Power Supply Design Seminar

Design Review:
A Step-By-Step Approach to AC
Line-Powered Converters
Topic Categories:
Design Reviews – Full Power Supply
Two-Switch Forward

Reproduced from
2004 Texas Instruments Power Supply Design Seminar
SEM1600, Topic 3
TI Literature Number: SLUP229

© 2004, 2011 Texas Instruments Incorporated

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training modules are available at:
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     
   
 


An offline, three-output, 150-W forward converter is used as an example to illustrate the design process
for typical isolated converters. This example emphasizes the basics with a double-ended forward
topology using coupled inductors for output accuracy. Design issues and trade-off decisions to optimize
power efficiency while keeping costs to a minimum are highlighted. Finally, the presentation of
measured performance results confirms the design process.

  Load Concerns

      
        
       
      
       
       
        
       
        
      
        
       
    
    

        
      
       
      
 
A. Defining Requirements
          
      
     
       
      
      
      
  
•     

•     
•      

•    
•    
•  
      
       
      
     
    
   
Power Train Concerns
•       
     
•      
•  
•  
     
      
    
       
      




Texas Instruments 1 SLUP229

      

   

        
    
   
     
     
     
 
           
 
   
 
   
     
 
          
 
     
 
     
     
 
      
  
     
 
     
    
   
  
 
       
   
 
   
  
  
    
   
  
      
 
    
 
   

        

B. Defining the Topology      
            
             
          VRMS ×  
      
   
C. Defining the Input Configuration

       

  
        

        
•          
•          
       
• 
•     
       
•            
•              
•              
       
      


Texas Instruments 2 SLUP229

              
           
          
              
              
             
               
       
        
     
     
             
   
      
     
     
      
             
            
         
               
              
      
VBULK
     
       


C1
VC1  
220 V
CIN
Switching
Regulator
F. Output Filter Design
110 V         
VC2 C2
       
      
Input
230 V AC, 50 Hz
       
120 V AC, 60 Hz       
        
Fig. 1. A voltage doubling input range switch
      
configuration.
  
      
D. Transformer Design         
          
              
                
               
      
             
           
              
              
        
        
E. Voltage-Mode or Current- Mode Control       
            
     
      
      

Texas Instruments 3 SLUP229
    
    
       
       
       
       
       
 
A. Defining the Requirements (Plan of Record)
   
       
       
  
•   
•           
     
•          
      
•           
      
•       
•        
   
•      
•  ≥ 
•          
 
•         
•     
     
  
•      
•     
•      
  
B. Defining the Topology and Control Method
       
         
     
       
     
       
      
       
Texas Instruments
        

     
          
       
     
       
      
      
         
     
        
      
   

      
          
       
       
      
automatically      
       
     
      
       
         
          
  
      
     
     
   

  Ω
Ω 
    
    
      
     
      
       
       
        
 

4 SLUP229
 VBULK

L
Q1 D1

}
C1 D3 VOUT
T2

CIN COUT
NP NS D4

C2

Q2 D2 NA

Fig. 2. Two-Switch Forward Converter

           
VDC  = VRMS ×  =  V  peak 
       
       
      VDC  = VRMS ×  =  V  peak 
     
       VDC  
      VSEC  = × VSEC  = × 
VDC  

= V  with  × derating   V diode required 
C. Defining the Input Section
Voltage Doubler vs. Full-Wave Bridge Input     
            
              
             
       
        
VDC  = VRMS ×  ×  =  V  peak 
       
         
         VDC  = VRMS ×  ×  =  V  peak 
         
      
       
       
       

        
     V DC  =  ×  =  V  peak 
VOUT   V       
VSEC  = = = V
Duty          

     
         VDC  = VRMS ×  =  V  peak 
       
 


Texas Instruments 5 SLUP229

 VDC   VMIN
VPK
VSEC  = × VSEC  = ×  V =  V
VDC  
 with  × derating only a  V diode is required  tC

       Capacitor

Voltage tR
       
T
       
     
Capacitor ICHARGE
      Current

   Fig. 3. Input Capacitor Waveforms


  
    
    
      W
PIN = POUT × η = =  W

              
           
•       
         POUT    WOUT 
   
       PIN  η    
       WIN = = =
f LINE f LINE  Hz
  
•         =  Joules
         
 WIN
•       
C IN =
[
(VPK ) − (VMIN )

]
      
•       
              
     
        V PK   V  = V RMS  × 
        =  V −  × 

=  V use  to be conservative
Input Capacitors
       VMIN   V  = VPK   V  − VRIPPLE = V × 
    
use  ripple to be conservative
       
        = V
            
        
        WIN 
C IN = =
         [(V PK ) 
− (VMIN )

] () 
− ( )


     

=  µF
       
                 µ
           


Texas Instruments 6 SLUP229
              
               
               
             
       
  W 
       Ω,  
PIN           Ω, 
WIN = = =  Joules
f LINE  Hz       
       
 W     Ω  
C = C  =  
 (V [
 CPK  ) − (VC  )
 
] 

     
      
         
•                
                
      
•       
       D. Transformer Turns Ratio
        
′  V  = V RMS  ×
VCPK         
=  V −  ×         
      
=  V use  to be conservative       

(VMIN ′ ) ( ×  − )
− VCPK
VC  = = =  V Secondary Turns
 
    
     
 W 
C = C  =        
 (VCPK
 ′ [ ) 
− (VC  ]
) 
       
        
  J        
=   =  µF
 ( )[
− ( ) ]
 
   

    V  N

    
     
      µ 
       
 
=
V  N
      
          
       
       
      
     


Texas Instruments 7 SLUP229
       
      
      
     
       
        
       
    
   
     
   
   
   
   
        
         
          
        

        
          
       
         
           

Primary Turns
      
      
    
      
      
       
      
      
       
      
     
       
         
 
       
       
        
      
        
      
Texas Instruments
     
      
       
     
VIN 
N P  = = =  turns at high line
[V  T ] 
     
       
   
       
    
        
         
VIN 
N P  = = =  turns at low line
[V  T ] 
     
      
      
    
      
        
      
           
        
          
       
      
        

     
     Unitrode Magnetics
Design Handbook   
       
      
     
      
      

8 SLUP229
              
      
•            
•               
         
•       Ω         
•                 
 Ω         
•           Ω           
  I P − P =  × I MIN =  A
•      
•         
      
•   
dt
6 L =V ×
3
12 V @ 3.0 V
di
230 V to 375 V
(input) 7 
1 8 5V
5 •          
12 V @ 0.1 A 9 3.3 V •        
(bias)
4 10          
       
Fig. 4. Transformer schematic. •       
     
E. Output Inductor         
         
      coupled VOUT N
inductor,       Duty Cycle = × P
VIN  N S
       
      
         
t OFF = ( − D MIN ) ×  
steered  adjusted        f SW 
        
       
         
            
Duty Cycle =   ×   = 
            
     
        •    µ
       •    µ
        
            
       dt  ×  µs
       L =V × = =  µH use  µH 
di  A
   
   
  
 
  


Texas Instruments 9 SLUP229
       F. Output Capacitors
 µ                 
             
            
       Capacitor Equivalent Series Resistance (ESR)
               
            
             
     
        I RIPPLE × RESR
VRIPPLE =
       VOUT

        
6         
2,1 (5 V)
9.3 µH
        
(12 V) 7       
50 µH 9       
(3.3 V)
5,4 4.14 µH        
10       
       
Fig. 5. Inductor schematic.     
         VOUT  mV
           R ESR  = =
I MIN  p − p   A
      
       =  mΩ   V output 
       
         mV
R ESR = =  mΩ V output 
       A
        
          mV
     R ESR = =  mΩ  V output 
A
      
         
             
                  
            
       


    

     
      µ
µ  Ω
Ω 
        
      
       


Texas Instruments 10 SLUP229
Capacitor Value        
      dV = VOUT (VOUT − VSETPOINT )
    =  V ( −  ) = V  =  mV
      
              
   ∆      
          A ×  µs
         C= =  µF
V
     
           
∆I dV = VOUT (VOUT − VSETPOINT )
dV = × dt
C =  V ( −  ) = V  =  mV
            
       
     
  A ×  µs
C= =  µF
V
dt
C = ∆I ×
dV       
            µ
       RMS Ripple Current
            
              
        
  
I PEAK
I RMS =
dV = VOUT (VOUT − VSETPOINT ) 
= V ( − ) = V  =  mV
         
                
        A
       I RMS = =  A

       
                  
 µ       µ            
 A
   ∆     I RMS = =  A

   
       
dt  µs         
C = ∆I × =  A× =  µF
dV 
 A
        I RMS = =  mA

      
       
      
    



Texas Instruments 11 SLUP229

 
Final Selection f =      
      µ π LC
Ω                
             
   µ    Ω

        Q=
      R LC
   µ    Ω         
          
     
 
    µ R= =
       Q LC LC
               
       Ω       
          
           
    
 P = C V  f SW
             
  µ   µ       
      
      
        
G. Output Rectifier Snubbers
      
     
      
        
        
        
        Ω, 
        
      
       
     
      
         
    
        
        
    
       
        H. Output Rectifiers
                
               
             
                
      
       
   
          
 µ
µ  Ω)
Ω)    µ
µ   Ω)
Ω)
 
         

 
         

          



Texas Instruments 12 SLUP229

        
   

 
VPK  N S  × 
VR = = ≅    
NP      

          
 
 
VPK  N S    
 × 
VR = = ≅     
NP 
    
      
      
   I. Power Switching FETs
             
        
       
I DIODE = I OUT  + I RIPPLE  peak  =  A + A =  A      
                Ω
       
      
I DIODE = I OUT  + I RIPPLE  peak  =  A +  A =  A       
     
             
       
I DIODE = I OUT  + I RIPPLE  peak  =  A +  A =  A       
        
               
             
            Design and
Application Guide for High Speed MOSFET Gate
PAVG = I PEAK + VF × Duty Cycle Drive Circuits      
       
               
              
        
          
       µ    
PDIODE = VF × I PEAK       
       
         
    


Texas Instruments 13 SLUP229
 VDRV
+VDRV - VC
VCC
+VDRV - VC +VDRV - VD

0V VC - VD - VD
+ - - +
OUT
R5 C5 C9
D5 R10

GND

Fig. 6. Isolated gate drive transformer.

J. IC PWM Controller •         

                
       
         •         
            
       µ 
       •        
   
     
    0.5
 
•        
0.4
     
•      
IIN - Supply Current - mA

Turn Turn
Off On
•   0.3
•       
•   
•    0.2

•    

PWM Bias Supply and VCC Capacitance 0.1
      
       
         0
OFF ON
        
VCC - Supply Voltage - V
     
       Fig. 7. Input voltage (VCC) hysteresis window
  
      
       
 



Texas Instruments 14 SLUP229

•       
       
 
•      µ 
      
       
   start-up current 
       
      
   
 VDC          
   − VCLAMP 
 
I=  =  mA
 kΩ
      

•      
      
       
       
       

•       
     
operating supply current  
      
      
      
       
         
        
      
 
I = QgF =  nC ×  kHz =  mA
ITOTAL = I MAX + I FETdrive =  mA +  mA
=  mA
•            
     
      
    
dt 
C = ∆I × =  × =  µF ≅  µF
dV 
Texas Instruments
      
  µ   µ    
      
         
       
      
       
        
       
      
        
 
       
       
       
    
      
     
   µΗ    
       
     µ  
       
 
         
      
      
      
  Ω     
       
 
Primary Current Sense Resistor
         
      
       
        
      
      
   
         
        
      
       
       
      
       


15 SLUP229
 VBULK
To Power Stage
+ C1
VC1 43 kΩ
Ω
220 V

110 V
- UCC3813 39 kΩ
Ω L
VC2 C2 200 Ω
VCC
GND
0.1 µF 47 µF 12 V 2.2 µF

Fig. 8. PWM start-up and bias current.

′N  K. Setting Up the Loop

I P = I MAG + I S  S  where
 NP         
N         
′
I S = I PEAK  S  for each output         
 NP           
           
=    +    +    =  A
          current source only, 
      
V            
I MAG =  IN   (tON  )=   ( µs )        
 L    mH       
=  A       
        
′     
I P = I MAG + I S =  A +  A =  A
       
               µ
          
                
        
VS  V       
RS = = =  Ω          
IS  A
       
                
          
 Ω
       
       
       
      
  



Texas Instruments 16 SLUP229

       
   µ       
       
         
        
       
    
  µ Ω   
     Ω
       
      
      
      
      
        
      µ  
      
       
       
       
      
  µ      
       
        
R7
150 Ω
       
    
        
      
        
      
        
      
         
     
(V − V − V ) =  Ω
R =
 A
      
        
       
      
   
V
R = =  Ω
 mA
12-V
VOUT

R18
COMP UCC3813-1 10 kΩ
Ω
1
REF

Q3 R16 D12 C26

FB + REF
4N36 200 Ω 10 V 2.2 µF
2 8 5 1 5-V 3.3-V
VOUT VOUT
R6 R17
OPEN 6
750 Ω C24
TBD
4 2

C22 R19 R20 R22

TBD TBD 10 kΩ
Ω OPEN

U2
TL431A R21
10 kΩ
Ω

Fig. 9. Isolated power supply loop closed.


Texas Instruments 17 SLUP229

Closing the Loop
      
       
        
        
     µ   
      
      
       
      
 
L. A Few Optional Ideas
      
 
•         
       
        
    
      
      
      
       
     
   
     
•        
        
        
        
       
        
        
      
 
•          
      
      
      
           
       
•       
      
  
      
     
   
  
Texas Instruments
     
     
  
      supervisory
circuits      
•     
     
      
       
      
        
        
       Ω
       
      
    
      
       
  
       
   
A. Efficiency
       
     
       
       
      
     
      
       
      
     
      
     
        
        
     
        
      
       
          


18 SLUP229
 +

+
+
+

32CTQ030

+
+

Fig 10. Forward converter schematic.


Texas Instruments 19 SLUP229
 0.82
      
      
0.81 106 W         
       
0.80        
      
       
Efficiency - %

0.79
      
0.78       
      
0.78 144 W         
25 W       
0.77
14
12.96
0.76
1.0 1.5 2.0 2.5 3.0 3.5 4.0 12
11.44
Fig. 11. Efficiency. 10

VOUT - Output Voltage - V

        
       8
    
       6
4.95 4.96
B. Cross Regulation 4
      3.49
3.11
       2
•         
      0
•        Output Loading
}

}
        5 V Max 5 V Min
        3.3 V, 12 V Min 3.3 V, 12 V Max

       
   
•       
•      
•    
     
       
      
       
      
      
      
       
       
       
      
      
    
Fig. 12. Cross regulation extremes.
C. Input Capacitor Ripple
       
      
 µ     
     µ
 
        
         
       
       
      
     
        
       
    


Texas Instruments 20 SLUP229
       
       
       Q1 Drain Current (2 A/div)
        
      
       
     

Bulk Capacitor Voltage

(50 V/div)

Q1 Drain Voltage (100 V/div)

t - Time - 2.5 µs/div

Fig. 14. Q1 drain-to-source voltage and drain

t - Time - 2.5 ms / div
Fig. 13. Bulk capacitor input ripple at 90-VAC,
maximum load.
     
       

current at maximum load and 90-VAC input.
       
  
    µ   µ
        
     
       
  
Q1
Drain Current
(2 A/div)

D. Primary Waveforms
      
       
      
       
         Q1
Drain Voltage
    (100 V/div)
     µ   
       
t - Time - 2.5 µs/div
        
   Fig. 15. Q1 drain-to-souce voltage at maximum
    µ   µ   load and 264 VAC input.
      
        
       



Texas Instruments 21 SLUP229
E. Output Ripple Voltage
        12-V Ripple Voltage (50 mV/div)
      
      
      
       
        
      
        
        
     
    
t - Time - 5 µs/div
   

   Fig. 16. 12-V Ripple voltage.

  
   
    5-V Ripple Voltage (10 mV/div)

   

       

        
      
        
       
       
        
      
        
         t - Time - 5 µs/div
       Fig. 17. 5-V Ripple Voltage.
      
     
3.3-V Ripple Voltage (50 mV/div)

t - Time - 5 µs/div

Fig. 18. 3.3-V Ripple voltage.


Texas Instruments 22 SLUP229
F. Diode Voltage
        
        
       
       
      
       
      
       
        
       
           
  
5-V Diode Input Voltage (10 V/div)
t - Time - 2.5 µs/div
Fig. 19. Diode blocking voltage.
      
        
        

 
      
       
     
       
       
      
   
      
      
     

     
      
Texas Instruments
    
      
      
     
      
 

      
   Unitrode
Magnetics Design Handbook Topic R5 
   (SLUP132)
    
    
  Application Note 
    
       
    
 Unitrode Power Supply Design
Seminar SEM-100 Section I1    
 
    
    
    
    
 Application Note 
    
    
      
 Application Note 
    
    
    
   
  TI Power Supply
Design Seminar SEM-1500, Topic  
     (SLUP204)

     
     
  TI Power Supply Design
Seminar SEM-1400    
 (SLUP169)

      
       
  

23 SLUP229
  

Fig. 20. Design PCB

    


     

           
            
          
      µ      
 
     µ     

           
      µ      
      µ      
     µ    
     µ      
  
       µ    

  
      µ       
 
 
     µ    Ω   




Texas Instruments 24 SLUP229

 
     

           
            
          
           
          
           
            
            
          
 
     
 
     
     
    
     
     
    
              
              
     µ    Ω     
 
           

            
         
     Ω      
     Ω      
     Ω      
     Ω      
     Ω      
       Ω      
     Ω      
     Ω      
     Ω      
     Ω      
     Ω      
     Ω      
    Ω      
     Ω      
     Ω      
     Ω      
     Ω      
     Ω      
     Ω      
      Ω       
 
       

   
 
          

 
         

        
        

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Texas Instruments 25 SLUP229
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