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Control Challenges for Low Power AC/DC Converters Brian King and Rich Valley

Control Challenges for Low Power AC/DC Converters …edu.21ic.com/uploads/down/edu/2015/1440996072_4887.pdf · Control Challenges for Low Power AC/DC Converters ... flyback transformer

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Control Challenges for Low Power AC/DC Converters

Brian King and Rich Valley

5-2 Texas Instruments – 2014/15 Power Supply Design Seminar

Content Outline

1. The Low Power Flyback Converter •  Characteristics •  Key performance •  Typical operating and control modes

2. PSR Regulation Methods •  Constant Voltage (CV) – regulating VOUT

•  Constant Current (CC) – regulating IOUT

3. Low Standby Power •  Lowering consumption •  Achieving low input power

4. Results and Comparison (10 W at 5 V) •  DCM and variable frequency – primary side voltage and current control •  DCM and fixed frequency – optical coupler feedback •  DCM, variable frequency – optical coupler feedback, primary side current control

Typical

Low Power

AC/DC

Configuration

VAC

CBLK

VBULK

COUT

VOUT

CDD

RCS

Opto-Coupler

TL431

Isolation

Boundary

Start Up

Primary

AuxiliaryPower

Inductor

Secondary

Controller

GND

FB

DRV

VDD

CS

+

-

5-3 Texas Instruments – 2014/15 Power Supply Design Seminar

The Low Power AC/DC Flyback

Key Points 1.  Power inductor

•  AKA, flyback transformer •  3rd “bootstrap” winding

2. PWM Control •  Peak current control •  Switching frequency control •  Low pin count •  Requires start-up circuit

3. Feedback •  TL431 network •  Optical Coupler

1

2

3

Texas Instruments – 2014/15 Power Supply Design Seminar 5-4

The Low Power AC/DC Power Supplies

3-35 Watts, 3 V to 20 V •  Universal input, 85-265 VRMS •  AC/DC adapters and chargers •  Set top boxes •  E-meters •  Auxiliary supplies – DTV, servers…  

Key Parameters •  Size and cost •  Voltage and current control •  Efficiency •  Standby power

Ou

tpu

t V

olt

ag

e (

Vo

lts)

Load Current (Amps)

6

5

4

3

2

1

0

0.0 0.5 1.0 1.5 2.0 2.5

115 VAC/60 Hz 230 VAC/50 Hz

60%

65%

70%

75%

80%

85%

90%

0 10 20 30 40 50

Nameplate Power (NPP) - Watts

DOE Avg , July 2013

DOE LV Avg , July 2013

COC T2 Avg , Jan 2016

COC T2 LV Avg , Jan 2016

COC T2 10% NPP , Jan 2016

COC T2 LV 10% NPP , Jan 2016

5-5 Texas Instruments – 2014/15 Power Supply Design Seminar

Performance – Efficiency

Efficiency standards for External Power Supplies (EPS) •  Department of Energy, DOE •  European Commission Code of Conduct, COC

5-6 Texas Instruments – 2014/15 Power Supply Design Seminar

Performance – Standby Power

Efficiency standards for External Power Supplies (EPS) •  European Commission, Tier 2 – January 2016 75 mW •  Department of Energy – July 2013 100 mW •  5 Star Charger 30 mW

•  OEM specifications at 10 mW and asking for 5 mW

5-7 Texas Instruments – 2014/15 Power Supply Design Seminar

Discontinuous Current Mode (DCM)

•  Single switch control •  TON:

–  Switch on-time –  Energy taken from VIN and

stored in primary –  Core is “magnetized”

•  TDM: –  Switch is off –  Stored energy is fully

transferred to VOUT

–  Core is “demagnetized” •  TDIS:

–  Discontinuous time –  Currents are zero –  TDIS = 0 à transition mode

++ VOUT

TSW = 1/fSW

TDM TDISTON

IPRI

IPRIIPRI(peak)

0

0

VIN

++ VOUTVIN

++ VOUT

ISEC

ISEC

VIN

Control

Primary Secondary

SW

SW

LP, NP NS

Basic Flyback Toplogy

Closed

Open

Energy Storage

Energy Transfer

NS

NP

NP

NS

NP

NS

VOUT + VDFWD

-VIN x

VIN +(VOUT + VDFWD) x

IPRI x

5-8 Texas Instruments – 2014/15 Power Supply Design Seminar

Power Control with the DCM Flyback

•  Each switching cycle –  A controlled energy is taken from the input –  This energy (minus some losses) is delivered to the load –  The system is at the same condition at the beginning of every cycle

•  Power is modulated by changing: –  Cycles/second – frequency modulation –  Energy/cycle – amplitude modulation

1) CEST = 12 LP × IPRI(peak)2 (transformer energy stored each cycle)

2) PIN ≅ fsw × CEST (converter input power)

3) η = POUTPIN

(overall converter efficiency)

5-9 Texas Instruments – 2014/15 Power Supply Design Seminar

DCM or TM(Transition Mode) with Valley Switching

•  Waiting for a zero crossing prevents continuous conduction mode (CCM)

•  Switching on a valley reduces dissipation and EMI

•  1/fSW(limit) sets a minimum period

DCM-TM – Quasi-Resonant DCM – Valley Switching

TR

VBLK

Deep DCM

Drain Voltage

1/fSW(limit)

5-10 Texas Instruments – 2014/15 Power Supply Design Seminar

DCM, Fixed Frequency Control

•  Frequency is constant

•  Peak current is modulated

+  Controlled switching frequency -  Lower efficiency -  High stand-by power -  Limited dynamic range

Control Law ProfileFixed Frequency

Current Mode Control

I PP

(Pea

k Pr

imar

yC

urre

nt)

I PP

– %

of M

axim

um

IPP (max)

IPP (min)

IPP

fSW (set)

f SW

f SW

– k

Hz

fSW and IPP ResponseFixed Frequency, 10 W at 5 V

DCM, LP = 750 µH

Control Voltage – VCL

Percent of Full Output Power

11010090807060504030

0% 20% 40% 60% 80% 100%

100%

80%

60%

40%

20%

0%

fSW (DCM) IPP (DCM)

5-11 Texas Instruments – 2014/15 Power Supply Design Seminar

DCM, Variable Frequency Control

•  Peak current is modulated

•  Frequency is modulated

•  Approaches TM at low line full load

+  Smallest inductance

+  Good efficiency +  Best current control

-  Wide frequency range

Control Law ProfileDCM Mode

I PP

I PP

– %

of M

axim

um

IPP (max)

IPP (min)

IPP

fSW (limit)

fSW (max)

fSW (mid)

fSW (min)

f SW

(lim

it)f S

W –

kH

z

fSW and IPP Responsewith DCM Control

LP = 750 µH, 10 W at 5 V

Control Voltage – VCL

Percent of Full Output Power

100

80

60

40

20

00% 20% 40% 60% 80% 100%

100%

80%

60%

40%

20%

fSW IPP/IPP (max)

Control Law ProfileQR Mode

I PP

I PP

– %

of M

axim

um

IPP (max)

IPP (min)

IPP (mid)

IPP

fSW (limit)

fSW (max)

fSW (min)

f SW

(lim

it)

f SW

– k

Hz

fSW and IPP Responsewith TM/DCM Control

LP = 1.7 mH, 10 W at 5 V

Control Voltage – VCL

Burst

Percent of Full Output Power

140125

11958065503520

0% 20% 40% 60% 80% 100%

100%

80%

60%

40%

20%

fSW (110)IPP/IPP(max)(220)fSW (220)

IPP/IPP(max)(110)

5-12 Texas Instruments – 2014/15 Power Supply Design Seminar

TM/DCM, Variable Frequency Control

•  Peak current is modulated

•  Frequency is modulated

•  Operates TM at full load

+  Better full load efficiency -  Larger primary inductance -  Wide frequency range -  Reduced input voltage rejection

5-13 Texas Instruments – 2014/15 Power Supply Design Seminar

Primary Side Regulation (PSR)

Constant Voltage (CV) and Constant Current (CC) Methods

5-14 Texas Instruments – 2014/15 Power Supply Design Seminar

Primary Side Regulation (PSR)

•  Controlling output voltage and current with no direct sensing

•  Constant Voltage (CV) for IO = 0 A to IOCC

•  Constant Current (CC) for VO = VOHU to VOCV

•  The output hold up voltage, VOHU, depends on the primary controller supply dropout

VOCV

VOHU

Out

put V

olta

geOutput Current IOCC0

TL431

VAC VAC

COUT COUT VOUT

RCSRCS RF4

CC1

RF3RF2

RF1

VOUT NP

NA RS1

RS2

CB2CB1CB2CB1

CDDRS1

RS2

RF6

CDD

NS

AuxiliaryAuxiliary

Primary SecondaryPrimary Secondary

Controller

GND

VS DRV

VDD HV

CS

Controller

GND

VS DRV

VDD HV

CS

+

-+

-

5-15 Texas Instruments – 2014/15 Power Supply Design Seminar

PSR – Component Reduction

•  Opto-coupler and TL431 circuits are eliminated •  Less parts = lower cost, smaller supply, higher reliability •  Less design, also less design flexibility

From This To This

COUT

RCS

VOUTNP NS

VBULK

RS1NA

TON

TON = the switch ON timeTDM = the transformer demagnetization timeTDIS = the discontinuous current time

TDM TDIS

Auxiliary

Primary Secondary

Controller

GND

VS DRV

VDD HV

CS

5

2

4

1

3

NA

NS

NA

NP

0 V

Auxiliary winding voltage

(VOUT + VD) x

– (VBLK ) x

5-16 Texas Instruments – 2014/15 Power Supply Design Seminar

PSR – Feedback Concept

1.  VOUT + VD, scaled by a turns ratio, at Aux during TDM

2.  Use for voltage feedback (at VS input)

But….. 3.  Signal is not continuous 4.  NA / NS must be controlled 5.  VD (output diode voltage) is a

source of error 6.  Nothing is this simple

5-17 Texas Instruments – 2014/15 Power Supply Design Seminar

PSR – Feedback Concept

Auxiliary winding waveform: Leakage inductance

–  Reset spike –  Rings with CSWN

1.  ESR – 

2.  CSWN rings with LP

Best regulation if sampled when ISEC goes to zero à “VS sample”

ISEC × RESR slope

COUT

RCS

CSWN

VOUTNP NSVBULK

RS1

RS2

NA

TON TDM TDIS

Auxiliary

Primary Secondary

Controller

GND

VS DRVSnubberClamp

EquivalentSeries Resistance

(ESR)LeakageInductance

VDD HV

CS

13

2

NA

NA

NS

NP

0 V

VS Sample

(VOUT + VD + ISECRESR) x

– (VBLK ) x Auxiliary winding voltage

5-18 Texas Instruments – 2014/15 Power Supply Design Seminar

PSR – Voltage Loop

•  Samples output at fSW rate

•  fSW has wide range, >100:1, for low stand-by power

•  Compensation (M(s)) done internally

+

+ -

ESR impact ~ 0

since VOUT is sampled

with the secondary loop

current = 0

VCL, filtered E/A output

and input to the Control

Law function

VOUT

COUT

VD

NP

VBULK

RCS

NS

RLOAD

-AEA

RS2

RS1NA

REF

Sampler

Controller

M(s)

(VOUT + VD) x NA

NS

Control

Law

Minimum

Period

and Peak

Primary

Current

GD

CS

DRVVS

5-19 Texas Instruments – 2014/15 Power Supply Design Seminar

PSR – Transient Response Problem

Poor Transient Response from Zero Load 1.  Low switching

frequencies

2.  Feedback is only available during a switching event

3.  Poor transient performance, or a very large output capacitor

ΔVOUT =

IOUT(step)COUT × fSW(min)

As  Bad  as:    

21

3¨VOUTVOUT

VAUX

IOUT(step)IOUT

fSW(min)

1

5-20 Texas Instruments – 2014/15 Power Supply Design Seminar

PSR Voltage Error Sources •  Reference, Error Amplifier, Resistors

•  Rectifier Diode Drop –  Actually regulating VOUT + VD

–  Diode-to-diode VD at a fixed low current is consistent for a given diode selection

–  Diode temperature variation will impact VOUT if not compensated for

•  Transformer –  Reasonable manufacturing gives good turn control –  Impact of leakage inductance is small

•  Winding Voltage Sampling Errors (generally seen at light loads) –  Auxiliary diode, snubber diode, snubber noise corrupting signal –  Auxiliary to secondary cross-regulation at light loads –  VS filtering

•  Generally +/- 5% is readily achievable across line and load

5-21 Texas Instruments – 2014/15 Power Supply Design Seminar

Constant Current Control – Concept

1) IO = ISEC(Avg) =ISEC(peak)

2 ×

TDMTSW

2) ISEC(peak) = IPRI(peak) × NPNS

Therefore: 3) IO =IPRI(peak)

2 ×

NPNS

× TDMTSW

•  Controlling the peak primary current and the demagnetization duty-cycle (TDM / TSW) will regulate the output current accurately

(~+/-5% achievable)

0

0

TON TDM

TSW

NS

NP

IPRI (peak)IPRI

ISEC

IPRI (peak) x

5-22 Texas Instruments – 2014/15 Power Supply Design Seminar

Standby Power (PSB)

Power consumed with zero external load, a very common state for power supplies

5-23 Texas Instruments – 2014/15 Power Supply Design Seminar

PSB = fSW(sb) × CEIN(min) + PSTRT + PLKG

Where:

fSW(sb)= converter switching frequency during stand-by

CEIN(min) = converter minimum input cycle energy

PSTRT =Start-up power

PLKG = Capacitor and junction leakage losses∑

PSB Components

•  Generally fSW x CEIN dominates –  Encompasses output preload and primary bias power

•  PSTRT can be significant at low target PSB

VVDD

PWM Enable

VAC Applied

UVLO (on)

UVLO (off) Controller

Controller

Start-UpCurrent

HV

VDD

GND

VDD

GND

SupplyControl

PWMControl

SupplyControl

PWMControl

VAUX

VBLK

CDD

VAUX

VBLK

RSTR

CDD

NSVAUX level during TDM = (VO + VD) x NA

5-24 Texas Instruments – 2014/15 Power Supply Design Seminar

PSB – Start-Up

Active Start-Up: No PSB penalty

Resistive Start-Up:7-300 mW to PSB

5-25 Texas Instruments – 2014/15 Power Supply Design Seminar

PSB Control Law Must Haves

•  Low input energy / cycle •  Low switching frequency •  Constant time / cycle

–  Burst mode versus constant fSW(sb) –  Same average cycles / second – worse transient response

Switching Cycle During Standby

Burst

Constant fSW

Same PSB but worsetransient response

5-26 Texas Instruments – 2014/15 Power Supply Design Seminar

PSB and CEIN(min)

•  The minimum cycle energy is dependent on the AM range and fSW(max)

•  The maximum AM range, KAM, will typically be limited to 3-5 •  This expression does not take into account the impact of the

switch-node capacitance •  ηT is an efficiency estimate ignoring capacitive and bias loss

CEIN

(min) =PO

(max)

ηT × fSW

(@P max)

1

KAM

⎛⎝⎜

⎞⎠⎟

2

where: KAM

=IPRI

(peak,@P max)

IPRI

(peak, min)

5-27 Texas Instruments – 2014/15 Power Supply Design Seminar

•  Delta input cycle energy

•  A portion of this is dissipated in the switch and tank,

•  A portion goes into the transformer à output,

PSB – Switch Node Capacitance Impact

ΔCEIN(cap, total)=CSWN × VBLK2

ΔCEIN(cap, dissipated)= 12 × CSWN × VBLK

2 + VR2( )

ΔCEIN(cap, out)= 12 × CSWN × VBLK

2 – VR2( )

TR+

+

+

-

Drain

VoltageVR = (VO + VD) x

VBLK

VBULK

NP NS

VD

VO

CSWN

DRV

0 V

NP

NS

5-28 Texas Instruments – 2014/15 Power Supply Design Seminar

PSB – Switch Node Capacitance Impact

Example Power Supply Parameters PO (max) 10 W

fSW (max) 100 kHz

VBLK (max) 365 V

VR (nom) 80 V

KAM 4

CSWN 70 pF

ηT* 80%

For the example to the right ignoring the effect of CSWN:

* Efficiency estimate ignoring capacitive and bias loss

CEOUT(min) = ηT × CEIN(min) = 6.25 µJ

Total minimum energy w/ CSWN: Limits very light load efficiency and dictates a minimum load

CEIN(min) = 7.81 µJ

ΔCEIN(cap, total) = 9.33 µJ

ΔCEIN(cap, dissipated) = 4.89 µJ

ΔCEIN(cap, out) = 4.44 µJ

ΔCEOUT(cap, out) ≅ ηT × ΔCEIN(cap, out) = 3.55 µJ

CEIN(min, total) = 7.81 µJ + 9.33 µJ = 17.14 µJ

CEOUT(min, total) = 6.25 µJ + 3.55 µJ = 9.80 µJ

Incremental energy due to CSWN:

5-29 Texas Instruments – 2014/15 Power Supply Design Seminar

PSB – Minimum Load Requirements

•  The converter has a minimum load it will deliver that is equal to:

•  Bias power plus a preload will adjust fSW(sb) to approach fSW(min), or exceed for improved transient response

•  If the preload is not adequate then regulation will be lost with VO rising  

PO

(sb, total) > fSW

(min) × PO

(@P max)

fSW

(@P max)

1

KAM

⎛⎝⎜

⎞⎠⎟

2

+ ηT × C

SWN × (V

BLK2 – V

R)2

2

⎝⎜

⎠⎟

5-30 Texas Instruments – 2014/15 Power Supply Design Seminar

PSB – Versus Transient Response

PIN

(sb, total) > fSW

(sb) × P

O(max)

ηT

× fSW

(@Pmax)1

KAM

⎝⎜⎞

⎠⎟

2

+ CSWN

× 2 VACRMS2

⎝⎜⎜

⎠⎟⎟

PIN(sb) and fSW(sb) Versus VACPOUT(sb) and Transient Delta Versus fSW(sb)

25%

20%

15%

10%

5%

0%

50

40

30

20

10

0

22

20

18

16

14

2100

1900

1700

1500

13000 1000 2000 3000 4000 5000 85 135 185 235

VAC Input – VRMSFSW(sb) – Hz

F SW

(sb)

– H

z

¨9O

UT (

0.5

A, m

ax) –

%V O

UT

P IN(s

b) –

mW

P OU

T(sb

) – m

W

5 V, 10 W ExampleCOUT = 820 µFVAC =260

5 V, 10 W ExampleAdjusting POUT(sb) = 12 mWfSW(sb) > 1 kHz

¨9OUT (0.5 A, max)% POUT(sb, total) PIN(sb, total) fSW(sb)

For: VO < 10% fSW > 1200 Hz 12 mW POUT

CSWN Impact on fSW and PSB

5-31 Texas Instruments – 2014/15 Power Supply Design Seminar

Low Power Flyback Control Recap

•  Discontinuous operation with variable frequency optimizes efficiency across load

•  Primary side regulation can provide good V and I regulation but transient response can suffer

•  Standby power benefits from: -  Low switching frequencies -  Low bias and start-up overhead -  Low switch-node capacitance

5-32 Texas Instruments – 2014/15 Power Supply Design Seminar

Results and Comparison

How do different controllers affect the performance of a typical power supply?

5-33 Texas Instruments – 2014/15 Power Supply Design Seminar

AC/DC 5 V / 10 W Adaptor

General Specifications: •  Universal AC input : 85 V to 265 V, 50/60 Hz •  5 V output; 2 A max output current Control Methodologies Evaluated: •  DCM, fixed-frequency, control with opto feedback (DCM/FF/Opto) •  DCM with valley switching and PSR (DCM/VS/PSR) •  DCM with valley switching and opto feedback (DCM/VS/Opto) Controlled Parameters: •  All designs operate at ~100 kHz at maximum load •  Same transformer, FET, diode used on all designs

5-34 Texas Instruments – 2014/15 Power Supply Design Seminar

DCM/FF/Opto Example

1. Start-up resistors increase standby power 2. Large bias cap; factors include IDD, opto current, UVLO hysteresis 3. TL431 and opto-coupler for regulation

4. Faster loop response allows smaller output caps 5. Minimum on-time requires turn-on resistor at no load operation

T1435 µH13.5:1:3(Pri: Sec: Bias)

D4

SBR10U45SP5

C61 µF

C4220 µF

+ +1 µH

L2

C5220 µF

C71 µF

5 V Output at 2 A

R50

C10

2200 pF++

+

-

~ ~

+

L1

R61.00 k

R121.00 k

U2TL431AIDBZ

C130.022 µF

R9249

R101.00 k

U3

LTV-817S

VREF

VREF

C81 µF

C322 µF

R449.9

Q1AOD3N60

D5

BAS316

D290 V

D3

R349.9

R1150 k

R2150 k

C26.8 µF

C16.8 µF

100 µHD1

F1LINE

NTRL

85 to 265 VAC Input

C9

0.01 µF

C11100 pF

R75.23 k

R87.87 k

C141000 pF

U1FB

SS

RT1

RT2

REF

VDD

OUT

GND

1

2

5 3

4

UCC2809D-2 R100

100D100

BAS316

R111.00 k

R141.00 k

R101.5

49.9R3

13.5:1:3(Pri:Sec:Bias)

D3

90 VD2

435 µHT1

C6

6.8 µFC2

6.8 µFC1D1

F1

1 µF1 µFC7

820 µFC4

820 µFC5

2200pF

C10

L1

L2

100 µH

1 µH

LINE

NTRL

3.01 R18

Q1AOD3N60

1 µFC3

U1

0.91R10

1.78 k

R1131.6 kR16

133 kR15 49.9

R4D5

BAS316

100 kR17

D4

SBR10U45SP5

+ +

5 V Output at 2 A

++

+

-

~ ~

85 to 265 VAC Input1

25

3

4

VDD

VS

CBC

GND

HV

DRV

CS

UCC28710D

5-35 Texas Instruments – 2014/15 Power Supply Design Seminar

DCM/VS/PSR Example

1. No start-up resistors (lower standby) 2. Small bias capacitor

3. PSR eliminates opto-coupler and TL431

4. Larger output capacitors needed for transients 5. Small pre-load resistor needed for no load operation

T1435 µH13.5:1:3(Pri: Sec: Bias)

D4

SBR10U45SP5

C61 µF

C4220 µF

+ +1 µH

L2

C5220 µF

C71 µF

R50

C10

2200 pF++

+

-

~ ~

L1

R61.00 k

R121.00 k

U2TL431AIDBZ

C130.022 µF

R92.00 k

R102499R101

499

C1000.01 µF

U3

LTV-817S

VDD

VDD

Q1AOD3N60

U1

D290 V

D3

R349.9

C26.8 µF

C16.8 µF

100 µHD1

F1LINE

NTRL

R15133 k

R1710 k

R1630.1 k

C310 µF

U1

1

2

3

4

R111.78 k

R1430.1 k

R100.91

VDD

VS

FB

GND

HV

DRV

CS

UCC28740D

D5

BAS316

R449.9

R10310 k

5 V Output at 2 A85 to 265 VAC Input

5-36 Texas Instruments – 2014/15 Power Supply Design Seminar

DCM/VS/Opto Example

1. No start-up resistors (lower standby power) 2. Medium sized bias capacitor 3. TL431 and opto-coupler regulation

4. Faster loop response allows smaller output caps

5-37 Texas Instruments – 2014/15 Power Supply Design Seminar

Photographs

1. Start-up resistors

2. Bias capacitor

3. TL431 and opto-coupler

4. Bias capacitor

DCM/FF/Opto www.ti.com/tool/pmp9203

DCM/VS/PSR www.ti.com/tool/pmp9202

DCM/VS/Opto www.ti.com/tool/pmp9204

5-38 Texas Instruments – 2014/15 Power Supply Design Seminar

1.008

1.006

1.004

1.002

1.000

0.998

0.996

0.994

0.992

0.0 0.5 1.0 1.5 2.0 2.5

Load Currents (Amps)

Ou

tpu

t V

olt

ag

e (

No

rm

ali

ze

d)

DCM/FF/Opto DCM/VS/PSR DCM/VS/Opto

Load Regulation

•  TL431 and opto-coupler provides excellent load regulation

•  PSR uses cable-drop compensation -  Compensates for resistive drops on the secondary side -  Keeps load regulation within +/-1%

5-39 Texas Instruments – 2014/15 Power Supply Design Seminar

6

5

4

3

2

1

0

0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0

Load Currents (Amps)

Ou

tpu

t V

olt

ag

e (

Vo

lts

)

DCM/FF/Opto DCM/VS/PSR DCM/VS/Opto

Overload Protection

•  Traditional fixed-frequency controller: -  Frequency and peak current held constant -  Currents during overload can become excessive

•  DCM/VS controllers include current regulation feature

5-40 Texas Instruments – 2014/15 Power Supply Design Seminar

•  All designs achieve >80% efficiency at max load •  DCM/VS controllers provide better efficiency at low to medium loads

-  Due to reduced frequency operation

•  Start-up resistors have major impact at higher input voltages

Efficiency Ef

ficie

ncy

85%

80%

75%

70%

65%

60%

55%0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00

Load Currents (Amps)

DCM/FF/Opto DCM/VS/PSR DCM/VS/Opto

230 VAC / 50 Hz Input

0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00

Load Currents (Amps)

Pow

er L

oss

(W)

DCM/FF/Opto DCM/VS/PSR DCM/VS/Opto

230 VAC / 50 Hz Input2.5

2.0

1.5

1.0

0.5

0.0

5-41 Texas Instruments – 2014/15 Power Supply Design Seminar

Standby Power Consumption

•  Pre-load resistor of PSR design accounts for a large portion of Psb

•  TL431 and opto-coupler biasing increases Psb

•  Fixed frequency example Psb dominated by start-up resistors

1,000

100

10

80 100 120 140 160 180 200 220 240 260

Input Voltage (Vrms)

Po

we

r L

os

s (

mW

)

DCM/FF/Opto DCM/VS/PSR DCM/VS/Opto

5-42 Texas Instruments – 2014/15 Power Supply Design Seminar

Load Transient Response O

utp

ut

Vo

lta

ge

(A

C C

ou

ple

d,

Vo

lts

) 0.2

0.0

-0.2

-0.4

-0.6

-0.8

-1.0

-1.2

-1.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0

Time (ms)

DCM/VS/PSR 0 A to 2 A DCM/VS/PSR 10 mA to 2 A DCM/FF/Opto

Ou

tpu

t V

olt

ag

e (

AC

Co

up

led

, V

olt

s) 0.2

0.0

-0.2

-0.4

-0.6

-0.8

-1.0

-1.2

-1.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0

Time (ms)

•  PSR response varies -  Dependent on when in the switching cycle the transient hits -  Starting at 0 A vs. a few mA makes a big difference

•  TL431 and opto-coupler response is predictable -  Dependent on output capacitance and bandwidth

 

5-43 Texas Instruments – 2014/15 Power Supply Design Seminar

•  DCM/VS/PSR example design can be laid out to fit into a 1”x1” cube

•  Two secondary transformer wires are the only electrical connection

between the two circuit boards (not possible with opto feedback)

•  Small product size requires efficiency >80% to prevent thermal issues

•  PMP8363 available on PowerLab: http://www.ti.com/tool/pmp8363

Small Form Factor Example

5-44 Texas Instruments – 2014/15 Power Supply Design Seminar

Comparison Summary

DCM/FF/Opto DCM/VS/PSR DCM/VS/Opto

Output Voltage Accuracy +/-2% +/-5% +/-2%

Load Regulation +/-0.1% +/-0.6% +/-0.1%

Max Load Eff. (115 VAC / 230 VAC) 82.0% / 80.4% 82.2% / 82.5% 81.3% / 81.7%

Standby Power (115 VAC / 230 VAC) 216 mW / 584 mW 14 mW / 16 mW 57 mW / 64 mW

Load Transients (0 A to 2 A) -200 mV -1100 mV -200 mV

Current Regulation Not Provided +/-5% +/-5%

# of Components 41 27 37

Relative Cost Low Lowest Low

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