If your mains frequency is 50Hz then I'd guess that your problem lies
with the PFC / DC filter, like not enough filter C or a loop that can't
fully follow / suppress the line-bridge ripple before it overwhelms
the filtering you've got.
Check out some mid-points in the conversion lineup and maybe you
will find the culprit / soft spot.
Single phase PFC generates 100 Hz ripple by nature. To isolate it from load current, you need 1. sufficient DC link capacitance 2. a certain voltage regulation capability of the LLC.
Single phase PFC generates 100 Hz ripple by nature. To isolate it from load current, you need 1. sufficient DC link capacitance 2. a certain voltage regulation capability of the LLC.
I feel that it is PCB line interference. Please eliminate the issues of whether the ground wire of the control part, the ground wire of the power part, the current sampling point, the voltage sampling point, and the signal line pass by the strong interference source.
It would be helpful to see circuit schematic with DC link capacitor values.
A single phase PFC controller suppresses 100 Hz ripple in no way. Question is if the LLC stage has voltage/current regulating capabilities and if the LLC controller makes use of it to achieve a clean output.
Ripple current into a good quality battery can be high because the battery is very sensitive to volt ripple given its impedance at 100Hz is very low, i.e 10mV of ripple and 2 m-ohm battery Z = 5A ripple
this is why the PFC must have low ripple ( a lot of capacitance ) and the gain of the feed back loop on the LLC at 100Hz must be very high . .. basic physics and power electronics
yes...it would be interesting for you to see the battery datasheet, and see if that current ripple is actually damaging to the battery.
I too apart one offline 6kW charger and it had no electrolytic caps, or other big caps...so it was obviously giving high ripple current to the battery...presumably it didnt matter.
battery don't care for charging only - however interestingly - Li-Fe-PO4 has a noticeable heating effect if charged by substantial 100Hz current - this is noted in papers and confirmed in our lab.