Transcript Document

Designing a 90% efficiency 150W power supply with
PFC in hours
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
1
Next 2.5 hours
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•
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2:30 – 2:45
2:45 – 3:15
3:00 – 3:15
3:15 – 3:45
3:45 – 4:00
4:00 – 4:45
4:45 – 5:00
Old vs New
Active Diode & IC
EMI Cancellation & IC
Design Methodology – How we trained?
Tea Break
Designed by PowerEsim – New design procedure
Q&A
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
2
Old
VS
New
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
3
Old engineer vs Young engineer
20 years ago . . . .
20 years old . . . .
“
“
For a MOSFET
For a MOSFET
Conduction loss = 1/3
Conduction loss = 2/3
Switching loss = 2/3
Switching loss = 1/3
”
”
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
4
Old MOSFET VS Young MOSFET
47 ns vs 5 ns, 10 times different
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
5
Where is the ZVS ?
Adaptor – A efficiency demanding
product.
How many of them
are using ZVS
circuit?
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
6
Where is the ZVS ?
Active Clamp  2 Switch Forward
Full Bridge  Phase Shift Bridge
Asym. Half-Bridge  Half-Bridge
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
7
Where is the losses?
Example :
12V@4A
82%
10W loss
30 %
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
10 %
15 %
25 %
www.powerEsim.com
8
Where money can buy
•
•
•
Pay for ZVS
Pay for lower Rds
Pay for lower tr, tf . .
10 %
• After all, it is only 10%
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
9
Where money can’t buy
Copper Loss
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
Copper &
Ferrite
Band Gap Loss
www.powerEsim.com
10
Why not use less copper?
• Active EMI
Filter
• WT6001
Y-Cap
Booster
• Next
section
Old
New
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
11
Why not of not using diode?
Old
•
•
•
•
STPS20H100
0.6V @ 2*7A 100 deg
TO200 package
USD ?? / pcs
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
New
•
•
•
•
IRF540Z 22m Ohm
0.54V @ 14A 100 deg
TO200 package
USD ?? / pcs
www.powerEsim.com
12
If TO220 has the same price . . .
• Active
Diode
• WT6002
active
diode IC
•
•
•
•
STPS20H100
0.6V @ 2*7A 100 deg
TO200 package
USD ?? / pcs
• Next
section
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
•
•
•
•
IPP05CN10 5m Ohm
0.08V @ 14A 100 deg
TO200 package
USD ?? / pcs
www.powerEsim.com
13
Transformer design calculation
• After all those mathematics,
how will it perform ?
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
14
Mathematics for the loss
• Do you calculate it every time
on your design stage?
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
15
What exactly you are doing?
Do=?
Np = ?
Co=?
Wire =?
Ns = ?
Wire=?
M1=?
• Just simple fill in
the blank
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
16
Transformer – core and wire only
• PowerEsim – It is not giving parameters for
play with design, It is a tool to build the
design.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
17
98% VS 99% - not 1% different
• 98% efficiency
• 2% loss
• 30W loss
• 99% efficiency
• 1% loss
• 15W loss
• Efficiency is not just a figure, it does matter.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
18
98% VS 99% - 200% different
• 98% efficiency
• 2% loss
• 150W converter
• 99% efficiency
• 1% loss
• 300W converter
• Selling price double by 1% losses cut
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
19
What is all about
• Active Diode vs Diode – almost same cost.
• EMI IC vs filter – greatly improve efficiency.
• PowerEsim vs Paper design – no cost.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
20
Active Diode
&
EMI IC
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
21
EMI solutions: Passive filter
 Conventional EMI solutions depend on passive filter using
inductors and capacitors:
 Inductors: CMC, DMC
 Capacitors: X-cap, Y-cap
 There are limitations when using passive filters:
 Inductors: Large size and high conduction loss
 Capacitors: leakage current specifications
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
22
Active EMI cancellation IC WT6001:
An effective EMI solution – Y-cap booster
WT6001
 A patented technology developed in PowerELab.
 An SO-8 IC WT6001 developed with W2.
 Equivalent to a Y-cap with very large value within the EMI concerned
frequency range only.
 No boosting effect in the leakage current test concerned frequency
range (50 – 800Hz).
 Greatly reduce the common mode inductor size and requirements.
 Reduce converter size and improve conversion efficiency.
 Provide effective and efficient EMI solution.
 Built-in electrical surge protection which can easily pass the EN610004-4 and EN61000-4-5 immunity standard.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
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Applications: Replace passive Y-cap
Replaced by Y-cap booster
LISN
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
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Effect measurable by oscilloscope when using Ycap booster
Noise voltage across Y-cap in
switching converter
Noise voltage across Y-cap booster
in switching converter
More application examples can be found in the datasheet of WT6001
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
25
Practical application examples
 The original EMI filter design cannot pass the EN55022 class B limit.
 Filter component:
 2 x 20mm high mu toroid for common mode filters
 2 x 0.15uF X – cap
 1 x 1n Y1-cap connected between primary and secondary
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
26
Practical application examples:
Original filter schematic
P1
TH1
L1B
F1
L2B
4
3
4
3
1
2
C2
1
2
1
C1
P2
1
• It is a commonly used filter configuration
• L2B is wound with many turns which intends to suppress the low to
mid-frequency common mode noise. Its leakage inductance together
with C1 also provides differential mode noise filtering
• L1B is a single layer, bi-filer wound common mode choke for high
frequency common mode noise filtering
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
27
Practical application examples:
EMI measurement
DM noise
dBuV
80
Y-cap: From 1n to 3n3
Improved but not enough
dBuV
CM noise
80
70
70
230V pri-sec Y1n U shielded original
230V pri-sec Y3n3 U shielded original
60
60
EN 55022; Class B Conducted, Quasi-Peak
50
40
40
30
30
20
20
10
10
0
EN 55022; Class B Conducted, Average
0
1
10/3/200510:55:40
EN 55022; Class B Conducted, Quasi-Peak
50
EN 55022; Class B Conducted, Average
10
(Start = 0.15, Stop= 30.00) MHz
1
10/3/200516:08:11
10
(Start = 0.15, Stop= 30.00) MHz
Failure was identified to be caused by:
• Insufficient leakage inductance of the common mode choke for DM noise
attenuation.
• The two common mode choke cannot effectively block out the common mode
current.
• Further increase of Y-cap can reduce CM noise but fail to meet leakage
current specifications.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
28
Practical application examples:
Solution using Y-cap booster
dBuV
80
70
60
50
EN 55022; Class B Conducted, Quasi-Peak
230V CB U shield SDMC SCMC .33uF
EN 55022; Class B Conducted, Average
40
30
20
10
0
1
10/3/200516:39:55
10
(Start = 0.15, Stop= 30.00) MHz
 Y-cap booster is used to replace the primary to secondary Y-cap
 After using the Y-cap booster, L2B is replaced by a small differential
mode filter and L1B is reduced to a 9mm toroid with only a few turns
to tackle the high frequency common node noise. The test results pass
the required limit lines
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
29
Practical application examples:
Filter comparison: Before and After...
Failed design even with more
cost, loss and bigger size for the
filter
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
Passed design using Y-cap booster
with much smaller filter size that
saves cost, power and space
www.powerEsim.com
30
Another practical application examples:
Filter comparison: Before and After...
Original EMI solution using passive filter
in ATX converter
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
New EMI solution using Y-cap booster
in ATX converter
www.powerEsim.com
31
Conclusion
 Y-cap booster breaks the relationship between the Y-cap values and
leakage current requirement.
 Greatly reduce product design period and resources.
 It can be applied to any position with conventional Y-cap.
 Significantly reduce the size and loss of common mode choke implies
higher power density and efficiency.
 EMI less sensitive to transformer winding capacitance implies more
rooms for improving transformer coupling.
 Very suitable for equipment required low leakage current like medical
equipment.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
32
Active Diode – An easy to use and high efficiency rectifier
suitable for all converters
Stringent requirements of nowadays converters:





Compact size
Low heat generation and high conversion efficiency
High output power and output current
Low cost
………!!!
Conventional technologies cannot meet the requirements!!
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
33
Synchronous rectifier
 Use MOSFETs to replace diode rectifiers.
0.24 V
K
9 m
A
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
K
7.8 m
A
www.powerEsim.com
34
Synchronous rectifier
 Provides low conduction loss.
 Can operate at higher high current without heatsink.
SCK 2.8W losses @ 10A
3
2.5
W
2
1.5
1
MOSFET 0.7W losses @ 10A
0.5
0
0
2
6
4
8
10
A
STPS30L30
SO8 Active Diode
Losses comparison between SCK and AD
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
35
Synchronous rectifier
 Usage not limited to converters with high profit margin.
 Price of nowadays low RDSon MOSFETs comparable to
schottky diodes using the state of the art technology.
 Provide even lower converter cost because of reduced
heatsink, more output power, higher conversion efficiency…..
 Emerge in low cost converter like adaptors, standard open
frame converters, ATX …… .
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
36
Synchronous rectifier
AD
AD
 Problematic for some conventional topologies
 Special and sometimes complicated driving circuits SR
are needed for different topologies
 Performance sensitive to transformer leakage
inductance and operating conditions
 Converter cannot be paralleled – Reverse current
 Poor efficiency at low load
 Simple circuit
 Discontinuous mode is allowed
 Good low load efficiency
 Converter can be paralleled
 High conversion efficiency
 Works just like a diode
 Limited input voltage range
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
37
Active diode – Operating principle
A
K
A1
N1
N2
N3
D1
N4
D2





N1 is the current sense winding
N2 provides MOSFET driving signals
A1 driver circuit (IC WT6002)
N1 N3 & D1 form energy recovery circuit
N4 & D2 form reset circuit
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
38
Active diode – Operating principle
Voltage across winding N2 or
gate drive voltage Von of SR
depends on ratio of N2 to N3
and voltage Vo
Toff
N
Von  Vo 2
N3
A
K
Ii
Von
VN2
A1
N1
Voltage source Vo
can be any voltage
source in a converter,
e.g. output voltage
Vo
N2
VN3
Vo
N3
D1
VN4
N4
D2
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
39
Application of Active Diode in different topologies
Lf
+
+
+
Co
Vo
+
Vin
-
S
-
Freewheel
SR
Magnetic
Reset
Vin
Flyback SR
Co Vo
-
S
Forward SR
-
Flyback
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
Forward
www.powerEsim.com
40
Application of Active Diode in different topologies
Lf1
Lf
+
S1
C1
SR1
Vin
-
S2
C2
+
Co Vo
-
SR2
Half Bridge centre tap
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
+
S1
C1
S2
C2
SR1
Co
Vin
+
Vo -
SR2
Lf2
Current Doubler
www.powerEsim.com
41
Application of Active Diode in different topologies
SR1
Co
+
Vo
-
ISIN
SR2
and many others….
Resonant converter
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
42
Successful application of Active Diode in
converter products
AD on 150W ACDC
AD on 50W ACDC
AD on 120W ACDC
AD on 300W ACDC
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
AD on 1.5 V 200 A ACDC
AD on 60W ACDC
AD on 100W DCDC
www.powerEsim.com
43
Conclusion
 A new “Active Diode” technology is presented.
 A kind of current driven synchronous rectifier technology that
provides high conversion efficiency and eliminates many
conventional synchronous rectifier application problems.
 Patented technologies.
 An Active Diode driver IC WT6002 for easy implementation of the
technology.
 Well proven by many converter product design.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
44
References
•
Liu, J.C.P.; Poon, F.N.K.; Xuefei Xie; Pong, M.H.; current driven synchronous rectifier with energy recovery sensor Power
Electronics and Motion Control Conference, 2000. Proceedings. PIEMC 2000. The Third International , Volume: 1 , 2000, page(s):
375 -380 vol.1
•
Xuefei Xie; Liu, J.C.P.L.; Poon, F.N.K.; Man Hay Pong; Current-driven synchronous rectification technique for flyback
topology, Power Electronics Specialists Conference, 2001. PESC. 2001 IEEE 32nd Annual , Volume: 1 , 2001, Page(s): 345 350 vol. 1
•
Xuefei Xie; Liu, J.C.P.; Poon, F.N.K.; Man Hay Pong; A novel high frequency current-driven synchronous rectifier for low
voltage high current applications, Applied Power Electronics Conference and Exposition, 2001. APEC 2001. Sixteenth Annual
IEEE , Volume: 1 , 2001, Page(s): 469 -475 vol.1
•
Liu, J.C.P.; Xuefei Xie; Poon, F.N.K.; Pong, B.M.H.; Practical solutions to the design of current-driven synchronous rectifier
with energy recovery from current sensing, Applied Power Electronics Conference and Exposition, 2002. APEC 2002.
Seventeenth Annual IEEE , Volume: 2 , 2002, Page(s): 878 -884 vol.2
•
Xuefei Xie; Joe Chui Pong Liu; Poon, F.N.K.; Man Hay Pong; A novel high frequency current-driven synchronous rectifier
applicable to most switching topologies, Power Electronics, IEEE Transactions on , Volume: 16 Issue: 5 , Sep 2001, Page(s):
635 -648
•
Xie Xuefei; Liu, J.C.P.; Poon, F.N.K.; Pong, B.M.H.; Two methods to drive synchronous rectifiers during dead time in
forward topologies, Applied Power Electronics Conference and Exposition, 2000. APEC 2000. Fifteenth Annual IEEE , Volume:
2 , 2000, Page(s): 993 -999 vol.2
•
US patent "Current driven synchronous rectifier with energy recovery" patent number 6,134,131
•
US patent “Self-driven synchronous rectifier by retention of gate charge” patent number 6,377,477
•
US patent “Current driven synchronous rectifier with energy recovery using hysterisis driver”, patent number 6,597,587
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
45
We are trained to
fill in a value
NOT
design a circuit
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
46
Fill in values by experience . . .
Vi=100
Vo=12
Vo=Vi*D*Ns / (1-D)*Np
Vi+Vo*Np/Ns=0.8Vds_max
Vo=Ns*0.3*fs/(1-D)
0.5*Vo_ripple=Q/Co
Vds_max_M1=lowerest cost in stock
Ids_max_M1=lowerest cost in stock
IF_max_Do=2*Io
VR_max_Do=1.2*(Vi*Ns/Np+Vo)
Core_T1=recommended table from ferrite manufacturer
Wire_Np=fully filled
Wire_Ns=fully filled
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
47
Then again . . .
• Replace 100pcs of components at bench
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
48
Fine, but no need to replace at the bench . . .
• Why not replace 100pcs of components at
PowerEsim
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
49
www.powerEsim.com
• It’s on-line
• It’s for everyone
• Worldwide access
• 100% server side
simulation
• It’s free
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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Build virtual and real converter
PFC
Developed
under
Infineon
TDA4863
Evaluation
Design
DC-DC
Developed
under
Infineon
ICE3DS01
Evaluation
Design
150W 90% LCD Converter
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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51
160 W PFC – simulation vs measurement
Input Votlage Vs Efficiency %
100.00
90.00
80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
Measured
85
110
230
265
160W PFC Input Voltage Vac
PowerEsim
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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52
150 W Flyback – simulated vs measured
I/P Votlage Vs Efficiency %
100.00
90.00
80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
Measured
300
350
405
150W flybackInput Votlage Vdc
PowerEsim
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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53
Loss and Temp.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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54
Component Based Approach
Real components
• Find MOSFET
Abstract Concept
Rds*Crss
• Find Diode
Vf*trrm
• Find Capacitor
CV
• Find Core
k1, k2, k3
• Find Wire
Current density
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
55
PowerEsim vs Traditional Design
PowerEsim turn design into
result oriented adaptive iteration
instead of
skill of knowledge application
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
56
But first . . .
• Find a circuit that has closest specification to
your need, e.g. 160W TDA4863 for PFC front
end.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
57
Ask our expert
• Enter the input &
output specification
• Chose an application
• Click “Recommend
Design”
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
www.powerEsim.com
58
How our expert system work.
Specification
Search for closest
evaluation design
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
Search for best
topologies
www.powerEsim.com
59
If you like more freedom
• Click “Topologies”
• Chose the topology you like
• Enter the input & output specification
Designing a 90% efficiency 150W power supply with PFC in hours
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PowerELab Limited
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Re-define specification
• Click “Detail Spec.”
• Change specification
as you like
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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61
Click the main MOSFET
Designing a 90% efficiency 150W power supply with PFC in hours
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PowerELab Limited
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How we model component?
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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63
Click, click, click and select
• A particular one – total &
individual loss
• Highlighted one – total,
individual loss and stress
• Selected one – total
individual loss and stress
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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64
Other than loss, Stress is important
Designing a 90% efficiency 150W power supply with PFC in hours
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PowerELab Limited
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More clever method – Smart Optimizer
Click “Select All”
All MOSFET will
dump into a
optimizer pool
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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Smart Optimizer – just a click
• Enter
maximum
iterations
• Wait a few seconds
• Click
“Smart
Optimizer”
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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67
Multi dimensional optimization
1
10 resistor
2
10 MOSFET
x
:
10
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
x
:
x
10 diode
= 1010 combination
= 31 years simulation
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68
Smart Optimizer – how it work
Data set
SPD07N60C3
Smart Scan
BU60
SPN04N60C2
SPB07N60S5
IPP50R520CP
Genetic Algorithm
Search for good component
BU60
SPD07N60C3
SPN04N60C2
SPB07N60S5
IPP50R520CP
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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Sorted one by one
• Result will be ranked
• Click to view each result
• Optimized Component will be
shown
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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Now Active Diode
• Click the diode you
like to replace by
Active Diode or
Sync Rect.
• In the Component
Finder, change it’s
“Rectifier Type” to
Active Diode
Designing a 90% efficiency 150W power supply with PFC in hours
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PowerELab Limited
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Search more MOSFET
• Extend to higher
current range is
usually needed
• Extend the body
diode’s trrm can
find more MOSFET
Designing a 90% efficiency 150W power supply with PFC in hours
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PowerELab Limited
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Select a better Sync Rect.
• 0.5W Active
Diode loss
• 2.54W
SCK loss
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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Which component is more critical?
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
•
Why M1, D3 &
T1
•
Loss Analysis
– the most
useful page
•
It rank the loss
and it’s details
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74
Follow the step
• Follow the tips from the header is a good practice.
• Just click the box, it will redirect you to other tools
• Go through each box step by step
Designing a 90% efficiency 150W power supply with PFC in hours
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PowerELab Limited
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Click T1 and go to Magnetic Builder
Designing a 90% efficiency 150W power supply with PFC in hours
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PowerELab Limited
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Step 1 – select the core you like
•
Chose the range of Ae
•
Select Core shape
•
Select Manufacturer
Designing a 90% efficiency 150W power supply with PFC in hours
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PowerELab Limited
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Instant preview winding when thing change
•
Click the “preview winding”
•
Corresponding winding cross section will be
shown
•
Supported on Core, N and Wire.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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78
Step 2 – find the best Lm
•
Click the “Inductance” button
•
Enter the range of inductance
•
Highlight each in the list, select according to
total loss and stress.
•
Double check OCP is not be triggered.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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79
Step 3 – find the best N0
•
Click the “Number of turn” button
•
Enter the range of turn
•
Highlight each in the list, select according to
total loss and stress.
•
Double check OCP is not be triggered.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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Don’t forget preview winding
•
Click the “Preview Winding” button
•
Observe how winding structure change with
number of turn.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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81
Step 4 – need more copper?
•
•
•
Click the “Change Wire” button
Click the “No. of Parallel Wire”
Add more parallel wire as you like.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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160 W PFC – simulation vs measurement
Input Votlage Vs Efficiency %
100.00
90.00
80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
Measured
85
110
230
265
160W PFC Input Voltage Vac
PowerEsim
Designing a 90% efficiency 150W power supply with PFC in hours
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PowerELab Limited
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150 W Flyback – simulated vs measured
I/P Votlage Vs Efficiency %
100.00
90.00
80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
Measured
300
350
405
150W flybackInput Votlage Vdc
PowerEsim
Designing a 90% efficiency 150W power supply with PFC in hours
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PowerELab Limited
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84
DVT – check the stresses
• DVT Report check every components
stress and also circuit design constraint.
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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Thermal – knowing Temp. at day 1
Designing a 90% efficiency 150W power supply with PFC in hours
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PowerELab Limited
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MTBF – how long it last
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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Designing a 90% efficiency 150W power supply
with PFC in minutes
•Live
Demonstration
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu
PowerELab Limited
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88