Professional Documents
Culture Documents
Reproduced from
2012 Texas Instruments Power Supply Design Seminar
SEM2000, Topic 2
TI Literature Number: SLUP300
2012, 2013 Texas Instruments Incorporated
Power Seminar topics and online powertraining modules are available at:
ti.com/psds
Equipping devices with at least one microcontroller is becoming more popular. The flexibility of such
devices is enormous and makes them unique. Switch-mode power supplies can be pure analog, pure
digital or mixed designs. Mostly, the power is still controlled by an analog controller, but other tasks like
monitoring, safety functions and interfacing are handled by microcontrollers. This paper will show a
complete, state-of-the-art, high-performance and high-efficient analog power-supply system with full
monitoring by a microcontroller.
I. Introduction
Input
Output
85 to 265 VAC at 50 or 60 Hz
12- to 14-VDC adjustable
A. Specifications
Mechanics
Extras
Texas Instruments
2-2
SLUP300
Topic 2
Abstract
Topic 2
B. Overview
L
N
Input
EMI
Filter
Primary
AC
Rectifier
PFC
Secondary
Isolated
DC/DC
Converter
12-14 V DC
25-A/30-A peak
Output
EMI
Filter
+
-
Analog
Voltage
Current
Temperature
CLK (fswitch)
Microcontroller
for
Monitoring
Vout Setting
Man-Machine
Interface
Aux.
Power
Supply
Digital
2-3
SLUP300
J1
L
N
G
FB1
L1
4.7 H
FB2
F1
5A
FB3
FB4
L2
400 H
C3
0.68 F
C1
1 nF
L3
2.6 mH
R1
open
4.7 nF
R2
open
FB5
C5
FB6
C2
4.7 H
L4
1 nF
L_OUT
C4
0.68 F
C6
RT1
275 V
RT2
275 V
N_OUT
4.7 nF
Texas Instruments
2-4
SLUP300
Topic 2
V, I (AC)
V, I (DC)
+Vpeak
+Ipeak
AC
+Vpeak
+Ipeak
-DC
-Vpeak
-Ipeak
Sinusoidal, without rectification:
1
2
Veffective, AC = +Vpeak
Vaverage, AC = 0 V
1
2
Veffective, DC = + Vpeak
1
Vaverage, DC = + V peak
Half-Wave
Rectifier
Full-Wave
Rectifier
Vaverage, DC = + Vpeak
Figure 4 Four-diode bridge rectifier.
[A]
V
Diode Current
Topic 2
B. AC/DC Rectifier
[V]
Forward Voltage
2-5
SLUP300
(1)
PDiode, n
IDiode, avg
IDiode,rms
= n VForward
+ n R Diode
(2)
PDiode, n
I2Diode, rms
= VForward IDiode, avg + R Diode
n
(3)
1
PDiode PDiode, n = R Diode I2Diode, rms 1
n
(4)
Texas Instruments
2-6
SLUP300
Topic 2
Topic 2
IDiode
IMOSFET
Diode Bridge
Rectifier GSIB2040
400 V, 20 A, 0.6-V threshold from 10-mA, 20-m
dynamic resistance
PBridge rectifier = 4 x 5.2 W
= 20.8 W
20.8 W = 1.3% of the total
input power
Texas Instruments
(7)
(6)
MOSFET Bridge
Rectifier with
IPP200N25N3G
250 V, 64 A, 20-m
on-resistance
PBridge rectifier = 4 x 1.1 W
= 4.4 W
4.4 W = 0.3% of the total
input power
(5)
2-7
SLUP300
+DC
High-Side
Gate Driver
UCC27324
Phase
AC
Neutral
Q2
D2
R2
Q3
D3
R3
High-Side
Gate Driver
UCC27324
ILoad
Input
EMI
Filter
Interleaved
CCM PFC
Q1
D1
R1
Q4
D4
R4
Low-Side
Gate Driver
UCC27323
Low-Side
Gate Driver
UCC27323
RShunt
-DC
Operational
Amplifier
OPA333
Microcontroller
MPS430F2012
Texas Instruments
2-8
SLUP300
Topic 2
Topic 2
1
2
U1
UCC27324D
N/C
N/C
INA
OUTA
3 GND
4
INB
VDD
OUIB
8
C1 10 F
7
6
+12V_PAC
5
C2
100 nF
T1
980 H
1
5
3
4
D3
BAT54C
D1
1N4148
R1
Gate
D2
BAT54
D5
BZX84C15
D4
1N4148
33
R2
27.4
R3
10.0 k
Q2
MMBT2907
R4
12.1 k
C4
1 nF
Q1
MMBT2907
C3
100 nF
Source
Texas Instruments
2-9
SLUP300
Topic 2
Figure 9 Ramp-up and ramp-down of the gate-source voltage, 10 s/div.
The voltage, which represents the load current,
is compared to a fixed threshold value. The
threshold value is selected so that a certain load
current flows through the diodes. If the MOSFETs
are not switched on, a higher threshold is set than
when the MOSFETs are active. By having different
thresholds for switching on and off, hysteresis is
achieved and the system becomes more immune
to noise and malfunctions.
The status of the three elements is stored in
one variable each of the microcontrollers memory.
If the digital input is a logic one (phase, neutral),
the variable is incremented by one; if it is a logic
zero, it is decremented by one.
This functionality is implemented for the load
current analogous to the voltage measurement. If
the converted value is higher than the threshold
value, the variable is incremented by 1; otherwise
it is decremented by 1. The software limits the
variables to a minimum of 0 and a maximum of 3.
If a variable reaches 3, that means that a logic
one state has been ascertained three times in a row.
A variable value of 0 corresponds to a logic zero
state on three consecutive occasions.
Only if these three variables are 0 or 3 are they
are checked for plausibility; where appropriate,
the MOSFETs are activated. This method,
described and shown in Figure 11, ensures the
establishment of a stable state, while also
minimizing malfunctions.
2-10
SLUP300
Initialization
25-s Bygone?
NO
Topic 2
YES
Sample Current
Current>Threshold?
NO
YES
Int_Current++
Limit to 3
Int_Current
Limit to 0
Neutral High?
NO
YES
Int_Neutral++
Limit to 3
Line High?
Int_Neutral
Limit to 0
NO
YES
Int_Line++
Limit to 3
Int_Current=3
&&
Int_Line=3
&&
Int_Neutral=3
YES
Switch Q1 and Q3 Off
Switch Q2 and Q4 On
Int_Line
Limit to 0
NO
Int_Current=3
&&
Int_Line=0
&&
Int_Neutral=3
NO
YES
Switch Q2 and Q4 Off
Switch Q1 and Q3 On
Texas Instruments
2-11
SLUP300
C. PFC
Line Voltage
Neutral Voltage
Variable current = 3
Variable current = 3
Variable phase = 3
Variable phase = 0
Variable neutral = 0
Variable neutral = 3
Conducting
MOSFETs
Q2, Q4
Q1, Q3
Texas Instruments
2-12
SLUP300
Topic 2
AC/DC
Rectifier
Full
Bridge
Topic 2
Bulk
Capacitor
Gate Driver
UCC27324
Active
In-Rush
Control
Gate Driver
UCC27324
Current
Sense 1
PWM 2
PWM 1
Mains Voltage
Current Sense 2
Interleaved CCM
PFC Controller
UCC28070
PFC Voltage
CLK
350 kHz
Texas Instruments
2-13
SLUP300
Texas Instruments
iii. Measurements
1.00
0.95
0.90
0.85
0.80
0.75
10
15
20
25
30
230 V AC
2-14
SLUP300
Topic 2
P ower F ac tor
Topic 2
1200
1000
800
600
400
200
0
3.4
1.9
1.0
0.5
0.4
0.3
0.3
0.2
0.2
Harmonic Order
Harmonic Content
80
Max/Ref Lv1
80 dBV
0 dBV
1 MHz
Limit check:
Passed
70
60
Marker 1 (T1)
48.87 dBV
8.75411965 MHz
RBW
VBW
SWT
10 kHz
100 kHz
60 s
RF Att
10 dB
Unit
dBV
10 MHz
A
SGL
67DB
50
1AP
40
30
20
10
0
-10
-20
F1
Center 2.121320344 MHz
Texas Instruments
2-15
SLUP300
Interleaved
CCM PFC
Phase C
12 to 14 VDC
25-A cont./30-A peak
Phase D
+
Full Bridge
Transformer
Phase E
Phase F
Phase A
Current Sense
Transformer
Phase B
Gate Signals
Phase A, B, C, D
Gate Drive
Transformers
Phase-Shifted
Full Bridge
Controller
UCC28950
+12-V
Sec.
CLK
350 kHz
PWM
Vout
OUT
OUT1
Gate
Driver
Gate
Driver
OUT2
2-16
SLUP300
Topic 2
Topic 2
Disadvantages
Transformer
saturation
issues
Must be placed
close to
MOSFET
CDC =
1
R total 5 fswitch
(8)
C1
+12 V_S
1
High Side
Low Side
2
3
4
U1
UCC27324D
N/C
N/C
INA
OUTA
GND
VDD
INB
OUIB
D2
BAT54C
D1
HRW0202A
C2
100 nF
D5
T1
450 H
3
1
10
4
HRW0202A
C4
C3
100 nF
D6
BAT54A
100 nF
Q1
PMD3001D
1
6
2
D3
8 BAT54S
7
C2 100 nF
22 nF
R2
R1
H-OUT1
D4
MURS360T3G
100
10.0
R3
100
Q2
IRFB9N65A
C6 22 nF
Low Drive
C7
R4
H-OUT2
100 nF 100
Texas Instruments
2-17
SLUP300
CSnubber = 4 CBias
R Snubber
L Mag
(9)
CBias
2-18
SLUP300
Topic 2
To Current
Sense Pin
D1
To Current
Sense Pin
Topic 2
Primary
Current
Primary
Current
2-19
SLUP300
C =
2 fSwitch U
1.5 A
2 157 kHz
390 V
100
= 390 nF
(10)
Texas Instruments
2-20
SLUP300
Topic 2
In summary:
Use a topology with synchronous
rectification for a high-performance and
high-speed power supply. Only then is it
possible to work in two quadrants and thus
achieve good transient behavior.
Disable any burst or power-safe mode and
enable CCM all the time. This reduces
efficiency at low or no load conditions, but
it is the only way to react fast to load
changes.
Avoid any components with low-pass
behavior like an optocoupler in the voltage feedback loop. You will achieve the highest
bandwidth by placing the PWM controller
on the secondary side.
Use voltage-mode control and bidirectional
current sensing to avoid instabilities when
current flows backwards (from the
secondary side to the primary side).
Hot
20.000
Hot
16.000
Impedance [m]
Topic 2
Hot
Hot
Primary
Ground
Hot
12.000
8.000
100
200
300
400
500
Frequency [kHz]
Electrolytic
Ceramic
SLUP300
R
R ESR, parallel = ESR, single
n
V=
(12)
I ZCout (fCrossover )
(15)
(13)
Texas Instruments
(14)
R ESR =
V 138 mV
=
6.3 m
I
22 A
2-22
SLUP300
Topic 2
Topic 2
iv. Measurements
Texas Instruments
2-23
SLUP300
+12 V at 50 mA, AC
UCC2813D-0
Usage
Synchronous bridge rectifier
All circuits on the primary side:
2-24
SLUP300
Topic 2
Topic 2
A. Overview
Texas Instruments
2-25
SLUP300
Primary
Secondary
CLK PFC
SA74LVC1G17
Mains Voltage
12-Bit
ADC
85-265 VAC
SCL
SDA
ADS 1015
PFC Voltage
390 VDC
OPA 2335
ADC Card
Common-Mode Filter
CLK
MCU
Card
I2C
ISO 7520
ISO 7521
Texas Instruments
2-26
SLUP300
Topic 2
Topic 2
D. Common-Mode Filter
Texas Instruments
Common-Mode Filter
SCL (I2C)
ADC
Card
SDA (I C)
MCU
Card
VCC
2-27
SLUP300
A. Overview
ADC Card
PFC Voltage
MCU Card
Spy-Bi-Wire
Debugging
I2C Bus
LCD
2 x 16
JTAG
USCI
Digital I/O
Push-Buttons
4
10-Bit
ADC
Controller
MSP430F2252
Temperature
Chassis
Temperature
PFC, Full Bridge
Output Voltage
Output Current
Digital I/O
Enable
Timer_A
PWM 1
Vout Adjustment
Timer_B
PWM 2
CLK
Texas Instruments
2-28
SLUP300
Topic 2
Topic 2
VRef
R1
PWM
R2
Q1
R3
Error
Amplifier
C1
R2
Feedback from
Voltage Divider
Texas Instruments
2-29
SLUP300
C. Software
Topic 2
Start
Initialization
Read-Out
ADC Card
Read-Out
Analog Inputs
Update Display
Read-Out
Push-Buttons
Update Outputs
(PWM, Enable)
Check
Parameters
Process Input
YES
User Inputs?
NO
Update Display
Texas Instruments
2-30
SLUP300
92.5
Efficiency (%)
92.0
91.5
91.0
90.5
90.0
89.5
94
89.0
90
130
170
210
250
82
78
74
70
66
62
90
FET AC Recifier
86
Efficiency (%)
Topic 2
V. Conclusion
10
15
20
25
30
110 VAC
Texas Instruments
2-31
SLUP300
10 dB
Unit
dBV
10 MHz
Limit check:
Passed
A
SGL
67DB
50
1AP
40
30
20
10
0
-10
F1
-20
Universal Input
85-265 VAC, 50/60 Hz
L
N
Input
EMI
Filter
Primary
Interleaved
CCM PFC
UCC28070
AC Rectifier
with
MOSFETs
390 VDC
Phase-Shifted
Full Bridge
Powerstage
PWM
Phase-Shifted
Full Bridge
Controller
UCC28950
High-Side
Carrying
Gate Driver
Current Sense
PWM
PWM
PWM
Gate Drive
AC Rectifier
Control Circuit
MSP430F2012
Output
E MI
F ilter
Synchronous
Rectification
Full Bridge
PWM
12-14 VDC
25-A/30-A peak
Secondary
PRI AUX
Auxiliary
Power Supply
UCC2813
AC AUX
SEC AUX
Output Voltage
60
RF Att
MCU Card
MSP430F2252
Flyback Transformer
Synchronization
ADC
Card
ISO7520
ISO7521
Synchronization
I2C
2-32
SLUP300
Topic 2
1 MHz
70
10 kHz
100 kHz
30 s
Output Current
80
RBW
VBW
SWT
Marker 1 (T1)
51.00 dBV
1.24704133 MHz
Max/Ref Lv1
80 dBV
0 dBV
Topic 2
Input
Output
85 to 265 VAC at 50 or 60 Hz
12- to 14-VDC adjustable
Mechanics
4
4
Extras
4
4
2-33
SLUP300
VI. References
Texas Instruments
Topic 2
2-34
SLUP300
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SLUP300
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