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									                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

      •    2:30 – 2:45                    Old vs New
      •    2:45 – 3:15                    Active Diode & IC
      •    3:00 – 3:15                    EMI Cancellation & IC
      •    3:15 – 3:45                    Design Methodology – How we trained?
      •    3:45 – 4:00                    Tea Break
      •    4:00 – 4:45                    Designed by PowerEsim – New design procedure
      •    4:45 – 5:00                    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 %                                        10 %   15 %           25 %




Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited                  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 &
                                                                 Ferrite
                 Copper Loss                                                 Band Gap Loss




Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited               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                                                 New




        •    STPS20H100                                          •   IRF540Z 22m Ohm
        •    0.6V @ 2*7A 100 deg                                 •   0.54V @ 14A 100 deg
        •    TO200 package                                       •   TO200 package
        •    USD ?? / pcs                                        •   USD ?? / pcs
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited             www.powerEsim.com   12
                  If TO220 has the same price . . .

                                                • Active
                                                  Diode

                                                • WT6002
                                                  active
                                                  diode IC

      •    STPS20H100                                            •   IPP05CN10 5m Ohm
      •    0.6V @ 2*7A 100 deg                  • Next           •   0.08V @ 14A 100 deg
      •    TO200 package                          section        •   TO200 package
      •    USD ?? / pcs                                          •   USD ?? / pcs

Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited          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                                          • 99% efficiency
       • 2% loss                                                 • 1% loss
       • 30W 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                                          • 99% efficiency
       • 2% loss                                                 • 1% loss
       • 150W converter                                          • 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 EN61000-
             4-4 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   23
                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   24
                Effect measurable by oscilloscope when using Y-
                cap booster




                Noise voltage across Y-cap in                    Noise voltage across Y-cap booster
                switching converter                              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      F1        L1 B                   L2 B
                           1




                                               3



                                                          4




                                                                      3



                                                                                 4
                                                                 C1                  C2




                                               1



                                                          2




                                                                      1



                                                                                 2
                          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
                                                                                                 Y-cap: From 1n to 3n3
     dBuV
                     DM noise                                                                                              dBuV                               Improved but not enough
      80
                                                   CM noise                                                                 80

      70                                                                                                                    70
            230V pri-sec Y1n U shielded original                                                                                  230V pri-sec Y3n3 U shielded original
      60                                               EN 55022; Class B Conducted, Quasi-Peak                              60                                                EN 55022; Class B Conducted, Quasi-Peak

      50                                                 EN 55022; Class B Conducted, Average                               50                                                  EN 55022; Class B Conducted, Average

      40                                                                                                                    40

      30                                                                                                                    30

      20                                                                                                                    20

      10                                                                                                                    10

        0                                                                                                                     0
                                                   1                                            10                                                                        1                                            10
     10/3/2005 10:55:40                                                                 (Start = 0.15, Stop = 30.00) MHz   10/3/2005 16:08:11                                                                  (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                               EN 55022; Class B Conducted, Quasi-Peak

                                   50
                                                       230V CB U shield SDMC SCMC .33uF
                                                                      EN 55022; Class B Conducted, Average
                                   40

                                   30

                                   20

                                   10

                                     0
                                                          1                                                  10

                                  10/3/2005 16:39:55                                                 (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                         Passed design using Y-cap booster
            cost, loss and bigger size for the                   with much smaller filter size that
            filter                                               saves cost, power and space


Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited                     www.powerEsim.com   30
                Another practical application examples:
                Filter comparison: Before and After...




        Original EMI solution using passive filter               New EMI solution using Y-cap booster
        in ATX converter                                         in ATX 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      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                       K        7.8 m   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   34
                   Synchronous rectifier

        Provides low conduction loss.

        Can operate at higher high current without heatsink.
        3
                                                          SCK 2.8W losses @ 10A
       2.5

        2
   W




       1.5

        1
                                                         MOSFET 0.7W losses @ 10A
       0.5

        0
             0     2       4         6    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
                                                                  Simple circuit
        Special and sometimes complicated driving circuits SR
                                                                  Discontinuous mode is allowed
        are needed for different topologies
                                                                  Good low load efficiency
        Performance sensitive to transformer leakage
                                                                  Converter can be paralleled
        inductance and operating conditions
                                                                  High conversion efficiency
        Converter cannot be paralleled – Reverse current
                                                                  Works just like a diode
        Poor efficiency at low load
        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

     K                                 A


                          A1
                N1          N2



                     N3    N4
           D1                     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                 N                   Toff
    gate drive voltage Von of SR         Von  Vo 2
                                                 N3
    depends on ratio of N2 to N3
    and voltage Vo                                                                                    Ii
                             K                                   A               Von

                                                                                                  VN2
                                                   A1
                                                                                 Vo
                                         N1          N2                                           VN3

          Voltage source Vo                                                                 Vo
          can be any voltage                                                                      VN4
                                              N3    N4
          source in a converter,
                                    D1                     D2
          e.g. output voltage



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                +
                                                                       Magnetic                Freewheel
                                                                                                           Co Vo
                Vin                                                     Reset                     SR
                                               -
                      S                                          Vin                                          -
                 -           Flyback SR
                                                                             S    Forward SR
                                                                  -




                      Flyback                                                Forward
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited                              www.powerEsim.com       40
                    Application of Active Diode in different topologies
                                            Lf                                             Lf1
               +                                                   +
                     S1   C1        SR1              +                   S1   C1
                                                  Co Vo                                 SR1      Co
               Vin                                    -
                                                                   Vin
                                                                 +                      SR2
                -    S2   C2                                             S2   C2
                                    SR2                          Vo -                      Lf2
                                                                  -




           Half Bridge centre tap                                        Current Doubler
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited                      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 120W ACDC                 AD on 1.5 V 200 A ACDC




        AD on 50W ACDC          AD on 300W ACDC                  AD on 60W ACDC        AD on 100W DCDC



Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited                      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          www.powerEsim.com   50
                  Build virtual and real converter


       PFC                                                                  DC-DC
    Developed                                                             Developed
      under                                                                 under
     Infineon                                                              Infineon
    TDA4863                                                               ICE3DS01
    Evaluation                                                            Evaluation
      Design                                                                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    www.powerEsim.com   51
                     160 W PFC – simulation vs measurement


                   Input Votlage Vs Efficiency %
          100.00
           90.00
           80.00
           70.00
           60.00
           50.00                                                  Measured
           40.00
           30.00
           20.00
           10.00
            0.00
                     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    www.powerEsim.com   52
                    150 W Flyback – simulated vs measured


                      I/P Votlage Vs Efficiency %
          100.00
           90.00
           80.00
           70.00
           60.00                                                  Measured
           50.00
           40.00
           30.00
           20.00
           10.00
            0.00
                     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    www.powerEsim.com   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    www.powerEsim.com   54
                  Component Based Approach
             Real components                                     Abstract Concept
       • Find MOSFET                                              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   Search for best
                                             evaluation design      topologies




Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited     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
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited    www.powerEsim.com   60
                  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    www.powerEsim.com   61
                  Click the main MOSFET




Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited    www.powerEsim.com   62
                  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    www.powerEsim.com   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                 www.powerEsim.com   64
                  Other than loss, Stress is important




Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited    www.powerEsim.com   65
                  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         www.powerEsim.com   66
                  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               www.powerEsim.com   67
                  Multi dimensional optimization

   1                                                                10 resistor
                                                                              x
                                                                    10 MOSFET
   2                                                                          x
                                  :                                           :
                                                                              x
10                                                                  10 diode
                                                                 = 1010 combination
                                                                 = 31 years simulation
Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited          www.powerEsim.com   68
                  Smart Optimizer – how it work


               Data set                            Smart Scan           Genetic Algorithm
                                            Search for good component
                           BU60                               BU60
       SPD07N60C3                           SPD07N60C3
             SPN04N60C2                            SPN04N60C2
       SPB07N60S5                             SPB07N60S5
                  IPP50R520CP                           IPP50R520CP




Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited           www.powerEsim.com   69
                  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         www.powerEsim.com   70
                  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
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited           www.powerEsim.com   71
                  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
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited          www.powerEsim.com   72
                  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    www.powerEsim.com   73
                  Which component is more critical?

                                                                    •   Why M1, D3 &
                                                                        T1

                                                                    •   Loss Analysis
                                                                        – the most
                                                                        useful page

                                                                    •   It rank the loss
                                                                        and it’s details




Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited    www.powerEsim.com   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
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited    www.powerEsim.com   75
                  Click T1 and go to Magnetic Builder




Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited    www.powerEsim.com   76
                  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
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited    www.powerEsim.com   77
                  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               www.powerEsim.com   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                 www.powerEsim.com   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                   www.powerEsim.com   80
                  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              www.powerEsim.com   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               www.powerEsim.com   82
                     160 W PFC – simulation vs measurement


                   Input Votlage Vs Efficiency %
          100.00
           90.00
           80.00
           70.00
           60.00
           50.00                                                  Measured
           40.00
           30.00
           20.00
           10.00
            0.00
                     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    www.powerEsim.com   83
                    150 W Flyback – simulated vs measured


                      I/P Votlage Vs Efficiency %
          100.00
           90.00
           80.00
           70.00
           60.00                                                  Measured
           50.00
           40.00
           30.00
           20.00
           10.00
            0.00
                     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    www.powerEsim.com   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    www.powerEsim.com   85
                  Thermal – knowing Temp. at day 1




Designing a 90% efficiency 150W power supply with PFC in hours
Prepared by Dr. Franki Poon & Dr. Joe Liu   PowerELab Limited    www.powerEsim.com   86
                  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    www.powerEsim.com   87
                    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    www.powerEsim.com   88

								
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