design infineon lcd tv power solution with poweresim 31/aug/07 prepared by dr. franki poon powerelab...

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07

Prepared 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



Our junior Engineer Gary spend . . . Our junior Engineer Gary spend . . .

0.00

10.00

20.00

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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



OldOldVSVS

NewNew



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 ”



Old Old MOSFETMOSFET VSVS Young Young MOSFETMOSFET

47 ns vs 5 ns, 10 times different



Where is the ZVS ?Where is the ZVS ?

Adaptor – A efficiency demanding product.

How many of them are using ZVS circuit?



Where is the losses?Where is the losses?

25 %15 %30 % 10 %

Example :

12V@4A

82%

10W loss



Do we need complicated circuit?Do we need complicated circuit?



Why not use less copper?Why not use less copper?

Old New

• 50% losses come from magnetic circuit.

• Better design by using less copper



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



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



fill in a value

NOT

design a circuit

We are trained to



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



Then again . . .Then again . . .

• Replace 100pcs of components at bench



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



www.powerEsim.comwww.powerEsim.com

• It’s on-line

• It’s for everyone

• Worldwide access

• 100% server side simulation

• It’s free



Build virtual and real converterBuild virtual and real converter

PFCDeveloped

underInfineon

TDA4863 Evaluation

Design

DC-DCDeveloped

underInfineon

ICE3DS01 Evaluation

Design

150W 90% LCD Converter



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

85 110 230 265

160W PFC Input Voltage Vac

Measured

PowerEsim



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



Loss and Temp.Loss and Temp.



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



PowerEsim vs Traditional DesignPowerEsim vs Traditional Design

result oriented adaptive iteration

instead of

skill of knowledge application

PowerEsim turn design into



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



But first . . .But first . . .

• Find a circuit that has closest specification to your need, e.g. 160W TDA4863 for PFC front end.



Ask our expertAsk our expert

• Enter the input & output specification

• Chose an application

• Click “Recommend Design”



If you like more freedomIf you like more freedom

• Click “Topologies”• Chose the topology you like• Enter the input & output specification



Click the main MOSFETClick the main MOSFET



How we model component?How we model component?



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



Other than loss, Stress is importantOther than loss, Stress is important



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



Search more MOSFETSearch more MOSFET

• Extend to higher current range is usually needed

• Extend the body diode’s trrm can

find more MOSFET



Select a better Sync Rect.Select a better Sync Rect.

• 2.54W SCK loss

• 0.5W Active Diode loss



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



Click T1 and go to Magnetic BuilderClick T1 and go to Magnetic Builder



Step 1 – select the core you likeStep 1 – select the core you like

• Chose the range of Ae

• Select Core shape

• Select Manufacturer



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.



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.



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.



Don’t forget preview windingDon’t forget preview winding

• Click the “Preview Winding” button

• Observe how winding structure change with number of turn.



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.



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 +• . . . . .



DVT – check the stressesDVT – check the stresses

• DVT Report check every components stress and also circuit design constraint.



Connecting Power SuppliesConnecting Power Supplies



Thermal – knowing Temp. at day 1Thermal – knowing Temp. at day 1



MTBF – how long it lastMTBF – how long it last



It’s Done and On PowerEsimIt’s Done and On PowerEsim

• Enjoy using PowerEsim

design infineon lcd tv power solution with poweresim 31/aug/07 prepared by dr. franki poon powerelab...

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