Analysis of Taigao Technology 84W Electric Bicycle Charger Solution (RS5M SMC/YFW Youfeng Micro)

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Preface

Taigao Technology has launched two cost-effective solutions for electric bicycle lithium battery chargers. One of them is a 10
string lithium battery charger with an input voltage of 100-240Vac, an output voltage of 42Vdc, an output current of 2A, and
an output power of 84W. This charger adopts a flyback architecture and uses Taigao Technology's gallium nitride devices.

By using gallium nitride devices, this charger has a volume that is 2/3 of the traditional solution, with an efficiency 4% higher
than the traditional solution. At 230VAC input, the conversion efficiency is as high as 92.5%, and it has the ultimate cost
advantage. Perform EMI testing based on EN55032 class B standard, with a margin of over 6dB. The charging head network
has already obtained this charger solution. This article brings an analysis of the 84W charger solution, let's take a look at the
materials and design of this solution together.

Appearance of Taigao Technology 84W Electric Bicycle Charger Solution

The Taigao Technology 84W electric bicycle charger is equipped with heat sinks on both sides for cooling the rectifier bridge and rectifier tube.

Stick tape insulation at the position of the heat sink corresponding to the high-voltage filter capacitor.

The back of the PCBA module is equipped with components such as the main control chip, gallium nitride switch tube, surface mount Y capacitor, feedback optocoupler, operational amplifier, and output current sensing resistor.

The heat sink is insulated with adhesive tape on the low-voltage side.

The charger input terminal is equipped with an eight wire socket.

The length of the PCBA module measured using a vernier caliper is approximately 117.5mm.

The width of the PCBA module is approximately 42.4mm.

The thickness of the PCBA module is approximately 25.7mm.

The measured weight of the PCBA module is approximately 150g.

Analysis of Taigao Technology's 84W Electric Bicycle Charger Solution

After watching the appearance display of Taigao Technology's 84W electric bicycle charger solution, let's analyze the materials and design of this solution.

The input fuse comes from Bet Electronics, with a discharge number of 932 and a specification of 3.15A 250V.

NTC thermistors are used to suppress surge currents when chargers are plugged in.

The 10D471K varistor is used for surge overvoltage protection.

The safety regulation X2 capacitor comes from SCC All Electronic, with a specification of 0.68 μF.

The first level common mode inductor is wound with insulated wire and enameled wire.

The second level common mode inductor is wound with enameled wire.

The rectifier bridge comes from SEP Weiwang, model GBU810, specification 1000V 8A, and adopts GBU packaging.

The high-voltage filtering capacitor comes from HOWLET Zhongyu Technology, with a specification of 400V120 μF.

The primary control chip is silk screened with 6891 and supports direct drive enhanced gallium nitride switch tubes, packaged in SOT23-6.

The switch tube adopts TaiGao Technology TG65180S, which is an enhanced gallium nitride power device with a withstand voltage of 650V and a conductivity of 180m Ω. All pins of the device are equipped with ESD protection, and the switching speed can be adjusted through a resistor connected in series with the gate. The device has reverse conduction capability, no reverse conduction loss, and high-frequency switching capability.

The TG65180S from Taigao Technology uses low-voltage insulated heat dissipation pads connected through current sampling resistors, providing better heat dissipation performance. Supports totem pole PFC, half bridge/full bridge LLC applications, mobile fast charging, laptop power supply, LED lighting power supply, motor drive, server and inverter applications. The device is packaged in 5 * 7 * 0.8mm QFN to save board area.

The diode used for RCD absorption circuit is from YFW Yufeng Micro, model RS5M, a fast recovery diode with a specification of 1000V 5A, and packaged in SMC. YFW Youfeng Micro Brand

Yufeng Microelectronics "is a high-tech enterprise specializing in the research and development, production, and sales of semiconductor discrete devices. The company mainly produces and sells: ordinary rectifier diodes, fast recovery diodes, high-efficiency diodes, ultrafast recovery diodes, Schottky diodes, low voltage drop Schottky diodes, silicon carbide diodes, rectifier bridge stacks, fast recovery rectifier bridge stacks, Schottky bridge stacks, TVS transient suppression diodes, ESD electrostatic protection components, voltage regulators, transistors, thyristors, MOSFETs, and so on. For more details, please visit our official website www.yfwdiode.com.