV/EV monitor and protector with passive balancing
bq76PL536 Monitor Passive Balancing 2nd Protector
Three to six cells High measurement accuracy of 1 mV typical Fast response to OV, UV, OT due to independent, integrated safety comparators Dedicated alert/fault and convert/ready signals No isolation for IC-to-IC communication Bypass/bleed cell balancing topology, integrated gate drivers with external FETs Fast multiplexed A/D converter Measures six Vcells, Vstack, two temp, one aux
HEV/EV monitor and active cell balancing
bq76PL537 Monitor Active Balancing
Three to six cells High measurement accuracy of 1 mV typical No isolation components required for IC-to-IC communication Advanced PowerPump bidirectional charge transfer cell with active cell balancing Balancing, integrated gate drivers for external FETs PowerPump balancing available during charge, discharge or idle conditions Multiple synchronized A/D converters Measures six Vcells, Vstack, six aux (temperature) Dual redundant communication channels
Fully integrated monitoring solutions provide very accurate insight into the status of the cell stack. The PL536 provides basic passive cell balancing, integrated secondary OV battery protection and communicates via
different SPI channels (non-isolation required) plus signals for fault detection. The PL537 offers active cell balancing, enhancing the batterys energy usage for extended ranges using PowerPump technology.
For the BMS central microcontroller, the TMS570 is an excellent choice, described later in this guide.
PowerPump technology for active cell balancing.
P-FET turned on energizing inductor. V3 Current P-FET
V3 V2 Control signals from PL537
V2
P-FET turned off. Stored inductor energy transferred through body diode of N-FET. V2
V1
Current V1
N-FET
Battery Management: bq76PL536 and bq76PL537
10

Battery Management: Applications
Preview
Battery Management bq76PL536

Get samples, datasheets, EVMs and app reports at: www.ti.com/sc/device/BQ76PL536 Key Features Three- to six-series cell support, all chemistries hot-pluggable Stackable vertical SPI interface No isolation components required High-speed SPI for data communications Dedicated fault signals High-accuracy A/D converter: 1-mV typical, 3-mV max 14-bit resolution 3-s conversion time Nine ADC inputs: six cell voltages, one 6-cell brick, voltage, two temperatures, one general-purpose input Built-in comparators (secondary protector) for overvoltage, undervoltage and over- temperature protection Programmable thresholds and delay times Supply voltage range from 5.5 V to 30 V Low power: 12-A sleep current (typical) 48-A idle current (typical) Integrated precision 5.0-V 3-mA LDO
The bq76PL536 is a stackable, three- to six-series cell lithium-ion battery pack protector and analog front end (AFE) that incorporates a precision analog-to-digital converter (ADC), independent cell voltage and temperature protection, cell balancing and a precision 5-V low dropout regulator (LDO) to power user circuitry. The bq76PL536 provides full protection (secondary protection) for overvoltage, undervoltage and over-temperature conditions. When safety thresholds are exceeded, the bq76PL536 sets the fault output. No external components are needed to configure or enable the protection features. Cell voltage and temperature protection functions are independent of the ADC. The bq76PL536 is intended to be used with a host controller to maximize the functionality of the battery management system. However, the protection functions do not require a host controller. The bq76PL536 can be stacked vertically to monitor as many as 192 cells without additional isolation components between ICs.
REG50 LDOD LDOA VBAT AUX
bq76PL536
LDO-A LevelShifted North Comms Interface EEPROM Shadow RAM
UV
LDO-D
5-V LDO (User Circuitry) Thermal Shutdown
OT1 OT2 OV
TS2+ TS2 TS1+ TS1 VC6
UV OV
CB6 VC5 CB5 VC4
Host Interface
OV
Level Shift and MUX
VREF 2.5 V
Ultra-Precision Bandgap
Digital Control Logic LevelShifted South Comms Interface OSC WDT
14-Bit ADC
OV UV OV
AMP
Cell Balancing
UV
CB4 VC3 CB3 VC2
UV OV UV
CB2 VC1 CB1 VC0
REF2 + GPAI+ GPAI VREF VSS VSS
bq76PL536 Evaluation Module

Can handle up to 18 cells, three PL536 on the board Works with battery cells or power supply input Includes 2.5-kV galvanic isolation for host CPU or PC Software interface for easy system evaluation Order part number: BQ76PL536EVM Available 2Q 2010
Preview
GPIO

Introduction to DC/DC Converter Module
11
High Voltage
PWM 3 a PWM 4 a
Low Voltage
PWM 3 a PWM 4 a
High-Voltage Battery
PWM 3 b PWM 4 b PWM 3 b PWM 4 b
12-V Vehicle Power Net
Gate Drivers
Gate Drivers
PWM Controller
PWM Controller
PWM ADC Reference ADC
V and I Sense
Temp Sensor
ADC
Digital Isolator
MCU/DSP Core and I/O Supply
V and I Sense
ADC
System Power
Legend
Network MCU CAN Isolated DC/DC Converter
CAN
Supervisor
Processor Interface Power ADC Design Option Amplier
The DC/DC converter module is used to connect the high-voltage battery to the 12-V vehicle Power Net. The system can either be realized with fixed PWM
controllers or an MCU controlling both the high- and low-voltage side of the converter. This method offers more flexibility using a common hardware
platform, with adjustments done in the software only and additional capabilities like diagnostic features.
12

DC/DC Converter: Applications
Advanced Phase-Shift Resonant Controller UCC2895

Get samples, datasheets, EVMs and app reports at: www.ti.com/sc/device/UCC2895 Key Features Qualified for automotive applications Programmable output turn-on delay Bidirectional oscillator synchronization Voltage-mode, peak-current-mode or average-current-mode control Programmable soft start/soft stop and chip disable via a single pin 0 to 100% duty-cycle control 7-MHz error amplifier Operation to 1 MHz Typical 5-mA operating current at 500 kHz Very low 150-A current during undervoltage lockout (UVLO) The UCC2895 is a phase-shift pulse-width modulation (PWM) controller that implements control of a full-bridge power stage by phase-shifting the switching of one halfbridge with respect to the other. It allows constant frequency PWM in conjunction with resonant zero-voltage switching to provide high efficiency at high frequencies. The part can be used either as a voltage- or current-mode controller. Although the UCC2895 maintains the functionality of the UC3875/6/7/8 family and UC3879, it improves on that controller family with additional features such as enhanced control logic, adaptive delay set and shutdown capability. Because it is built using the BCDMOS process, it operates with dramatically less supply current than its bipolar counterparts. The UCC2895 can operate with a maximum clock frequency of 1 MHz.
UCC2895 1 EAIN EAP 20 2 EAOUT SS/DISB 19 3 RAMP 4 REF 5 GND 6 SYNC 7 CT 8 RT 9 DELAB 10 DELCD OUTA 18 OUTB 17 PGND 16 VCC 15 OUTC 14 OUTD 13 CS 12 ADS 11
Q1
VIN1
VOUT B D
VIN
DC/DC Converter Using C2000 DSP Piccolo MCUs

IHV VHV VLV CT 1A 2A 3A ILV 4A CT
High Voltage
Low Voltage
1B
2B
3B
4B
HS DRV LS DRV
Piccolo CPU
32-bit DSP 60 MHz
3A 4A 3B 4B
HS DRV LS DRV
PWM1 A B PWM2 A B PWM3 A B PWM4 A B

I2C SPI UART CAN LIN
CLA
32-bit FPU 60 MHz
ILV IHV VHV VLV Temp
In automotive solutions, a bidirectional DC/DC converter is useful in many applications. For example, on the high voltage side, an H-bridge topology is used to drive an inverter for the electric motor. When the driver steps on the brake, an H-bridge on the secondary side can use the back EMF to recharge the battery. Alternatively, a bidirectional DC/DC converter can be used in systems that have both a high-voltage lithium-ion battery and an automotive 12-V battery to add more capabilities, as well as increase flexibility.
LIN/CAN Bus
ADC
12 bit
Isolation Isolation

C2000 DSPs Piccolo TMS320F2802x Family
Key Features C28x DSP 32-bit CPU Single-cycle 32-bit MAC Up to 60-MHz performance Full software compatibility with previous generations Memory Flash: 16, 32, 64 KB RAM: 4, 6, 10, 12 KB Peripheral Highlights Single 3.3-V supply Two high-accuracy on-chip oscillators (10 MHz) Best-in-class PWM and event capture 150-ps resolution on PWM duty and frequency 12-bit ratio-metric ADC with individual channel triggers and 4.6-MSPS speed Two analog comparators with 10-bit reference Robust serial communication interfaces Up to 22 general-purpose I/Os Packages: 38-pin TSSOP , 48-pin LQFP PWMs: Includes ePWM channels and captures used as basic PWMs. Timers: Timers include CPU, PWM and watchdog timers.
13
TMS320F2802x devices feature architectural advancements and enhanced peripherals in packages from 38 pins to bring the benefits of 32-bit real-time control to applications typically unable to justify the associated cost. Real-time control offers greater system efficiency and precision through the implementation of advanced algorithms. For more information, visit www.ti.com/piccolo.
VREF Lo VREF Hi A0 A1 A2 A3 A4 A5 A6 A7 B0 B1 B2 B3 B4 B5 B6 B7
ADC
C28 Core 32-bit - 40/60 MHz Flash 64 kB RAM 12 kB
VREF
PWM1 A B PWM2 A B PWM3 A B PWM4 A B
12-bit 4.6 MSPS Dual S/H Auto Seq
PWM - 1A PWM - 1B PWM - 2A PWM - 2B PWM - 3A PWM - 3B PWM - 4A PWM - 4B
Temp Sensor DAC 10 bit DAC 10 bit + CMP1 - OUT
TripZone Logic
+ CMP2 - OUT Analog Comparators Timers - 32 bit Timers - 0 Timers - 1 Timers - 2 System
TZ1 TZ2 TZ3 CMP1 - OUT CMP2 - OUT ECAP 3 2 1
CAP Comms UART SPI I2C
PWR GND X1 X2
2 3
VREG Int-OSC-1 Int-OSC-2 Ext-OSC-2 POR/BOR
WD PLL
GPIO Control
C2000 DSP Digital Power DC/DC Developer Kits

Digital power experimenters kit ($229) offers: Two-rail DC/DC EVM using TI PowerTrain modules (10 A), F2808 controlCARD controller subsystem On-board digital multimeter and active load for transient response tuning Order part number: TMDSDCDC2KIT DC/DC developers kit ($325) offers: Eight-rail DC/DC EVM using TI PowerTrain modules (10 A) Applications software with example code and full hardware details Demonstrates multirail and multiphase applications Includes F28044 controlCARD controller subsystem Order part number: TMDSDCDC8KIT Resonant DC/DC developers kit ($229) offers: Single transformer LLC resonant DC/DC converter Four different feedback methods for experimentation Lossless current sensing circuit for fault protection Active load for transient response tuning Includes F2808 controlCARD controller subsystem Order part number: TMDSRESDCKIT
14

On-Board Charger AC/DC with PFC
HighVoltage Battery
VRECT
VBOOST
DCBUS
VBUS
VOUT
95-275 VAC
A 1A
E CT
Filter
1B 2A 2B IPFC IPBB IPBA Piccolo CPU

32-Bit DSP Core 40/60 MHz
IOS B D F
IPBC
IPBD
PWM1 PWM2 PWM4
L8 DRV
1A 1B 2A 2B
A B C D
Piccolo
HS + LS DRV HS + LS DRV
Sync E F
PWM1 PWM2 PWM3 HS + LS DRV

VOUT VBUS IOS
CPU
32-Bit DSP Core 40/60 MHz
I/O Comms I2C SPI UART
ADC
12-Bit 4.6 MSPS
VREF
VRECT VBOOST IPFC IPHA IPHB IPHC IPHD
PWM4
ADC
12 -Bit 4.6 MSPS
VREF
Comms I2C SPI CAN UART
The charging of the HEV/EV via the main grid demands a flexible setup to meet the various voltage levels in single-phase (120-V, 230-V) and three-phase 380-V systems with different current levels (16 A to 63 A). The charging time is certainly an important feature for the cars end customer, but has to be balanced with
the long-term aging behavior of the battery pack. The AC/DC charging system shown offers a power factor control (PFC) function along with HV power conversion to directly generate the batterys DC
charging voltage. An optional power line communication (PLC) to communicate with the charging infrastructure can be implemented as well. This setup demands a high number of PWM and ADC channels, along with powerful CPU performance.
AC/DC Developers Kit with TMS320F280x

Complete, low-power rectifier development platform for prototyping communications systems AC/DC EVM with interleaved power factor correction (PFC) and phase-shifted full bridge Primary side control, synchronous rectification, peak current-mode control, two-phase PFC with current balancing Contains an 80-W (max) system that uses a two-phase interleaved PFC front end and a phase-shifted full-bridge rectifier stage Includes F2808 controlCARD controller subsystem Available for $695 Order part number: TMDSACDCKIT
15
Why Piccolo MCUs?

The Piccolo F2802x/F2803x family of C2000 MCUs provides a low-cost, high-integration solution to help driver processor-intensive real-time control into cost-sensitive applications. With a host of industry-leading integrated modules,
Benefit Improved system efficiency/accuracy Added functions/features Better R&D efficiency Increased reliability
such as a powerful ADC, dedicated high-resolution PWMs and the unique control law accelerator (CLA), Piccolo MCUs are ideal for power conversion in electric vehicles. For more complex systems, like those with integrated power
line communication, several additional family members of the C2000 family are available, offering floating-point performance up to 300 MHz and high-performance peripherals like a 12.5-MSPS 12-bit ADC. For more information, visit www.ti.com/piccolo.
Enabling Feature High-performance C28xTM DSP core supports adaptive control algorithms for efficiency across load curve High-resolution 150-ps PWM modules and high-speed on-chip ADC Communication with outside systems: CAN, LIN, I2C, UART, SPI Multiple PWMs allow multiple DC output rails Software control adaptable to multiple topologies and power ratings Digital control can adapt to environmental conditions and be recalibrated in software Software can implement failure prediction
Piccolo MCUs F2802x vs. F2803x

TMS320F2803x includes the same C28x DSP core, enhanced high-resolution PWM technology and high-speed ADC, but combines more features and additional memory. Get samples, datasheets, EVMs and app reports at: www.ti.com/piccolo. Key Features Up to 128-KB flash, 20-KB RAM All new CLA: independent, floating point processing unit with direct access to ADC and PWMs enables parallel control loop execution Additional three ePWM modules (six PWM outputs) Quadrature encoder interface (eQEP) Three on-chip comparators Added communication ports CAN 2.0B with up to 16 mailboxes, LIN/ UART and additional SPI Packages: 64-pin TQFP, 80-pin LQFP
VREF Lo VREF Hi A0 A1 A2 A3 A4 A5 A6 A7 B0 B1 B2 B3 B4 B5 B6 B7
+
ADC 12-bit 4.6 MSPS Dual S/H Auto Seq
C28 Core 32 bit - 60 MHz Flash 128 KB RAM 14 KB RAM 6 KB (Dual Access) CLA Core 60-MHz F1tPt (Accelerator)
VREF
PWM1 A B PWM2 A B PWM3 A B PWM4 A B PWM5 A B PWM6 A B

6
Temp Sensor DAC 10 bit DAC 10 bit DAC 10 bit 4 5 + CMP1 - OUT + Analog Comparators WD PLL CMP2 - OUT
PWM7 A B
TripZone Logic
CAP CMP3 - OUT QEP Comms Timers - 32-bit Timers - 0 Timers - 1 Timers - 2 System GPIO Control UART x2 SPI x2 I2C CAN
PWM - 1A PWM - 1B PWM - 2A PWM - 2B PWM - 3A PWM - 3B PWM - 4A PWM - 4B PWM - 2A PWM - 2B PWM - 3A PWM - 3B PWM - 4A PWM - 4B TZ1 TZ2 TZ3 CMP1 - OUT CMP2 - OUT CMP3 - OUT ECAP QEP
C28 32-Bit Core 60 MHz
ADC 12-Bit 4-6 MSPS CLA 60-MHz F1tPt Accelerator PWM1 PWM2 PWM3
Ch 1 Ch 2 Ch 16
1A 1B 2A 2B 3A 3B
Piccolo
4 6 2 2
PWR GND X1 X2
VREG Int-OSC-1 Int-OSC-2 Ext-OSC-2 POR/BOR
Piccolo MCU family overview

12-Bit ADC External Channels/ Memory Core On-Chip Speed RAM Flash ROM PWM HiRes Quadrature Event Conversion UART/ Bus Supply GPIO Oscillator/ (MHz) DMA CLA (KB) (KB) (KB) Channels PWM Encoder Captures Timers* Time (ns) McBSP I2C SCI SPI Lin CAN (Bit) (Volts) Pins Regulator Package 40 40 40 40 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 Yes Yes Yes Yes 12 12 12 12 12 12 12 12 12 12 16 16 20 20 20 20 20 20 20 20 32 32 64 64 32 32 64 64 32 32 64 64 64 64 128 128 64 64 128 128 Boot Boot Boot Boot Boot Boot Boot Boot Boot Boot Boot Boot Boot Boot Boot Boot Boot Boot Boot Boot 9 9 9 9 9 9 9 9 13 15 13 15 13 15 13 15 13 15 13 15 4 4 4 4 4 4 4 4 6 7 6 7 6 7 6 7 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 9 9 9 9 9 9 9 9 11 12 11 12 11 12 11 12 11 12 11 12 7/ 325 13/ 325 7/ 325 13/ 325 7/217 13/217 7/217 13/217 14/ 500 16/ 500 14/ 500 16/ 500 14/217 16/217 14/217 16/217 14/217 16/217 14/217 16/217 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 1 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 20 22 20 22 20 22 20 22 33 45 33 45 33 45 33 45 33 45 33 45 Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes Yes / Yes 38TSSOP 48LQFP 38TSSOP 48LQFP 38TSSOP 48LQFP 38TSSOP 48LQFP 64TQFP 80LQFP 64TQFP 80LQFP 64TQFP 80LQFP 64TQFP 80LQFP 64TQFP 80LQFP 64TQFP 80LQFP
Device Piccolo MCUs TMS320F28022DAQ TMS320F28022PTQ TMS320F28023DAQ TMS320F28023PTQ TMS320F28026DAQ TMS320F28026PTQ TMS320F28027DAQ TMS320F28027PTQ TMS320F28030PAGQ TMS320F28030PNQ TMS320F28031PAGQ TMS320F28031PNQ TMS320F28032PAGQ TMS320F28032PNQ TMS320F28034PAGQ TMS320F28034PNQ TMS320F28033PAGQ TMS320F28033PNQ TMS320F28035PAGQ TMS320F28035PNQ
AC/DC Applications
16

Two-Phase Interleaved Constant Current Mode (CCM) Power Factor Correction (PFC) Controller
UCC28070
Get samples, datasheets, EVMs and app reports at: www.ti.com/sc/device/UCC28070 Key Features Interleaved average current-mode PWM control with inherent current matching Advanced current synthesizer current sensing for superior efficiency Highly linear multiplier output with internal quantized voltage feed-forward correction for near-unity PF Programmable frequency (10 kHz to 300 kHz) Programmable maximum duty-cycle clamp Programmable frequency dithering rate and magnitude for enhanced EMI reduction Magnitude: 3 kHz to 30 kHz Rate: up to 30 kHz External clock synchronization capability Enhanced load and line transient response through voltage amplifier output slew-rate correction Programmable peak-current limiting Bias-supply UVLO, overvoltage protection, open-loop detection and PFC-enable monitoring External PFC-disable interface Open-circuit protection on VSENSE and VINAC pins Programmable soft start 20-lead TSSOP/SOIC package The UCC28070 is an advanced PFC device that integrates two pulse-width modulators (PWMs) operating 180 degrees out of phase. This interleaved PWM operation generates substantial reduction in the input and output ripple currents, and the conducted EMI filtering becomes easier and less expensive. A significantly improved multiplier design provides a shared current reference to two independent current amplifiers, ensuring matched average current-mode control in both PWM outputs while maintaining a stable, low-distortion sinusoidal input line current. The UCC28070 contains multiple innovations, including current synthesis and quantized voltage feed-forward to promote performance enhancements in PF, efficiency, THD and transient response. Features including frequency dithering, clock synchronization and slew-rate enhancement further expand the potential performance. The UCC28070 also contains a variety of protection features, including output overvoltage detection, programmable peak-current limit, undervoltage lockout and open-loop protection.
L1 D1 VOUT COUT
+
CCDR UCC28070 1 CDR 2 RDM 3 VAO 4 VSENSE RIMO RB RSYN 5 VINAC 6 IMO 7 RSYNTH 8 CSB 9 CSA 10 PKLMT CZV CPV RZV From Ixrms DMAX 20 RT 19 SS 18 GDB 17 GND 16 VCC 15 GDA 14 VREF 13 CAOA 12 CAOB 11 RPK1 RPK2 CREF CPC RZC CZC RDMX RRT
12 V to 21 V To CSB RS T1
RA
RRDM
CSS
M1
L2 D2 To CSA RS CZC CPC RZC M2 RB T2 RA
Motor Control
Introduction to DC/AC for Inverter Motor Control
Legend Processor Interface Power ADC Amplier
High-Voltage Battery
17
Isolation
Gate Driver
Current Sense
Core Supply
I/O Supply
MCU (TMS570 or C2000) Supervisor
Digital Isolator ADC Rotor Position
CAN
CAN
ADC
Temp Sensor
ADC
Isolated DC/DC Converter
Reference
The inverter will drive the electric motor for fully electric operation in full hybrids and EVs, but also for torque assist in a mild hybrid car concept. This can be done with a single motor positioned to drive one axis, but also by using
in-wheel motors to individually drive each wheel of the car. The used microcontroller has to meet strict safety requirements, as not only the driving but also recuperative braking are controlled via this unit. In addition, the PWMs output
signals and sensing inputs have to be controlled, still embedded in the overall safety concept. Like with any other element in the HEV/EV space, isolation is specifically important in the inverter module.
18
Motor Control
The Safe TI Microcontroller TMS570

Key Features ARM Cortex-R4F CPU Up to 160 MHz with floating-point support Dual CPUs in lockstep Memory Flash: 2 MB with ECC protection RAM: 160 KB with ECC protection Roadmap from 768 KB to 4 MB flash Peripheral Highlights FlexRay with 8-KB message RAM Three CAN interfaces Three multibuffered SPIs (MibSPI) Two UARTs both with LIN 2.1 Two 12-bit buffered ADCs (MibADC) Flexible timer module with up to 32 channels Trace and calibration interfaces Packages: 144 QFP, 337 nFBGA (16 x 16mm) www.ti.com/tms570
Preview
The TMS570 microcontroller family enables customers to easily build safetyrelated automotive applications, with up to 160 MHz of floating-point performance and an integrated safety concept. A wide choice of communication peripherals like CAN, FlexRay and LIN, in combination with a powerful timer coprocessor module (HET), makes the family a flexible solution for safety-critical control applications. The TMS570 family is specifically designed to meet IEC61508 SIL3 for safetycritical applications like HEV/EV. A SIL3 certificate and the required documentation are available. A dual CPU lockstep architecture simplifies development while eliminating redundant system requirements to reduce cost. CPU hardware builtin self test (BIST) detects latent defects without complex safety drivers or code size overhead. Hardware comparison of CPU outputs provides exceptional safety response time without additional software overhead. An enhanced ECC logic is integrated in the CPU to protect both memories and buses. All memories can be tested using hardware BIST for high diagnostic coverage, while an integrated memory protection unit (MPU) protects against deterministic errors in application software.
TMS570 Evaluation Kit Available 2Q10 ($695)

Software: Code Composer Studio v4.1 IDE Peripheral drivers with GUI interface Flash programming integrated into Code Composer Studio IDE HET GUI/simulator/assembler with SynaptiCAD WaveViewer Demo project/code examples Hardware: Separate CPU card and I/O card (transceivers/sensor I/F) XDS100 emulator on board Connectors for trace and calibration interfaces
System Solutions for Hybrid and Electric Vehicles Texas Instruments 2Q 2010
Third-party support: Variety of real-time OSs and AutoSAR RTE/MCAL drivers available

Analog Overview
Device Automotive signal chain INA19xA-Q1 INA213A-Q1 INA333 OPA365 TLV3502-Q1 LM2902/4-Q1 LM2901/3-Q1 TL4050yxx-Q1 TMP12x TPS380xx-Q1 TPS54x0-Q1 TPS54362-Q1 TPS54160-Q1 TPS40090-Q1 TLE4275-Q1 UCC2895-Q1 UC2856-Q1 UC2825A-Q1 UC2843-Q1 UCC2813-Q1 TPS40210-Q1 UCC280x-Q1 UCC28220-Q1 UCC2808A-2-Q1 Automotive gate driver TPS2811/2/3 TPS2829-Q1 TPS2816/7/8/9 UCC27200/1-Q1 UCC27323/5-Q1 UCC27423/4/5-Q1 UCC27321/2/4-Q1 Automotive digital isolators ISO721-Q1 ISO7221C-Q1 ISO72401/1-Q1 Automotive CAN interface SN65HVDA1050A-Q1 SN65HVDA1040A-Q1 SN65HVDA540-Q1 SN65HVDA541-Q1 ISO1050 EMC-optimized high-speed CAN transceiver EMC-optimized high-speed CAN transceiver CAN transceiver 5-V to 3.3-V MCU interface CAN transceiver 5-V to 3.3-V MCU interface, wake-up Isolated CAN transceiver Qualified Qualified Preview Preview Preview Single 100-Mbps digital isolator Dual-channel, 25-Mbps digital isolator Quad-channel, 25-Mbps digital isolator Qualified Qualified Preview Dual high-speed MOSFET drivers High-speed MOSFET driver High-speed MOSFET driver with active pullup and internal regulator 120-V boot, 3-A peak, high-frequency, high-side/low-side driver Dual 4-A peak high-speed low-side power MOSFET drivers Dual 4-A high-speed low-side MOSFET drivers with enable Single 9-A peak high-speed low-side power MOSFET drivers Preview Qualified Preview Qualified Qualified Qualified Qualified -16-V to 80-V common-mode-range current shunt monitors Voltage output, bidirectional zero-drift series current shunt monitor Micro-power, zero-drift, rail-to-rail out instrumentation amplifier 2.2-V, 50-MHz, low-noise, single-supply rail-to-rail operational amplifiers 4.5-ns rail-to-rail high-speed comparator Operational amplifier Differential comparator Precision micropower shunt voltage reference 1.5C accurate programmable temperature sensor with SPI interface Supply voltage supervisors 1-A/2-A/3-A/5-A wide-input-range step-down SWIFT converter Low Iq 3-A step-down converter 3.5-V to 60-V, 1.5-A step-down SWIFT converter with Eco-Mode 2-, 3-, or 4-phase programmable synchronous buck controller that is optimized for low-voltage, high-current application 5-V low-dropout voltage regulator BiCMOS advanced phase-shift PWM controller Improved current-mode PWM controller High-speed PWM controller Current-mode PWM controller Low-power BICMOS current-mode PWM Wide-input-range current-mode boost controller Automotive catalog low-power BiCMOS current-mode PWM Dual interleaved PWM controller with programmable max duty cycle Low-power current-mode push-pull PWM Qualified Qualified Preview Preview Qualified Qualified Qualified Qualified Preview Qualified Qualified Qualified Qualified Qualified Qualified Qualified Qualified Qualified Qualified Qualified Qualified Qualified Qualified Qualified Description AEC-Q100 status
19
Automotive power management DC/DC converter, LDO
Automotive power management PWM controller
Texas Instruments offers a wide range of devices specifically fitted for the use in the HEV/EV space. Please check www.ti.com for the latest device announcements.
20
Isolated CAN Transceiver ISO1050

Get samples, datasheets, EVMs and app reports at: www.ti.com/sc/device/ISO1050 Key Features 4,000-VPEAK isolation Failsafe outputs Low loop delay: 150-ns (typical) 50-kV/s (typical) transient immunity meets or exceeds ISO 11898 requirements Bus-fault protection of -27 V to 40 V Dominant timeout function UL 1577, IEC 60747-5-2 (VDE 0884, Rev. 2), IEC 61010-1, IEC 60950-1 and CSA approval pending 3.3-V inputs are 5-V tolerant Typical 25-year life at rated working voltage
Preview
The ISO1050 is a galvanically isolated CAN transceiver that meets or exceeds the specifications of the ISO 11898 standard. The device has logic input and output buffers separated by a silicon oxide (SiO2) insulation barrier that provides galvanic isolation of up to 4,000 VPEAK. Used in conjunction with isolated power supplies, the device prevents noise currents on a data bus or other circuits from entering the local ground and interfering with or damaging sensitive circuitry. As a CAN transceiver, the device provides differential transmit capability to the bus and differential receive capability to a CAN controller at signaling rates up to 1 Mbps. Designed for operation in especially harsh environments, the device features crosswire, overvoltage and loss of ground protection from -27 V to 40 V and over-temperature shutdown, as well as a -12-V to 12-V common-mode range.
Functional diagram
Galvanic Isolation RXD
DUB package VCC1 1 RXD 2 TXD 3 GND1 4

8 7
VCC2
TXD
CANH CANL
CANH 6 CANL 8 GND2
ISO72x Isolation
The problem No endurance existing isolation devices have a life expectancy of only seven to ten years. No high speed or precision existing isolation devices low speed, high skew, high jitter and high pulse distortion. No high temp existing isolation devices cannot operate at 150 Mbps at 125C. Only a few can operate at >100C at any speed. Low EMI immunity existing high-speed isolators are susceptible to EMI interference. The solution The TI integrated SiO2 isolation barrier technology provides the fastest, highest precision, highest temp, high EMI immunity and longest life solution.
OUT

Dual-Channel, 1/1, 25-Mbps Digital Isolator ISO7221Cxx
Get samples, datasheets, EVMs and app reports at: www.ti.com/sc/device/ISO7221Cxx Key Features Qualified for automotive applications 1-Mbps and 25-Mbps signaling rate options Low channel-to-channel output skew 1ns(max) Low pulse-width distortion (PWD) 1ns(max) Low jitter content: 1 ns (typical) at 150 Mbps 25-year (typical) life at rated voltage (see application report SLLA197 and Figure 14) 4,000-VPEAK isolation, 560-VPEAK VIORM UL 1577, IEC 60747-5-2 (VDE 0884, Rev 2), IEC 61010-1, IEC 60950-1 and CSA approved 50-kV/s typical transient immunity Operates with 3.3-V or 5-V supplies 4-kV ESD protection High electromagnetic immunity -40C to 125C operating free-air temperature range The ISO7220 and ISO7221 are dual-channel digital isolators. To facilitate PCB layout, the channels are oriented in the same direction in the ISO7220 and in opposite directions in the ISO7221. These devices have a logic input and output buffer separated by TIs silicon-dioxide (SiO2) isolation barrier, providing galvanic isolation of up to 4,000 V. Used in conjunction with isolated power supplies, these devices block high voltage, isolate grounds, and prevent noise currents on a data bus or other circuits from entering the local ground and interfering with or damaging sensitive circuitry.
21
A binary input signal is conditioned, translated to a balanced signal, then differentiated by the capacitive isolation barrier. Across the isolation barrier, a differential comparator receives the logic transition information, then sets or resets a flip-flop and the output circuit accordingly. A periodic update pulse is sent across the barrier to ensure the proper DC level of the output. If this DC refresh pulse is not received every 4s, the input is assumed to be unpowered or not being actively driven, and the failsafe circuit drives the output to a logic high state. The small capacitance and resulting time constant provide fast operation, with signaling rates available from 0 Mbps (DC) to 25 Mbps. The signaling rate of a line is the number of voltage transitions that are made per second expressed in the units BPS (bits per second). The A-option and C-option devices have TTL input thresholds and a noise filter at the input that prevents transient pulses from being passed to the output of the device.
ISO7220
Isolation
ISO7221
Isolation
VCC1 1 These devices require two supply voltages of 3.3 V, 5 V or any combination. All VCC1 1 8 VCC2 8 VCC2 7 INA 7 OUTA OUTA 2 INA 2 inputs are 5-V tolerant when supplied from a 3.3-V supply and all outputs are 6 OUTB 6 OUTB INB 3 INB 3 4-mA CMOS. 8 GND2 8 GND2 GND1 4 GND1 4
Single-Channel Functional Diagram

DC Channel Galvanic Isolation Barrier FIlter
ISO7220
Isolation
ISO7221
8 7 6 8
INA INB GND1
2 3 4
OUTA OUTB GND2
OUTA INB GND1
Isolation
VCC1
VCC2
VCC1
1 2 3 4
8 7 6 8
VCC2 INA OUTB GND2

IN
OSC + PWM
VREF
Pulse Width Demodulation
Single-Channel Functional Diagram

DC Channel OSC + Device PWM ISO721-Q1
ISO722x-Q1 ISO724x-Q1
Input + Filter
VREF
Data MUX AC Detect Output Buffer
OUT
Galvanic Isolation Barrier FIlter

Insulation Rating (VRMS) 2500 2500 2500 Supply Voltage Pulse Width (V) Demodulation 3.3, 5.0 3.3, 5.0 3.3, 5.0 Data MUX AC Detect Data Rate (Mbps) 100 1, 5, 25 1, 25 ESD (kV) 4 4 4 Operating Temp Range (C) -40 to 125 -40 to 125 -40 to 125 Package 8/SO 8/SO 16/SO Auto Qual (Q1) Y Y Y
Digital Isolator Selection Guide No. of Channels 1 2 4

VREF Channel Configuration
1/0 2/0, 1/1 4/0, 3/1, 2/2

VREF
IN
Input + Filter Texas Instruments 2Q 2010
OUT
Output Buffer
22

Preview
Safety DESAT protection, FAULT indicator, UVLO
ISO55xx Isolated Gate Driver Family (ISO5520/21 Shown)

Functional Diagram VCC1 VIA VIB GND1 MODE0 MODE1 DT GND1
Encoder Decoder
1 2 3 4 5 16 15 14
VDDA VOA GNDA VDDB VOB GNDB
Part No: ISO55xx
Standard Features
High Performance -40 to 125C, tP, LH(max) = 150 ns, PWD(max) = 25 ns ISO5500 Ease of Use Robust Drop in for HCPL 316J Reinforced insulation of 6 KV, high EM immunity, high lifetime Blanking Time Adjust ISO5512 (ULO = 14 V) ISO5513 (UVLO = 9 V)
High Side Low Side

11
Features
Decoder
Encoder
6 7 8
10 9
Separate Nch, Pch OUT
Soft Turn Off Option ISO5511 (UVLO = 9 V)
Isolation Barrier
ISO5501
ISO5510 (UVLO = 14 V)
ISO5520/5521 15-KV/s minimum transient immunity Configurable half-bridge/dual drivers Cross-conduction protection
Programmable dead time control Undervoltage lockout protection ISO5520 VO: 15-30 V, 35 V (max)
ISO5521 VO: 10-30 V, 35 V (max) tpHL: 80-ns typical, Tr/Tf: 50-ns typical IO: 2.5 A (peak)
Isolated ADC (1-Bit, 10-MHz, Second-Order, Isolated Delta-Sigma Modulator) AMC1203 Get samples, datasheets, EVMs and app reports at: www.ti.com/sc/device/AMC1203 Key Features 16-bit resolution SNR: 80.5-dB min THD: -88 dB max (AMC1203B) 280-mV input range with +5-V supply Internal 2.5-V reference voltage: 1% accuracy Gain error: 1% (AMC1203B) UL1577, IEC60747-5-2 (VDE0884, Rev. 2) and IEC61010-1 approved Isolation: 4,000 VPEAK Working voltage: 560 V Transient immunity: 15 kV/s
Preview
The AMC1203 is a 1-bit, 10-MHz, isolated delta-sigma modulator with an output buffer separated from the input interface circuitry by a silicon dioxide (SiO2) isolation barrier. This barrier provides galvanic isolation of up to 4,000 VPEAK. Used in conjunction with isolated power supplies, these devices prevent noise currents on a data bus or other circuits from entering the local ground and interfering with or damaging sensitive circuitry. The AMC1203 modulator operates from a +5-V supply with a dynamic range of 95 dB. The differential inputs are ideal for direct connection to shunt resistors or other low-level signal sources. With the appropriate digital filter and modulator rate, the device can be used to achieve 16-bit analog-to-digital (A/D) conversion with no missing codes. An effective resolution of 14 bits and an SNR of 85 dB (typical) can be maintained with a sinc3 filter that has a decimation ratio of 256. The modulator output is translated to a balanced signal and then transferred by the capacitive isolation barrier. Across the isolation barrier, a differential comparator receives the logic transition information, and then sets or resets a flip-flop and the output circuit accordingly.
Isolation Barrier VIN+ 2nd Order Modulator Interface Circuit VINVREF
Output Buffer
MDAT
POR
BIAS
POR
Buffer
2.5V VREF
20-MHz RC Oscillator
VREF
Output Buffer
MCLK
Charging Infrastructure
Charging Infrastructure Connecting the Car to the Smart Power Grid
NL
23
BR1
PWM AC/DC 10,980.4
System Power
Metrology ISENSE VSENSE
MSP430TM Embedded E-Meter SoC Signal Processor MCU, RTC, LCD

Home Area Network (HAN) Wireless Communication
Application Processor
Antenna
RF Front End
Application Processor Stellaris Cortex MS/ MSP430

Wide Area Network Power Line Communication Modem (PLC)
CC25xx 802.15.4 SoC Radio, MCU
Wireless Communication (858-/900-MHz ISM)
TX RX
PWM ADC
TMS320F28xx Flexible, 32-Bit PLC Controller
CC11xx/CC430 ISM-Band SoC Radio, MCU
Antenna
Matching Circuit
Interface Options
Wired Interface (RS485)
Enfora GSM/GPRS Module
Pre-Payment RFID (Wireless)
Legend Processor Interface Power Amplier
The charging infrastructure connects the car to the smart power grid. The cost for the individual charging spot has to be balanced with the additional expansion capabilities on the communication side. The obvious choice for communication is a wired system via the charging cable, where power line communication is a widely used method. In that area several activities for standardization are ongoing at the utilities side.
Texas Instruments is actively involved in this area and offers and develops solutions for SFSK and narrowband OFDM systems for the CENELEC A and B band, with OFDM standards like PRIME/G3. We are also investigating HomePlug GreenPhy. The TMS320F28x microcontroller family is a flexible platform meeting these standards, with reference designs available.
Other options like RF communication using ZigBee or ISM band solutions are available. For customer identification and prepayment options at the charging spot, RFID systems are available. The metering function for single-phase up to complex three-phase solutions can be realized with single-chip solutions out of the MSP430 MCU family. For more information, see www.ti.com/metering.
24
Charging Infrastructure
PLC Kit Using the TMS320F28335
HV Cap
Coupling Transformer
TMS320F28x
Line Driver + + PWM Out Flexible PLC SW Engine
Surge Protector
12-bit ADC
Receive Filter Power Line
The PLC kit for the TMS320F28x offers a complete evaluation system: PRIME/narrowband OFDM PHY (IEC/SFSK PLC band A/B available) Digital baseband algorithms implemented in TI F28x microcontroller are fully automotive- qualified and support on-chip CAN Analog filters, line driver and variable gain amp implemented on daughtercard Flexible, low-cost solution to support standard evolutions
Field and lab tested for robustness in harsh operating environments Software comes within the TI plcSUITE with API and documentation supporting PRIME PHY/MAC and convergence layer To order the reference design PLC kit, send an e-mail to metering@ti.com
ZigBee RF Using the CC2530 System-on-Chip

memory sizes allow for on-chip, overthe-air-download to support in-system reprogramming. Additionally, the CC2530 combines a fully integrated, high-performance RF transceiver with an 8051 MCU, 8-KB of RAM, 32-/64-/128-/256-KB of flash memory and other powerful supporting features and peripherals. For more information, see www.ti.com/zigbee.
TIs new CC2530 is a true system-onchip solution tailored for IEEE 802.15.4, ZigBee, ZigBee RF4CE and smart energy applications. With its large flash memory of up to 256 KB, the CC2530 is ideal for ZigBee Pro applications. The 64-KB and up versions support the new RemoTI network protocol stack for ZigBee RF4CE, which is the industrys first ZigBee RF4CEcompliant protocol stack. Larger
E-Bike, Scooter and Small Task-Oriented Vehicles (STOVs)

E-Bike, Scooter and Small Task-Oriented Vehicles
Optional
25
Backlight Clock GPIO

Brake SDRAM
LCD
Speedometer Battery Status
Relay Drivers Temperature Sensor
Horn Brake Light / Headlight Directionals
Controller
Throttle
Shunt Signal Conditioning and Comparators
Optional Isolation Gate Drivers
Pedal Rotation
System Power
Core and I/O Power

Optional
Sensor Control
Motor Power (from Battery)
Plug
AC/DC Converter with Green Mode Controller Temperature Sensor
Battery Charger
Fuel Gauge
Battery Protection Battery Management
AC Line
Electric transportation is not only relevant for cars, but already used in many millions of simple task-oriented vehicles around the world. The systems are more basic compared to those on the hybrid and electric car side, but consist of the same functional blocks.
For motor control, the Piccolo MCU family is a good choice, offering the combination of a powerful CPU engine with the required PWM and ADC capabilities for the control loop at an economical price point. The battery systems are typically operating at lower
voltages with less cells, so integrated solutions like the bq77PL900 managing and protecting as many as 10 cells are a good fit.
26
Integrated Gas Gauge, Protection and Active Cell Balancing bq78PL114

Get samples, datasheets, EVMs and app reports at: www.ti.com/sc/device/bq78PL114
RPRE
+
Key Features Three- to 12-series cell systems PowerPump technology cell balancing for longer run time and cell life Supports discharge current levels of 10 A, 35 A and 110 A Gauges 65-650 Ahr capacity batteries High resolution 18-bit integrating delta- sigma Coulomb counter for precise charge-flow measurements and gas gauging Multiple independent delta-sigma A/Ds: one-per-cell voltage, plus separate temperature, current and safety Fully programmable voltage, current, balance and temperature protection Remaining capacity indicators: LCD, LED, EPD
PACK+
Level Shift Circuits

Cell-Balancing Circuits
CHG
DSG
bq76PL102
SD02 SO13 P-LAN
bq76PL102
SDO0 VLD01 RSTN SPROT
V4
PRE SD11
bq78PL114
V2 V1
CCPACK
TAB VSS CBBAT CCBAT
CRA
CSPACK
Temperature Sensor (typ.)
XT
SPI-CLK SPI-DO SPI-DI SELECT SMBCLK SMBDAT
ESD Protection
V3 VLDO2
GPIO EFCID EFCID
6 Aux FET Control SPI SMBus
RSENSE
PACK
Standalone and Host-Controlled Battery Protection bq77PL900

Get samples, datasheets, EVMs and app reports at: www.ti.com/sc/device/bq77PL900 Key Features Five-, six-, seven-, eight-, nine- or 10-series cell primary protection PMOS FET drive for charge and discharge FETs Capable of operation with 1-m sense resistor Supply voltage range from 7 V to 50 V Low supply current of 450 A typical Integrated 5-V, 25-mA LDO Standalone mode Pack protection control and recovery Individual cell monitoring Integrated cell balancing Programmable threshold and delay time for: Overvoltage Undervoltage Overcurrent in discharge Short circuit in discharge Fixed overtemperature protection Host control mode I2C interface to host Fuse controller Charge bq77PL900 Pack + Analog interface for host cell measure- PCH FET Drive ment and system LDO, Thermal Output Drive charge/discharge current Overvoltage/ Host-controlled Undervoltage Protection protection recovery Host-controlled cell Cell-Balance Drive balancing
Serial Interface RAM Registers Overload Protection Short-Circuit Protection Pack Sense Resistor
Discharge

Digital Motor Control for E-bikes, Scooters and STOVs
The C2000 DSP platform of realtime controllers has been the industry leader in digital motor control since the inception of the TMS320F24x generation in 1996. In 2002 we debuted the F281x series, based on the C28x DSP engine, becoming the first 32-bit architecture specifically built for high-performance, mathintensive power electronics control. Based on the C28x DSP, we have created a family of code-compatible
27
devices to meet application needs across performance, price, pin-out and peripherals. To find out more, visit: www.ti.com/c2000dmc.
Piccolo MCU-based power factor correction (PFC) and motor control integrated into one development platform Support for three brushless motor types, AC induction, permanent magnet Synchronous motor, brushless DC motor 1-kW motor driver stage accepting up to 400 V 700-W PFC stage (line-level AC input ~110 to ~240 VAC)
Open-source software for power factor correction stage Open-source software for control of all three motor types Open-source hardware, including schematics, BOM and gerber files Motors of each type available separately directly from TI Available for $599 Order part number: TMDSHVMTRPFCKIT
controlSuite for C2000 microcontrollers is a cohesive set of infrastructure and software tools designed to minimize software development time. From device-specific drivers and support software to complete system examples in sophisticated system applications, controlSuite software provides libraries and examples at every stage of development and evaluation. controlSuite software contains a full digital motor control library as well as motor control kits. To find out more, visit: www.ti.com/controlsuite.
One stop for all C2000 software: Single, centralized location Intelligent installer eliminates the search for dependencies Open, real-world systems: Compilation of 15 years of systems and applications expertise Unique, optimized libraries for math, filtering, DSP and specific applications, with complete system examples utilizing incremental builds
Allows developers to focus on differentiation, not basics Program the MCU your way: Significantly reduce development time with hardware abstraction and extensive libraries Four interusable levels of hardware abstraction
controlSuite Support for Motor Control
Device Support
Bit Fields API Drivers Examples
Library Repository
Math Library DSP Library Application Library Utilities
Device Support
Hardware Package Software Examples Complete System Frameworks Graphical User Interfaces
Device Support
IDE
Motor ACI
Technique FOC FOC Trapezoidal Trapezoidal Sinusoidal Sinusoidal FOC FOC FOC Microstep DirectDrive
Type Speed and Torque Speed and Torque Speed Speed Speed Speed Speed and Torque Position Speed and Torque Position Speed and Position
Feedback Tachometer Sensorless Half Effect Sensorless Half Effect Sensorless Encoder Encoder Sensorless Sensorless Encoder
BLDC
RTOS
PMSM
Emulation
Stepper Brushed
Systems included or planned
controlSuite Software
High-Voltage PFC and Motor Control Developers Kit
TI Worldwide Technical Support

Internet
TI Semiconductor Product Information Center Home Page Asia
support.ti.com e2e.ti.com
Americas Brazil Mexico

TI E2E Community Home Page
Product Information Centers

Phone Phone Phone Fax Internet/Email +1(972) 644-5580 0800-891-2616 0800-670-7544 +1(972) 927-6377 support.ti.com/sc/pic/americas.htm
Phone European Free Call 00800-ASK-TEXAS (00800 275 83927) International +49 (0) 8161 80 2121 Russian Support +7 (4) 95 98 10 701 Note: The European Free Call (Toll Free) number is not active in all ountries. c If you have technical difficulty calling the free call number, please use the i nternational number above. Fax +(49) (0) 8161 80 2045 Internet support.ti.com/sc/pic/euro.htm
Europe, Middle East and Africa
Phone International +91-80-41381665 Domestic Toll-Free Number Australia 1-800-999-084 China 800-820-8682 Hong Kong 800-96-5941 India 1-800-425-7888 Indonesia 001-803-8861-1006 Korea 080-551-2804 Malaysia 1-800-80-3973 New Zealand 0800-446-934 Philippines 1-800-765-7404 Singapore 800-886-1028 Taiwan 0800-006800 Thailand 001-800-886-0010 Fax +886-2-2378-6808 E-mail t iasia@ti.com ti-china@ti.com Internet support.ti.com/sc/pic/asia.htm Important Notice: The products and services of Texas Instruments Incorporated and its subsidiaries described herein are sold subject to TIs standard terms and conditions of sale. Customers are advised to obtain the most current and complete information about TI products and services before placing orders. TI assumes no liability for applications assistance, customers applications or product designs, software performance, or infringement of patents. The publication of information regarding any other companys products or services does not constitute TIs approval, warranty or endorsement thereof. B121709 The platform bar, C2000, C28x, Code Composer Studio, controlCARD, controlSuite, MSP430, Predictive Gate Drive, Piccolo, PowerPump, PowerTrain, RemoTI, Stellaris and SWIFT are trademarks of Texas Instruments. All other trademarks are the property of their respective owners.
Japan
Phone Fax Internet/E-mail Domestic International Domestic International Domestic 0120-92-3326 +81-3-3344-5317 0120-81-0036 support.ti.com/sc/pic/japan.htm www.tij.co.jp/pic
2010 Texas Instruments Incorporated Printed in U.S.A. by (Printer, City, State)
PRSRT STD U.S. POSTAGE
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System Solutions For Hybrid and Electric Vehicles

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System Solutions For Hybrid and Electric Vehicles

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