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Totem_Pole PFC Coil Design 230318
Totem_Pole PFC Coil Design 230318
𝑑𝑖 𝑉 𝑑𝑖
𝑉 =𝐿 =
V= 작다 & L= 일정 𝑑𝑡 𝐿 𝑑𝑡
V= 일정 & L= 크다 𝑑𝑖
𝑑𝑡
V= 크다 & L= 일정
V= 일정 & L= 작다
𝑑𝑖
𝑑𝑡
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Totem_Pole PFC
Totem_Pole PFC Current Wave
𝑉 𝑑𝑖
=
𝐿 𝑑𝑡
3
Totem_Pole PFC
Totem_Pole PFC Coil Design 예
https://gansystems.com/wp-content/uploads/2018/01/GS665BTP-REF-rev170905.pdf
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Totem_Pole PFC
Totem_Pole PFC Spike Reduction
https://www.ti.com/lit/an/slyt650/slyt650.pdf?ts=1679135242874&ref_url=https%253A%252F%252Fwww.google.com%252F
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Totem_Pole PFC
Totem_Pole PFC Spike Reduction
Scenario 1 그림 5 에서 볼 수 있듯이 AC 제로 크로싱에서 작동 모드가 음의 주기에서 양의 주기로 변경되면 스위치 Q3 의
As shown in Figure 5, when the operation mode 듀티비가 거의 100% 에서 0 으로 급격히 변경됩니다 . 스위치 Q4 의 듀티비는 0 에서 거의 100% 로 급격히 변합니다 .
Q1 바디 다이오드의 느린 역회복과 Q2 의 큰 COSS 로 인해 Q2 의 VDS 전압은 여전히 VOUT(400V) 과 같습니다 . Q4
changes from negative cycle to positive cycle at the 가 켜지면 이 고전압이 인덕터에 인가되기 때문에 양의 전류 스파이크가 생성됩니다 . 이 시나리오는 Reference 3 에서
분석되었으며 이 문제를 해결하기 위해 Q4 소프트스타트 방법이 제안되었습니다 .
AC zerocrossing, the duty ratio of switch Q3
changes abruptly from almost 100% to zero. The
duty ratio of switch Q4 changes abruptly from zero
to almost 100%. Because of the slow reverse re-
covery of the Q1 body diode and the large COSS of
Q2, the VDS voltage of Q2 still equals VOUT (400
V). Since this high voltage is applied to the induc-
tor when Q4 turns on, a positive current spike is Negative Cycle End
generated. This scenario is analyzed in Reference 3
and a Q4 softstart method is proposed to solve this
issue.
Scenario 2
However, even with soft turn on of Q4, there are Positive Cycle Start
still excessive current spikes. This is because VAC
is very low right after zero-crossing and is therefore
insufficient for the inductor current to build up. On COSS
https://www.ti.com/lit/an/slyt650/slyt650.pdf?ts=1679135242874&ref_url=https%253A%252F%252Fwww.google.com%252F
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Totem_Pole PFC
Totem_Pole PFC Spike Reduction
Scenario 3 Q2 를 켜는 타이밍도 중요합니다 . Q4 소프트 스타트 전에 Q2 가 켜지고 Q1 의 바디 다이오드가 충분히 빨리 복구되지
Timing for Q2 turn on is also critical. A short- 않으면 단락이 발생할 수 있습니다 . (Q4 Off 후 Free Wheeling 될 때 Q2 가 켜지면 Arm_Short 발생 Q2 가 너무
빨리 On 되도 문제 ~!)
through can occur if Q2 turns on before Q4 soft
start and if the body diode of Q1 does not recover
quickly enough.
Scenario 4
If Q2 turns on too late, a negative current spike can
be generated (Figure 6). The high VBUS voltage
generates a reverse inductor current when Q3 is on
while Q2 is off. This reverse current first turns off Negative Cycle End
the Q2 body diode, then starts to charge COSS of
Q2 and the VDS of Q2 builds up to a high voltage.
Then, when Q4 turns on, the high voltage (VDS +
VIN) that is applied to the inductor results in high
rising current in the inductor. Therefore, the induc-
tor’s rising and falling currents are both large mag- Positive Cycle Start
nitude, which achieves a balance that maintains the
average current at a small positive value. Now, if
Q2 suddenly turns on at t1, VDS of Q2 will be COSS
7
Totem_Pole PFC
Totem_Pole PFC Spike Reduction
In this solution, when VAC changes from a negative to positive cy-
cle, after AC zerocrossing, Q4 first turns on with a very small
pulse width. The pulse width then gradually increases to D (the
duty cycle generated by control loop). By doing a soft-start on Q4,
정류
Q1 completely reverse recovers. Now the voltage, VDS, of Q2 PWM
Once the Q4 soft-start is complete, the sync FET, Q3, starts a soft
turn-on with a tiny pulse width and gradually increases until the
pulse width reaches 1 – D. This eliminates the negative current
spike caused by scenario 2.
PWM
PWM FET 먼저 Soft_Start 정류용 FET Soft_Start & Q2 On
그리도 모든 FET Off 구간을 둔다 ~! https://www.ti.com/lit/an/slyt650/slyt650.pdf?ts=1679135242874&ref_url=https%253A%25
2F%252Fwww.google.com%252F
8
Totem_Pole PFC
Totem_Pole PFC Block - Classic boost PFC
The average inductor current shown in Figure is conducted through two diodes of the rectifier bridge at all
times, and this causes significant conduction loss, especially at higher power and low-line conditions.
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Block - Bridgeless totem-pole PFC
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Block - 효율비교
13%
13% 22% 9%
43%
13% 9%
22% 4%
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Block - 효율비교
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Block – 요구사양
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Block – PFC Inductor Design
(
√ 2 ∙𝑉 𝑎 𝑐 . 𝐻𝐿
)
2
( )
1 𝑉 𝑎 𝑐 . 𝐻𝐿 1 ( 230 𝑉 )2 √ 2 ∙ 230𝑉 ∙ 1 =216 𝑢𝐻
𝐿= ∙ 1− ∙𝑇= ∙ 1−
% 𝑅𝑖𝑝𝑝𝑙𝑒 𝑃𝑜 𝑉𝑜 25 % 2500 𝑊 390 𝑉 65 𝐾𝐻𝑧
𝑉 =𝐿
𝑑𝑖
𝑑𝑡
𝐿=𝑉
𝑑𝑡
𝑑𝑖
𝐿=𝑉
∆𝑡
∆𝑖
𝐷=1 −
𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑝𝑘
𝑉𝑜
∆ 𝑡 =𝐷 ∙ 𝑇 = 1 −
𝑉𝑜 (
√ 2∙ 𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑟𝑚𝑠
∙𝑇 )
𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑟𝑚𝑠
𝑉 𝑎𝑐 . 𝐻𝐿∙ 𝑝𝑘=√ 2 ∙ 𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑟𝑚𝑠𝑉 𝑎𝑐 . 𝐻𝐿∙ 𝑟𝑚𝑠=
√2
√2 ∙ 𝑃𝑜
𝐼 𝐿 .𝑚𝑎𝑥 =
𝑉 𝑎 𝑐 . 𝐻𝐿 (
∙ 1+
% 𝑅𝑖𝑝𝑝𝑙𝑒
2 ) √ 2∙ 𝑃 𝑜 % 𝑅𝑖𝑝𝑝𝑙𝑒
∙
𝑉 𝑎𝑐 . 𝐻𝐿 ( 2 )
= √
𝑃 𝑃 2∙ 𝑃
𝑃=𝑉 ∙ 𝐼 𝐼 = = 𝐼 𝑅𝑖𝑝𝑝𝑙𝑒
⇒ 𝑉 𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑟𝑚𝑠 𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑟𝑚𝑠
𝐼 𝑎𝑣𝑔
√2
√2 ∙ 𝑃𝑜
𝐼 𝐿 .𝑚𝑎𝑥 =
𝑉 𝑎 𝑐 . 𝐻𝐿 (
∙ 1+
% 𝑅𝑖𝑝𝑝𝑙𝑒
2
=√
230 𝑉)
2 ∙ 2500 𝑊
∙ 1+
0.25
2
=17.2 𝐴 ( )
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Block – PFC Inductor Design
𝑃 𝑜 ∙ √2
𝐼 ( 𝑡 , 𝑃 𝑜 )= ∙ 𝑠𝑖𝑛 ( 2 𝜋 ∙ 𝑓 𝑙𝑖𝑛𝑒 ∙ 𝑡 )
𝑉 𝑎𝑐
𝐻 (𝑡 , 𝑃 𝑜)=
| 0.4 ∙ 𝜋 ∙ 𝑁 ∙ 𝐼 𝐿 ( 𝑡 , 𝑃 𝑜 )
𝑙 𝑒 ( 𝑐𝑚 ) |
( )
−3
0.9931+2.295 ∙ 10 ∙ 𝐻 (𝑡 , 𝑃 𝑜)
−4 2
𝜇 ( 𝑡 , 𝑃 𝑜 )= 𝜇𝑖
− 1.292 ∙10 ∙ 𝐻 (𝑡 , 𝑃 𝑜) 0.4 ∙ 𝜋 ∙ 𝑁 2 ∙ 𝜇 ( 𝑡 , 𝑃 𝑜 ) ∙ 𝐴 𝑒 ( 𝑐 𝑚2 ) 2
−7 3 𝐿 ( 𝑡 , 𝑃 𝑜 )= 𝐴𝑒 =3 ×65.6 𝑚 𝑚
+7.653 ∙ 10 ∙ 𝐻 (𝑡 , 𝑃 𝑜) 𝑙𝑒 ( 𝑐𝑚 )
−9 4
− 1.361 ∙10 ∙ 𝐻 ( 𝑡 , 𝑃𝑜)
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Block – PFC Inductor Design
Inductor copper loss
𝑃𝑜 2500 𝑊
𝐼 𝐿 .𝑟𝑚𝑠 ≅ 𝐼 𝑖𝑛.𝑟𝑚𝑠 = = =10.87 𝐴
𝑉 𝑎𝑐 . 𝐻𝐿 230 𝑉
2 2
𝑃 𝐿. 𝑐𝑜𝑛𝑑 = 𝐼 𝐿 .𝑟𝑚𝑠 ∙ 𝐷𝐶𝑅=( 10.87 𝐴 ) ∙ 0.052 Ω=6.15 𝑊
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Block – PFC Inductor Design
Inductor core losses
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Block – PFC Inductor Design
Inductor core losses
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Block – PFC Inductor Design
Inductor core losses
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Block - 효율비교
390VDC
340VDC
https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
Totem_Pole PFC Coil Design
https://www.monolithicpower.com/en/how-to-avoid-inductor-saturation-in-your-power-supply-design
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Totem_Pole PFC
Totem_Pole PFC Coil Design
https://www.monolithicpower.com/en/how-to-avoid-inductor-saturation-in-your-power-supply-design
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Totem_Pole PFC
Totem_Pole PFC Coil Design
https://www.monolithicpower.com/en/how-to-avoid-inductor-saturation-in-your-power-supply-design
23
Totem_Pole PFC
Totem_Pole PFC Coil Design
https://www.monolithicpower.com/en/how-to-avoid-inductor-saturation-in-your-power-supply-design
24
Totem_Pole PFC
Totem_Pole PFC Coil Design
Power: 650W
Input: 85-260 Volts DC input
Output: 370 Volts DC output
Frequency: 65 kHz
1
𝑇 = =15.4 𝑢𝑠𝑒𝑐
𝑓
650 𝑊
𝐼 𝑜𝑢𝑡 = =1.76 𝐴
370 𝑉
𝑉 𝑖𝑛
𝐷𝑚𝑎𝑥 = 1− 𝑚𝑖𝑛
= 0.77
𝑉 𝑜𝑢𝑡
𝑉 𝑖𝑛
𝐷𝑚𝑖𝑛 =1 − 𝑚𝑎𝑥
= 0.33
𝑉 𝑜𝑢𝑡
𝐷=𝐷𝑢𝑡𝑦 𝐶𝑦𝑐𝑙𝑒
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
25
Totem_Pole PFC
Totem_Pole PFC Coil Design
𝐼 𝑎𝑣𝑔 =1.76 ( 1
1 − 0.77 )
=7.65 𝐴 이것은 임의적입니다 . 인덕턴스와 손실 계산은 이
값에 따라 달라집니다 . 최악의 경우 인덕턴스와
리플이 함께 발생하지 않기 때문에 실제 결과는
-. At High Line Voltage 언더슈트가 됩니다 . 리플을 개선하거나 비용 / 공간을
개선하기 위해 설계를 반복할 수 있습니다 .
𝐼 𝑎𝑣𝑔 =1.76 ( 1 − 10.30 )=2.51 𝐴
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
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Totem_Pole PFC
Totem_Pole PFC Coil Design
▶ Inductance Current
Parameter Description Min. Typ. Max. Unit
Inductance Average Current (@Vin = Min) - 7.558 - A
I_avg
Inductance Average Current (@Vin = Max) - 2.500 - A
△Ripple Current % Maximum Ripple Current 40 %
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
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Totem_Pole PFC
Totem_Pole PFC Coil Design
𝑡 𝑜𝑛
𝑡 𝑜𝑛+ 𝑡 𝑜𝑓𝑓 =15.4 𝑢𝑠𝑒𝑐 𝐷𝑢𝑡𝑦 𝐶𝑦𝑐𝑙𝑒 ( 𝐷 )=
15.4 𝑢𝑠
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
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Totem_Pole PFC
Totem_Pole PFC Coil Design
▶ Ripple Current Check (허용범위 이내인지 확인, Ripple 범위 내에서 Coil이 포화하지 않는 충분한 L값 선정 필요)
Parameter Description Min. Typ. Max. Unit
V_f Diode 순방향 전압 - 1.000 - V
△I Inductance Ripple Current (@Vin = Max) - 2.000 - A
ܦȉܶ
L Inductance (@Vin=260V) ܮൌܸ - 592.3 - uH
οܫ
△I Inductance Ripple Current (@Vin = Min) - 1.7 - A
https ://www.monolithicpower.com/en/how-to-
※ 포화되지 않도록 포화되면 과전류로 발열이 심해짐
a voi d-inductor-saturation-in-your-power-supply-
des ign
구동주파수에 따른
<== 포화되면 과전류로 발열이 심해짐
충분한 L값 설정이
중요함
I_px_max=3.50A I_px_max=8.41A
I_avg=2.50A I_avg=7.56A
I_pk_min=1.50A I_pk_min=6.71A
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
29
Totem_Pole PFC
Totem_Pole PFC Coil Design
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
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Totem_Pole PFC
Totem_Pole PFC Coil Design
▶ Ferite Core 선택
Parameter Description Min. Typ. Max. Unit
LI^2 Ferite Core의 에너지 (@ mH) - 41.84752369 - w
Ferite Core Kool Mu 부품 번호: 0077439A7 - - -
u Core 사양에서 찾은 값 (아래 빨간선 참조, Core 마다 다름) - 60.00 - u
Ve 체적 - 21.30 - cm3
AL AL Value (Core가 정해 졌을 때 감는 수가 L과의 관계) - 135.000 -
le Max, Primary Current - 10.740 - cm
MLT The mean length per turn of wire for a core - 8.660 - cm
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
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Totem_Pole PFC
Totem_Pole PFC Coil Design
-. From the core selector chart below, Kool Mu part number: 0077439A7
-. μ = 60 Ve = 21.3 cm3
-. AL = 135 Aw = 4.27 cm2
-. le = 10.74 cm MLT = 8.66 cm (full)
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https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
32
Totem_Pole PFC
Totem_Pole PFC Coil Design
5. Determine Number of Turns. (MLT : The mean length per turn of wire for a core)
https://electronics.stackexchange.com/questions/485659/how-to-find-mean-length-per-turn-mlt-for-magnetic-design-from-ferrite-cores-da
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Totem_Pole PFC
Totem_Pole PFC Coil Design
▶권선 결정
Parameter Description Min. Typ. Max. Unit
L_fix 계산된 L값의 2배로 선정 - 1184.6 - uH
ܣܮȉ ܰ ଶ
계산된 Coil 권선 수 ܰ ൌ - 93.6745898 - Turn
N
선정된 Coil 권선 수 - 94 - Turn
H Core의 자화력 - 92.45 - Oer
유전율 계산된 H에 의한 유전율 (Core 사양 에서서 찾을 것) - 0.46 - -
다시 계산된 인덕턴스 (@Max 부하) - 548.72 - uH
L_fix_2nd
다시 계산된 인덕턴스 (@Min 부하) - 1184.62 - uH
0.46
93
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
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Totem_Pole PFC
Totem_Pole PFC Coil Design
𝐵 1 ∆𝐵
𝜇= 𝐸= 𝐿 𝐼
2
𝐻 2
H=NI
𝐵=𝜇 𝐻 𝜙=𝐵∙ 𝐴 𝑒
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
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Totem_Pole PFC
Totem_Pole PFC Coil Design
▶ Ripple Current Check Again ( 선정된 인덕턴스로 Ripple 전류 다시 계산함, Ripple 범위 내에서 Coil이 포화하지 않는 충분한 L값 선정 필요)
Parameter Description Min. Typ. Max. Unit
V_f Diode 순방향 전압 - 1.000 - V
△I Inductance Ripple Current (@Vin = Max) - 1.294 - A
포화 방지를 위한 자화력 재 검토 (@Ipk=3.51A) - 38.495 - Oer
H (자화력)
포화 방지를 위한 자화력 재 검토 (@Ipk=3.16A) - 34.611 - Oer
ଶ
L Inductance (@Vin=260V) ܮൌܦ௫ ȉ ܣ ܮȉ ܰ - 915.6 - uH
△I Inductance Ripple Current (@Vin = Min) - 1.829 - A
I_px_max=8.47A
I_avg=7.56A
I_px_max=3.15A I_pk_min=6.64A
I_avg=2.50A
I_pk_min=1.85A
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
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Totem_Pole PFC
Totem_Pole PFC Coil Design
I_avg_max=7.56A
I_avg_min=2.50A
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
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Totem_Pole PFC
Totem_Pole PFC Coil Design
▶ 권선 Wire 선택
Parameter Description Min. Typ. Max. Unit
Wa 선정된 Wire의 선경(면적, @#17 Gage) - 0.0122 - cm2
Fillfactor 권선 후 권선이 차지하는 면적 (%) - 26.9 - %
Wa 선정된 Wire의 선경(면적, @#16 Gage) - 0.0152 - cm2
Fillfactor 권선 후 권선이 차지하는 면적 (%) - 33.5 - %
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
38
Totem_Pole PFC
Totem_Pole PFC Coil Design
4810
4040
2170
1340
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
39
Totem_Pole PFC
Totem_Pole PFC Coil Design
5. Core Loss.
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
40
Totem_Pole PFC
Totem_Pole PFC Coil Design
https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design
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