600w llc demo board.ppt - infineon technologies · 2018-08-20 · title: microsoft powerpoint -...

600W LLC Demo Board

Francesco Di DomenicoIFAT PMM APS SE ACHV DC/DC Converters Applications

Table of contents

� General description

� Efficiency results

� Design Concept

Copyright © Infineon Technologies AG 2014. All rights reserved.

Prototype Specifications

Half Bridge LLC

with synchronous rectification

in center tap configuration

Vin 350-410VDC

Vin_nom 380VDC

Vout_nom 12VDC

Iout 50A

SR MOSFETs

• OptiMOSTM BSC010N04LS

• New generation

• Best FOM Rds,on x Qg

• Best FOM Rds,on x Qoss

Primary HV MOSFETs

• CoolMOSTM IPP60R190P6

• Reduced Gate Charge (Qg)

• Reduced Eoff

• High body diode ruggedness LLC analog controller

ICE2HS01G

HB Gate Drive IC

2EDL05N06PF

Bias QR Flyback

controller

ICE2QR2280Z

Iout 50A

Po 600W

fres=f0 157kHz

fmin 90kHz

fmax 210kHz

Transformer

turns ratio 16:1

Cr 66nF

Lr 15.5uH

Lm 195uH

Resonant inductor

RM12 core

Transformer

PQ35/35 core


PCB Boards Layout: main power board and Control and Bias daughter boards

• Power Density>20W/inch3

Controller BoardBias Board


Main Power Board Schematic


Bias Board Schematic


Analog Control Board Schematic


Digital Control Daughter Board Schematic

Dig

ital

Contr

oller

(DP2B /

XM

C)


PCB structure


Table of contents



� Design Concept


Efficiency plot at Vin=380Vdc (Bias consumption not included)


10%Pmax Vin=380Vdc

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

Turn-off losses

Body diode losses

Driving losses

Conduction Losses

0

0.5

1

1.5

2

2.5

3

3.5

4

10%Pmax Overall losses spread [W]

Tracks, Cin, sensing

Output capacitance

Output choke

Resonant choke

SR losses

Power trafo

Primary mosfets

(IPP60R190P6)

0

Loosses spread on each device at 10%Pmax [W]


50%Pmax Vin=380Vdc

0

0.2

0.4

0.6

0.8

1

1.2

Turn-off losses

Body diode losses

Driving losses

Conduction Losses

70

Losses spread on each device at 50%Pmax [W]

0

1

2

3

4

5

6

7

50%Pmax Overall losses spread [W]


Output capacitance

Output choke

Resonant choke

SR losses

Power trafo

Primary mosfets

(IPP60R190P6)


100%Pmax Vin=380Vdc

0

0.5

1

1.5

2

2.5

3

3.5

Turn-off losses

Body diode losses

Driving losses

Conduction Losses

180

Loosses spread on each device at 100%Pmax [W]

0

2

4

6

8

10

12

14

16

100Pmax Overall losses spread [W]


Output capacitance

Output choke

Resonant choke

SR losses

Power trafo

Primary mosfets (IPP60R190P6)


Table of contents



� Design Concept


Design procedure: input data

nomout

nomin

V

Vn

_

_

2 ⋅=

2

),,(max_

min_minmin

in

ox

V

VnFmQKM

⋅=≡

2

),,(min_

max_maxmax

in

ox

V

VnFmQKM

⋅=≡


Resonant tank components and related resonant frequencies

� n=Vin_nom/(2xVo)=380/(2*12)≈16

� Lm=195µH

� Lr=15.5µH

� Ln=Lm/Lr=12.5

� Cr=66nF� Cr=66nF

kHzCrLr

fo 1572

1=

⋅⋅=

πkHz

CrLmLrfp 7.42

)(2

1=

⋅+⋅=

π


1

1.1

1.2

dc-gain curve (600W LLC hardware revision E02)

5 A

2min_

max_max

in

o

V

VnM

⋅=

0.6

0.7

0.8

0.9

gain

frequency [Hz]

5 A

15 A

25 A

35 A

50 A2

max_

min_min

in

o

V

VnM

⋅=


Energy related calculations (ref. IPP60R190P6 device parameters)

ALf

Vn

msw

oag 672.0

2

22I

max_

min_m =⋅⋅

⋅⋅

⋅=

ππ

JILLEn magrmres µ1.95²)(2

1min_min_ =⋅+⋅=

1max_min_ capres EnEn >⇒

JVerCoEn DScap µ9²))(2(2

1max_max_ ≈⋅⋅=

max_min_ capres EnEn >⇒


Qoss, Imag,pk, tdead,min, tecs relationship

ICHB

Im,pk

IQ2

)1(I)( m,2

ecs

pkQ

t

ttI −⋅= ecstt ≤∀

0)(2 =tIQ ecstt ≥∀),,( ,,

gd

dsthgstotgecs

C

CVRft =

ICHBIm,pk

VHB

VBULK

Vecsdeadpkecspk

t

C QosstttdttI

dead

HB 400@min,m,m,

0

,2)(II2

1)(

min,

⋅=−⋅⋅⋅= +∫

tecs tdead,min

pk

Vossecsdead

Qtt

m,

400@,min,

I

2

2

⋅+=( )1


Time related calculations (ref. IPP60R190P6 device parameters)

ALf

Vn

msw

oag 66.1

2

22I

min_

max_m =⋅⋅

⋅⋅

⋅=

ππ

sec1302 400@,

nQt

tVossecs

≈⋅

+=

ALf

Vn

msw

oag 672.0

2

22I

max_

min_m =⋅⋅

⋅⋅

⋅=

ππ

sec130I

2

2 max,m

400@,min, n

Qtt

ag

Vossecsdead ≈

⋅+=

sec311I

2

2 min,m

400@,max, n

Qtt

ag

Vossecsdead ≈

⋅+=


Main transformer structure: PQ35/35 core with TDK PC95 ferrite material


Resonant choke: RM12 core, material N87


600w llc demo board.ppt - infineon technologies · 2018-08-20 · title: microsoft powerpoint -...

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