Transcript Document

Design Infineon LCD TV Power Solution with PowerEsim
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
1
Our junior Engineer Gary spend . . .
1 days to design Low cost 90% 150 W
LCD power supply
Poweresim
Measurement
100.00
90.00
80.00
70.00
60.00
3 days to build -
50.00
40.00
30.00
Low cost 90% 150 W LCD
power supply
20.00
10.00
0.00
85
110
230
265
Input Voltage Vac
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
2
Old
VS
New
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
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
”
”
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
4
Old MOSFET VS Young MOSFET
47 ns vs 5 ns, 10 times different
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
5
Where is the ZVS ?
Adaptor – A efficiency demanding
product.
How many of them
are using ZVS
circuit?
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
6
Where is the losses?
Example :
12V@4A
82%
10W loss
30 %
10 %
15 %
25 %
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
7
Do we need complicated circuit?
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
8
Why not use less copper?
• 50% losses come
from magnetic
circuit.
• Better design by
using less copper
Old
New
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
9
Why using diode?
Old
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New
STPS20H100
0.6V @ 2*7A 100 deg
TO200 package
USD ?? / pcs
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IRF540Z 22m Ohm
0.54V @ 14A 100 deg
TO200 package
USD ?? / pcs
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
10
If TO220 has the same price . . .
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STPS20H100
0.6V @ 2*7A 100 deg
TO200 package
USD ?? / pcs
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IPP05CN10 5m Ohm
0.08V @ 14A 100 deg
TO220 package
USD ?? / pcs
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
11
We are trained to
fill in a value
NOT
design a circuit
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
12
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
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
13
Then again . . .
• Replace 100pcs of components at bench
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
14
Fine, but no need to replace at the bench . . .
• Why not replace 100pcs of components at
PowerEsim
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
15
www.powerEsim.com
• It’s on-line
• It’s for everyone
• Worldwide access
• 100% server side
simulation
• It’s free
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
16
Build virtual and real converter
PFC
Developed
under
Infineon
TDA4863
Evaluation
Design
DC-DC
Developed
under
Infineon
ICE3DS01
Evaluation
Design
150W 90% LCD Converter
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
17
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
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
18
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
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
19
Loss and Temp.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
20
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
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
21
PowerEsim vs Traditional Design
PowerEsim turn design into
result oriented adaptive iteration
instead of
skill of knowledge application
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
22
Why PowerEsim ??
Design
Prototype
Design
Verify
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Mathcad
Excel
Paper & Pen
SPICE
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Trim R1
Redesign
Excel
T1 drawing
Rewind T1
Mathcad
Optimize T2
Optimize fs
Optimize R3
Optimize C2
Redesign
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Mathcad
Excel
SPICE
Design
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PowerEsim
Prototype
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Trim R1
PowerEsim
Redesign
Redesign
Design
Verify
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PowerEsim
SPICE
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
23
But first . . .
• Find a circuit that has closest specification to
your need, e.g. 160W TDA4863 for PFC front
end.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
24
Ask our expert
• Enter the input &
output specification
• Chose an application
• Click “Recommend
Design”
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
25
If you like more freedom
• Click “Topologies”
• Chose the topology you like
• Enter the input & output specification
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
26
Click the main MOSFET
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
27
How we model component?
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
28
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
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
29
Other than loss, Stress is important
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
30
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
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
31
Search more MOSFET
• Extend to higher
current range is
usually needed
• Extend the body
diode’s trrm can
find more MOSFET
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
32
Select a better Sync Rect.
• 0.5W Active
Diode loss
• 2.54W
SCK loss
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
33
Which component is more critical?
•
Why M1, D3 &
T1
•
Loss Analysis
– the most
useful page
•
It rank the loss
and it’s details
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
34
Click T1 and go to Magnetic Builder
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
35
Step 1 – select the core you like
•
Chose the range of Ae
•
Select Core shape
•
Select Manufacturer
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
36
Instant preview winding when thing change
•
Click the “preview winding”
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Corresponding winding cross section will be
shown
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Supported on Core, N and Wire.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
37
Step 2 – find the best Lm
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Click the “Inductance” button
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Enter the range of inductance
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Highlight each in the list, select according to
total loss and stress.
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Double check OCP is not be triggered.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
38
Step 3 – find the best N0
•
Click the “Number of turn” button
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Enter the range of turn
•
Highlight each in the list, select according to
total loss and stress.
•
Double check OCP is not be triggered.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
39
Don’t forget preview winding
•
Click the “Preview Winding” button
•
Observe how winding structure change with
number of turn.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
40
Step 4 – need more copper?
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Click the “Change Wire” button
Click the “No. of Parallel Wire”
Add more parallel wire as you like.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
41
Finally – a Xformer like this
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Copper foil +
Split bobbin +
Bi-filar winding +
Multi-layer winding +
Multi-winding in one layer +
Tight winding +
Distributed winding +
Center winding +
Faraday shield +
.....
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
42
DVT – check the stresses
• DVT Report check every components
stress and also circuit design constraint.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
43
Connecting Power Supplies
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
44
Thermal – knowing Temp. at day 1
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
45
MTBF – how long it last
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
46
It’s Done and On PowerEsim
• Enjoy using PowerEsim
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07
Prepared by Dr. Franki Poon
PowerELab Limited
www.powerEsim.com
47