design infineon lcd tv power solution with poweresim
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Design Infineon LCD TV Power Solution with PowerEsim. Poweresim. Measurement. 100.00. 90.00. 80.00. 70.00. 60.00. 50.00. 40.00. 30.00. 20.00. 10.00. 0.00. 85. 110. 230. 265. Our junior Engineer Gary spend . . . . 1 days to design - Low cost 90% 150 W LCD power supply. - PowerPoint PPT PresentationTRANSCRIPT
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 11
Design Infineon LCD TV Power Solution with PowerEsimDesign Infineon LCD TV Power Solution with PowerEsim
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 22
Our junior Engineer Gary spend . . . Our junior Engineer Gary spend . . .
0.00
10.00
20.00
30.00
40.00
50.00
60.00
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90.00
100.00
85 110 230 265
Input Voltage Vac
PoweresimMeasurement
3 days to build - Low cost 90% 150 W LCD power supply
1 days to design - Low cost 90% 150 W LCD power supply
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 33
OldOldVSVS
NewNew
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 44
OldOld engineer vs engineer vs YoungYoung engineer engineer
20 years ago . . . .“
For a MOSFET
Conduction loss = 1/3
Switching loss = 2/3 ”
20 years old . . . .“
For a MOSFET
Conduction loss = 2/3
Switching loss = 1/3 ”
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 55
Old Old MOSFETMOSFET VSVS Young Young MOSFETMOSFET
47 ns vs 5 ns, 10 times different
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 66
Where is the ZVS ?Where is the ZVS ?
Adaptor – A efficiency demanding product.
How many of them are using ZVS circuit?
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 77
Where is the losses?Where is the losses?
25 %15 %30 % 10 %
Example :
12V@4A
82%
10W loss
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 88
Do we need complicated circuit?Do we need complicated circuit?
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 99
Why not use less copper?Why not use less copper?
Old New
• 50% losses come from magnetic circuit.
• Better design by using less copper
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1010
Why using diode?Why using diode?
• STPS20H100• 0.6V @ 2*7A 100 deg• TO200 package• USD ?? / pcs
• IRF540Z 22m Ohm• 0.54V @ 14A 100 deg• TO200 package• USD ?? / pcs
Old New
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1111
If TO220 has the same price . . .If TO220 has the same price . . .
• STPS20H100• 0.6V @ 2*7A 100 deg• TO200 package• USD ?? / pcs
• IPP05CN10 5m Ohm• 0.08V @ 14A 100 deg• TO220 package• USD ?? / pcs
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1212
fill in a value
NOT
design a circuit
We are trained to
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1313
Fill in values by experience . . .Fill in values by experience . . .Vi=100
Vo=12
Vo=Vi*D*Ns / (1-D)*Np
Vi+Vo*Np/Ns=0.8Vds_max
Vo=Ns*0.3*fs/(1-D)
0.5*Vo_ripple=Q/Co
Vds_max_M1=lowerest cost in stock
Ids_max_M1=lowerest cost in stock
IF_max_Do=2*Io
VR_max_Do=1.2*(Vi*Ns/Np+Vo)
Core_T1=recommended table from ferrite manufacturer
Wire_Np=fully filled
Wire_Ns=fully filled
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1414
Then again . . .Then again . . .
• Replace 100pcs of components at bench
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1515
Fine, but no need to replace at the bench . . .Fine, but no need to replace at the bench . . .
• Why not replace 100pcs of components at PowerEsim
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1616
www.powerEsim.comwww.powerEsim.com• It’s on-line
• It’s for everyone
• Worldwide access
• 100% server side simulation
• It’s free
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1717
Build virtual and real converterBuild virtual and real converter
PFCDeveloped
underInfineon
TDA4863 Evaluation
Design
DC-DCDeveloped
underInfineon
ICE3DS01 Evaluation
Design
150W 90% LCD Converter
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1818
160 W PFC – simulation vs measurement160 W PFC – simulation vs measurement
Input Votlage Vs Efficiency %
0.0010.0020.0030.0040.0050.0060.0070.0080.0090.00
100.00
85 110 230 265160W PFC Input Voltage Vac
Measured
PowerEsim
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1919
150 W Flyback – simulated vs measured 150 W Flyback – simulated vs measured
I/P Votlage Vs Efficiency %
0.0010.0020.0030.0040.0050.0060.0070.0080.0090.00
100.00
300 350 405
150W flybackInput Votlage Vdc
Measured
PowerEsim
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 2020
Loss and Temp.Loss and Temp.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 2121
Component Based ApproachComponent Based Approach
• Find MOSFET
• Find Diode
• Find Capacitor
• Find Core
• Find Wire
Rds*Crss
Vf*trrm
CV
k1, k2, k3
Current density
Real components Abstract Concept
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 2222
PowerEsim vs Traditional DesignPowerEsim vs Traditional Design
result oriented adaptive iteration
instead of
skill of knowledge application
PowerEsim turn design into
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 2323
Why PowerWhy PowerEEsim ??sim ??• Mathcad• Excel• Paper & Pen• SPICE
• Trim R1• Redesign• Excel• T1 drawing• Rewind T1• Mathcad• Optimize T2• Optimize fs• Optimize R3• Optimize C2• Redesign
• Mathcad• Excel• SPICE
Design
Prototype
Design Verify
• PowerEsim
• Trim R1• PowerEsim• Redesign• Redesign
• PowerEsim• SPICE
Design
Prototype
Design Verify
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 2424
But first . . .But first . . .
• Find a circuit that has closest specification to your need, e.g. 160W TDA4863 for PFC front end.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 2525
Ask our expertAsk our expert
• Enter the input & output specification
• Chose an application
• Click “Recommend Design”
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 2626
If you like more freedomIf you like more freedom
• Click “Topologies”• Chose the topology you like• Enter the input & output specification
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 2727
Click the main MOSFETClick the main MOSFET
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 2828
How we model component?How we model component?
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 2929
Click, click, click and selectClick, click, click and select
• A particular one – total & individual loss
• Highlighted one – total, individual loss and stress
• Selected one – total individual loss and stress
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 3030
Other than loss, Stress is importantOther than loss, Stress is important
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 3131
Now Active DiodeNow Active Diode
• Click the diode you like to replace by Active Diode or Sync Rect.
• In the Component Finder, change it’s “Rectifier Type” to
Active Diode
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 3232
Search more MOSFETSearch more MOSFET
• Extend to higher current range is usually needed
• Extend the body diode’s trrm can
find more MOSFET
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 3333
Select a better Sync Rect.Select a better Sync Rect.
• 2.54W SCK loss
• 0.5W Active Diode loss
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 3434
Which component is more critical?Which component is more critical?
• Why M1, D3 & T1
• Loss Analysis – the most useful page
• It rank the loss and it’s details
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 3535
Click T1 and go to Magnetic BuilderClick T1 and go to Magnetic Builder
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 3636
Step 1 – select the core you likeStep 1 – select the core you like
• Chose the range of Ae
• Select Core shape
• Select Manufacturer
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 3737
Instant preview winding when thing changeInstant preview winding when thing change
• Click the “preview winding”
• Corresponding winding cross section will be shown
• Supported on Core, N and Wire.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 3838
Step 2 – find the best LmStep 2 – find the best Lm
• Click the “Inductance” button
• Enter the range of inductance
• Highlight each in the list, select according to total loss and stress.
• Double check OCP is not be triggered.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 3939
Step 3 – find the best N0Step 3 – find the best N0
• Click the “Number of turn” button
• Enter the range of turn
• Highlight each in the list, select according to total loss and stress.
• Double check OCP is not be triggered.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 4040
Don’t forget preview windingDon’t forget preview winding
• Click the “Preview Winding” button
• Observe how winding structure change with number of turn.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 4141
Step 4 – need more copper?Step 4 – need more copper?
• Click the “Change Wire” button• Click the “No. of Parallel Wire”• Add more parallel wire as you like.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 4242
Finally – a Xformer like thisFinally – a Xformer like this• Copper foil + • Split bobbin + • Bi-filar winding + • Multi-layer winding +• Multi-winding in one layer +• Tight winding +• Distributed winding +• Center winding +• Faraday shield +• . . . . .
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 4343
DVT – check the stressesDVT – check the stresses
• DVT Report check every components stress and also circuit design constraint.
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 4444
Connecting Power SuppliesConnecting Power Supplies
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 4545
Thermal – knowing Temp. at day 1Thermal – knowing Temp. at day 1
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 4646
MTBF – how long it lastMTBF – how long it last
Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07Prepared by Dr. Franki PoonPrepared by Dr. Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 4747
It’s Done and On PowerEsimIt’s Done and On PowerEsim
• Enjoy using PowerEsim