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Designing a 90 efficiency 150W power supply with PFC in hours

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Designing a 90 efficiency 150W power supply with PFC in hours

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    1. Designing a 90% efficiency 150W power supply with PFC in hours

    2. 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

    4. Old engineer vs Young engineer

    5. Old MOSFET VS Young MOSFET

    6. Where is the ZVS ?

    7. Where is the ZVS ?

    8. Where is the losses?

    9. Where money can buy Pay for ZVS Pay for lower Rds Pay for lower tr, tf . .

    10. Where money can’t buy

    11. Why not use less copper? Active EMI Filter WT6001 Y-Cap Booster Next section

    12. Why not of not using diode? STPS20H100 0.6V @ 2*7A 100 deg TO200 package USD ?? / pcs

    13. If TO220 has the same price . . . STPS20H100 0.6V @ 2*7A 100 deg TO200 package USD ?? / pcs

    14. Transformer design calculation

    15. Mathematics for the loss

    16. What exactly you are doing?

    17. Transformer – core and wire only

    18. 98% VS 99% - not 1% different 98% efficiency 2% loss 30W loss

    19. 98% VS 99% - 200% different 98% efficiency 2% loss 150W converter

    20. What is all about Active Diode vs Diode – almost same cost. EMI IC vs filter – greatly improve efficiency. PowerEsim vs Paper design – no cost.

    22. 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

    23. Active EMI cancellation IC WT6001: An effective EMI solution – Y-cap booster 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.

    24. Applications: Replace passive Y-cap

    25. Effect measurable by oscilloscope when using Y-cap booster

    26. 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

    27. Practical application examples: Original filter schematic

    28. Practical application examples: EMI measurement

    29. Practical application examples: Solution using Y-cap booster

    30. Practical application examples: Filter comparison: Before and After...

    31. Another practical application examples: Filter comparison: Before and After...

    32. 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.

    33. 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!!

    34. Synchronous rectifier

    35. Synchronous rectifier

    36. 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 …… .

    37. Synchronous rectifier

    38. Active diode – Operating principle

    39. Active diode – Operating principle

    40. Application of Active Diode in different topologies

    41. Application of Active Diode in different topologies

    42. Application of Active Diode in different topologies

    43. Successful application of Active Diode in converter products

    44. 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.

    45. 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

    47. Fill in values by experience . . .

    48. Then again . . .

    49. Fine, but no need to replace at the bench . . .

    50. www.powerEsim.com

    51. Build virtual and real converter

    52. 160 W PFC – simulation vs measurement

    53. 150 W Flyback – simulated vs measured

    54. Loss and Temp.

    55. Component Based Approach Find MOSFET Find Diode Find Capacitor Find Core Find Wire

    56. PowerEsim vs Traditional Design

    57. But first . . .

    58. Ask our expert

    59. How our expert system work.

    60. If you like more freedom

    61. Re-define specification

    62. Click the main MOSFET

    63. How we model component?

    64. Click, click, click and select

    65. Other than loss, Stress is important

    66. More clever method – Smart Optimizer

    67. Smart Optimizer – just a click

    68. Multi dimensional optimization

    69. Smart Optimizer – how it work

    70. Sorted one by one

    71. Now Active Diode

    72. Search more MOSFET

    73. Select a better Sync Rect.

    74. Which component is more critical?

    75. Follow the step

    76. Click T1 and go to Magnetic Builder

    77. Step 1 – select the core you like

    78. Instant preview winding when thing change

    79. Step 2 – find the best Lm

    80. Step 3 – find the best N0

    81. Don’t forget preview winding

    82. Step 4 – need more copper?

    83. 160 W PFC – simulation vs measurement

    84. 150 W Flyback – simulated vs measured

    85. DVT – check the stresses

    86. Thermal – knowing Temp. at day 1

    87. MTBF – how long it last

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