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Tutorial Cascade
Tutorial Cascade
1
About the Presenter
3
Common One-Switch Power
Converter Topologies
L
Vi n Vo
Vi n Vo
L
Vi n
Vi n
Np Ns Vo Np Ns Vo
Na ux
Forward Converter Flyback Converter
4
© 2003 National Semiconductor Corporation
Common Two-Switch Power
Converter Topologies
Vin
L
L
Np Ns Vo
Ns Vo
Vin
Np
Np Ns
Ns
Vin
L
Ns Vo
Np
Ns
IL
D*Ts
Ts
Q1
I(Q1)
VOUT
L1
D1
C1
I(D1)
VOUT = D * VIN
6
© 2003 National Semiconductor Corporation
Buck Converter
Characteristics
• Non-Isolated Grounds
• Voltage Step-down Only
• Single Output Only
• Very High Efficiency
• Low Output Ripple Current
• High Input Ripple Current
• High Side (Isolated) Gate Drive Required
• Large Achievable Duty Cycle Range
• Wide Regulation Range (due to above)
7
© 2003 National Semiconductor Corporation
Forward Converter
D1 L1
+
Vout
+
Np Nr Ns D2 C1 R
Vin
-
Vout = Vin x D x Ns
D3
Q1 I(L1) Np
1 2 3 4
Same transfer function as a
I(D1) =
Buck converter with an
I(Q1) x Np/Ns added turns ratio term
1 2 3 4
I(D2)
8
Forward Diode D1
Current
Freewheel
Diode D2
Current
Vin =48V
Vout =3.3V
Iout = 5A
9
© 2003 National Semiconductor Corporation
Forward Converter
Characteristics
• A Forward Converter is a Buck type converter
with an added isolation transformer
• Grounds are isolated
• Voltage Step-down or Step-up
• Multiple Outputs Possible
• Low Output Ripple Current
• High Input Ripple Current
• Simple Gate Drive
• Limited Achievable Duty Cycle Range
10
© 2003 National Semiconductor Corporation
Push-Pull Topology
D1 L
+
Vout
+
np ns C R
np ns
Vg D2
Vin
Q2 Q1
PUSH PULL
Q1 Vout = Vin x D x Ns x 2
Q2 Np
D
11
© 2003 National Semiconductor Corporation
Push-Pull Switching Waveforms
Vin = 48V
Output Vout =3.3V
Inductor
Current I(L1)
Iout = 5A
Push Primary
Switch VDS(Q1)
Pull Primary
Switch VDS(Q2)
12
© 2003 National Semiconductor Corporation
Push-Pull Diode Currents
Vin = 48V
Vout =3.3V
Output Diode
Current I(D1)
Iout = 5A
Output Diode
Current I(D2)
13
© 2003 National Semiconductor Corporation
Core Utilization: Forward &
Push-Pull Converters
FLUX DENSITY FLUX DENSITY
B (GAUSS) B (GAUSS)
BSAT BSAT
Operation in Operation in
Quadrant 1 only Quadrants 1 & 3
BR
MAGNETIC FIELD
MAGNETIC FIELD INTENSITY
INTENSITY H (OERSTED)
H (OERSTED)
15
© 2003 National Semiconductor Corporation
LM5030 Push-Pull Controller
Vin ENABLE 7.7V REG Vcc
Features CLK
OSC Vcc
• Internal 15-100V start-up regulator Rt / SYNC
16
0.45V SHUTDOWN
COMPARATOR
© 2003 National Semiconductor Corporation
LM5030 Push-Pull Demo Board
Performance:
Input Range: 36 to 75V
Output Voltage: 3.3V
Output Current: 0 to 10A
Board Size: 2.3 x 2.3 x 0.45
Load Regulation: 1%
Line Regulation: 0.1%
Current Limit
Output:
3.3V @ 10A
18
© 2003 National Semiconductor Corporation
LM5030 3G Base Station
RF Power Supply
Performance:
Input Range: 36 to 75V
Output Voltage: 27V
Output Current: 0 to 30A
Board Size: 6 x 4 x 2
Load Regulation: 1%
Line Regulation: 0.1%
Line UVLO, Current Limit
Output OV Protection
19
© 2003 National Semiconductor Corporation
LM5030 3G Base Station RF Supply
-48Vin to +27V @ 30A
20
© 2003 National Semiconductor Corporation
Cascaded Buck & Push-Pull
Power Converter (Voltage Fed)
Buck Push-Pull
Stage Stage
N : N : 1 : 1
Vin Vpp Vout
BUCK
PUSH
CONTROL
CONTROLLER OSCILLATOR
FEEDBACK PULL
Buck Control Output is Push-Pull Outputs operate Buck Stage: Vpp = Vin * D
pulse-width modulated to continuously, alternating at Push-Pull Stage: Vout = Vpp / N
regulate Vout 50% duty cycle Overall: Vout = Vin x D/N
21
© 2003 National Semiconductor Corporation
Cascaded Voltage-Fed
Converter Benefits
• A Voltage-Fed Push-Pull Converter is a Buck type
converter consisting of a Buck Regulation stage
followed by (cascaded by) a Push-Pull Isolation
Stage
• The Push-Pull Stage FET voltage stresses are
reduced to Vout x N x 2 over all line conditions
• The output rectification can be easily optimized due
to reduced and fixed voltage stresses
• The output rectification is further optimized since the
power is equally shared between the rectifiers over
all load and line conditions
• Favorable topology for wide input ranges
22
© 2003 National Semiconductor Corporation
Current Fed Push-Pull Concept
OUTPUT INDUCTOR REMOVED
Buck Stage Push-Pull Stage
33 - 76V Vout
Vcc
Vcc HB
Vin HI HO
HD
HS BUCK OUT CAP
REMOVED
LI LO
LD
LM5101
LM5041 Vss
PUSH
FEEDBACK
PULL
FB
• Push and Pull outputs operate continuously, alternating with a slight overlap.
• Output voltage is controlled by the Buck stage which operates at 2X the Push-Pull frequency.
• Continuous output current from the Push-Pull stage requires minimal filtering.
• High Efficiency achieved with low Push-Pull switching losses and matched Sync rectifier loading
23
© 2003 National Semiconductor Corporation
Cascaded Current-Fed
Converter Benefits
• A Current-Fed Push-Pull Converter is a Buck
type converter consisting of a Buck Regulation
stage followed by (cascaded by) a Push-Pull
Isolation Stage
• There is no high current output inductor!
• Reduced switching loss in Push-Pull stage
• Favorable topology for multiple outputs since all
outputs are tightly coupled
• Favorable topology for wide input ranges, since
the Buck stage pre-regulates while the Push-Pull
and Secondary operate independently of the
input voltage level
24
© 2003 National Semiconductor Corporation
Current-Fed Switching Voltages
Trace 1:
Push_Pull SWPUSHVDS
Vin = 60V
Trace 2: Vout =2.5V
Push_Pull SWPULL VDS Iout = 20A
Trace 3:
Buck Stage Switching
Node
25
© 2003 National Semiconductor Corporation
Current-Fed Push-Pull Switches
Ch 1,2
Push-Pull VDS
Ch 3,4
Push-Pull IDS
Vin = 48V
Vout =2.5V
Iout = 20A
26
© 2003 National Semiconductor Corporation
Current-Fed Switch Waveforms
Expanded Scale
Ch 1,2
Push-Pull VDS
Ch 3,4
Push-Pull IDS
Vin = 48V
Vout =2.5V
Iout = 20A
27
© 2003 National Semiconductor Corporation
Why is it important to reduce
secondary rectification losses?
Control
10%
Secondary
Transformer Rectifiers
20% 40%
Filter Inductor
15% Primary
Switching
15%
Estimate for typical 3.3V Output, 35 – 80V Input
28
© 2003 National Semiconductor Corporation
Comparison of Rectifier
Stresses
Example:
3.3V Out, 35 - 80V
Topology Rectifier Voltage Stresses Input Example: Assumptions
Forward Vin * (Ns/Np) 20V High Line with XFR Ratio 4:1
Push-Pull Vin * (Ns/Np) * 2 26.7V High Line with XFR Ratio 6:1
Cascaded PP Vout * 2 6.6V All Line conditions XFR Ratio 6:1
Example:
3.3V Out, 35 - 80V
Topology Rectifier Current Ratios Input Example: Assumptions
Forward Iout * D and Iout * (1-D) 16 / 84% Ratio at High Line
Push-Pull 50% * Iout 50% All line conditions
Cascaded PP 50% * Iout 50% All line conditions
29
© 2003 National Semiconductor Corporation
Sync Rectifier Waveforms
Ch 1
Sync1 VDS
Ch 2
Sync2 VDS
Vin = 48V
Vout =2.5V
Iout = 20A
30
© 2003 National Semiconductor Corporation
LM5041 Cascaded PWM
Controller
Features:
• Internal 100V Capable Start-up Bias Regulator
• Programmable Line Under Voltage Lockout with
Adjustable Hysteresis
• Current Mode Control
• Internal Error Amplifier with Reference
• Dual Mode Over-Current Protection
• Internal Push-Pull Gate Drivers with Programmable
Overlap or Deadtime
• Programmable Soft-Start
• Programmable Oscillator with Sync Capability
• Precision Reference
• Thermal Shutdown (165C)
Packages: TSSOP16 and LLP16 (5 x 5 mm)
31
© 2003 National Semiconductor Corporation
LM5041 Block Diagram
ENABLE Vcc
Vin 9V REG
UVLO
CS
2K 0.5V
R Q Vcc
SS 10uA CLK
DEADTIME
SS DIVIDE OR
OSCILLATOR Vcc
BY 2 OVERLAP
CONTROL
ENABLE
PULL
DRIVER
0.45V
SHUTDOWN
Rt / SYNC TIME 32
COMPARATOR
© 2003 National Semiconductor Corporation
LM5041 Current Fed Push-Pull
Demo Board
Performance:
Input Range: 36 to 75V
Output Voltage: 2.5V
Output Current: 0 to 50A
Board Size: 2.3 x 3.0 x 0.5
Load Regulation: 1%
Line Regulation: 0.1%
Line UVLO, Current Limit
34
© 2003 National Semiconductor Corporation
Cascaded Half-Bridge
Concept
Half-Bridge Vout
Stage
T1
Buck
Stage
Vin L1
33 - 76V
VDD
VDD
Vcc
Vin HD T1
LD
LM5100
LM5102
LM5041
PUSH
PULL
FB
FEED
BACK
35
© 2003 National Semiconductor Corporation
Cascaded Half-Bridge
Characteristics
• A Cascaded Half-Bridge Converter is a Buck type
converter consisting of a Buck Regulation stage
followed by (cascaded by) a Half-Bridge Isolation
Stage.
• The isolation stage is Voltage-Fed.
• Voltage splitter capacitors and a small output stage
inductor are required.
• Dead time is required for Half-Bridge switches
• The Half-Bridge Stage FET stresses are reduced, to
Vout * N. (2x less than the Push-Pull)
36
© 2003 National Semiconductor Corporation
Cascaded Full-Bridge Concept
Vout
Full-Bridge
Stage
Buck T1
Stage
Vin L1
33 - 76V
VDD VDD
VDD
Vcc
Vin HD T1
LD
LM5102 LM5100 LM5100
LM5041
PUSH
PULL
COMP
FEED
BACK
37
© 2003 National Semiconductor Corporation
Cascaded Full-Bridge
Characteristics
• A Cascaded Full-Bridge Converter is a Buck type
converter consisting of a Buck Regulation stage
followed by (cascaded by) a Full-Bridge Isolation
Stage
• The isolation stage is Current-Fed
• No voltage splitter capacitors or output stage
inductor are required as in the Cascaded Half-Bridge
• Overlap time is required for Isolation Stage switches
• The Full-Bridge Stage voltage stresses are Vout x N,
similar to the half-bridge
• Full-Bridge Stage current levels are half that of a
Half-Bridge.
38
© 2003 National Semiconductor Corporation
High Side Gate Driver Operation
VIN VIN
Vcc Vcc
Q2 Q2
LEVEL LEVEL
HI SHIFT HI SHIFT
Vcc Vcc
Q1 Q1
LI LI
41
© 2003 National Semiconductor Corporation
LM5102 Timing Diagram
HI
K x RT1
HO
LM5102
LI
Adjustable Leading
Edge Delay K x RT2
LO
42
© 2003 National Semiconductor Corporation
LM5104 Driver with Adaptive
Deadtime, Programmable Delay
Features Typical Applications
• 2Amp Driver for Complementary High and • Cascaded Power Converters
Low Side FETs • High Voltage Buck Regulators
• Adaptive Deadtime with programmable • Active Clamp Forward Power Converters
additional delay VDD
• Single TTL-Level logic input LM5104 HB
• Bootstraps drive high side gate to 116VDC Adapt DLY HO
• Short propagation delay (45ns) Logic Logic
HS
• Fast rise and fall times (10ns into 1nF)
• VDD supply under-voltage lock-out (6.7V)
• Low power consumption (1.5mA @ IN Adapt DLY LO
0.5MHz) Logic Logic