148V25A高效率开关电源开发

113yPowerQuarterlyReviewInvestigationoftheHighPowerInvestigationoftheHighPower--DensityDensityACAC--DCFrontDCFront--EndConverterEndConverterChuanyunWang,BingLu,YueChang,MingXu,FredC.LeePreparedfor3YPreparedfor3Y--PowerTechnologyPowerTechnology223yPowerQuarterlyReviewFront-EndConverterSpecifications™InputVoltage90~260Vacsinglephase™Outputvoltage12VDC™Outputpower1200W™Efficiency89%at230Vac,fullload™Powerfactor0.98™Hold-uptime20ms™Profile1UIntermediateBus400VPFCPFCDC/DCDC/DCACInputOutput12VBus333yPowerQuarterlyReviewChallengesandGoalsChallenges:Highpower-density,highefficiency™Shorttermgoal:Design,buildandtestahighpowerdensity1U1.2kWfront-endconverterfortheserverapplication¾Powerdensity:13.9W/inch3(Size:1.6”x4.75”x11.35”)¾Efficiency:89%¾Node-rating443yPowerQuarterlyReviewOutlinePartI.PFCStage™Finaldesign™ExperimentalresultsPartII.DC-DCStage™Finaldesign™Experimentalresults¾Measuredefficiencycurve¾Hold-uptimetest553yPowerQuarterlyReviewPartI.PartI.PFCStagePFCStage663yPowerQuarterlyReviewCoolMOS+LosslessSnubberPFCisChosen¾UseCoolMOStoreduceconductionlossandturnoffloss¾Usecurrentsteeringconcepttoreducereverserecoveryandturnonloss¾LosslesssnubbertorecovertheleakageinductorenergyLoadSImIsVDSIDoIDaIintttT0T1T3T4T5T0tttT2T6t773yPowerQuarterlyReviewPFCCircuitDesignLoad™140kHzswitchingfrequency™90~270Vac™1200WforDC-DCoutputTwo220uFelectrolyticcap+50nFceramiccapCo50nF(100V)ceramiccapCcTwo77083core,AWG#14InductorShindengen,D25XB60DiodebridgeSidiode,serialconnectionpackage,FEP16JTD,TO-220Da1,Da2Sidiode,commoncathodpackage,ISL9K860P3,TO-220Do,DaTwoInfineonCoolMOS60R99inparallel,TO-247S¾¾OnemoreTOOnemoreTO--220component220component¾¾TwomorewindingsTwomorewindings883yPowerQuarterlyReviewBoostInductorDesign@140kHz77083-A777083-A7™ForN1windingAWG#14wireisused™ForN2andN3windingLitzwireisused*[Ref]Zhao,Q.;Tao,F.;Lee,F.C.;Xu,P.;Wei,J.;IEEE200193yPower9PFCStageHardware1stVersion2ndVersionVoltageandcurrentstressreductioninsingle-stagepowerfactorcorrectionAC-DCconverterswithbulkcapacitorvoltagefeedback.pdf10103yPowerQuarterlyReviewDiodeReverseRecoveryVin=120VacPo=800W™Dohasnoreverserecovery™DahasasmallreverserecoverycurrentLoadDa5ADoNaturallyRecovered5A/divIN3IN211113yPowerQuarterlyReviewVoltageStressonDevicesDa+-VinSCo+Vo-LkIinDoDa2Da1Cc123RedOrange1213--™S,Do,Da1,Da2hasthenormalvoltagestressofVo™DahashighervoltagestressofVo+VCc12123yPowerQuarterlyReviewMeasuredEfficiencyv.s.InputVoltage*DatawascollectedfromVoltechPM3000A90%91%92%93%94%95%96%97%98%99%100%90140190240Vin(Vac)EfficiencyPo=1200WPo=1290WDevicevoltagestress:MOSFETVds:500VVDa:486VSnubberCap:61VDevicetemperature:MOSFET:48ºCDiode:54ºCDiodebridge:78ºCSensingR:82ºC13133yPowerQuarterlyReview90%91%92%93%94%95%96%97%98%0200400600800100012001400Po(W)EfficiencyVin=90VacVin=120VacVin=180VacVin=220VacVin=270VacMeasuredEfficiencyv.s.OutputPower¾Inputvoltage:90,120,180,220,270Vac¾Outputpower:240~1300WPF0.984*DatawascollectedfromVoltechPM3000A14143yPowerQuarterlyReviewPartII.PartII.DCDC--DCStageDCStage15153yPowerQuarterlyReviewProposedIsolatedDualBoost¾ZVSforbothprimaryandsecondaryswitches¾Constantswitchingfrequencyduringnormaloperation¾Optimalefficiencyat400V&wideinputrange¾Easiertorealizecurrentlimitingandsynchronousrectification16163yPowerQuarterlyReviewHighCurrentStress-SplittingTransformer¾Splittingtransformer¾Primarywindinginseries,automaticcurrentsharingontwooutputstages¾Largecurrentstressforsecondarysideswitches17173yPowerQuarterlyReviewPrototypeDesign34:1TransformerTurnsRatio0.2Q25uHInductor440uFHolduptimecapacitor180V~400Vinputvoltage12V,100Aoutput280kHzswitchingfrequencyEQ30.3F3InductorcoreEQ30,3F3TransformercoreIRF6691SecondarysideswitchesIRFP460APrimarysideswitches1.6”profile18183yPowerQuarterlyReview12C?12C?450V/330uF123Qa123Qb123Qd123QcC?4uFC?4uFT?T?L?L?12D?12D?12D?12D?12D?12D?12D?12D?123Q31123Q32123Q41123Q42123Q21123Q22123Q12123Q11C?C?..SVCCD1C1IN1VEE2VCC3OUT4IN_REF5INB6UDIN1VEE2VCC3OUT4IN_REF5INB6LM5112IN1VEE2VCC3OUT4IN_REF5INB6UBIN1VEE2VCC3OUT4IN_REF5INB6UAC?0.1uFC?0.1uFC?0.1uFC?0.1uFC?C?C?C?Vo+Vo-R?0R?0R?0R?0C?1uFC?1uFC?1uFC?1uFR?10kR?10kR?10kR?10k1234567J?CON7GND-PVCCGND-S?B1A1D1(A1)C1(B1)IN1VEE2VCC3OUT4IN_REF5INB6UDLM5112IN1VEE2VCC3OUT4IN_REF5INB6UCLM5112C?1uFL?L?L?12Z?12Z?12Z?12Z?IN1VEE2VCC3OUT4IN_REF5INB6UBLM5112IN1VEE2VCC3OUT4IN_REF5INB6UALM5112C?1uFL?L?L?12Z?12Z?12Z?12Z?C?0.1uFC?0.1uFC?0.1uFC?0.1uFC?cdc11C?cdc12R?4.76R?4.76R?4.76R?4.76R?10kR?10kR?10kR?10k400+400V-PrimaryDriveBoardC?0.47uF/630VC?CAP12C?ELECTRO112C?ELECTRO1123456789101112131415CONTROLS123456789101112131415CONTROLPCT1DCMVCCA1GNDB1C2D2IP5V12VGND5VC2(C1)D2(D1)GNDA1VCCB1D1C1SYNIPONLYboard19193yPowerQuarterlyReviewDrivetheSynchronousRectifiersDrivetheSynchronousRectifiers20203yPowerQuarterlyReviewNoSynchronousRectification(SR)abcdIp¾Nosynchronousrectification¾(S3,S4isdisabled,onlyD3,D4)21213yPowerQuarterlyReviewNewDrivingSchemeUsingIntersilHIP660122223yPowerQuarterlyReviewSimplifiedSRSchemeabcdIp¾Simplifiedgatesignalgeneration¾BodydiodeD3,D4conductingforashortperiodoftimeQ3Q2Q4Q1Q1Q3S1S2S2S3S4S1Va