quasi-resonant flyback converter simulations with saber - apec 2016

Alan Courtay

March 22, 2016

Quasi-resonant Flyback Converter Simulation

Saber Tutorial

© 2016 Synopsys, Inc. 2

Agenda

• Quasi-Resonant Flyback Converter (AN1326)

–Principles of Operation

–Simulation vs. Measurement

• Accurate Datasheet-Driven Modeling

–Controller Chip

–MOSFET

–Transformer

• Automated Verification

–EMI

– Loss / Efficiency


Vin: 50/60Hz, 88 to 264 Vac

Vout1: 105 V ± 5%

Iout1: 0.1 to 0.35 A

Vripple1: 1%

Vout2: 14 V ± 10%

Iout2: 0.1 to 1 A

Vripple2: 1%

L6565-Based 50W QR ZVS Flyback

Vout3: 5 V ± 5%

Iout3: 50 mA

Vripple3: <1%


Vin: 50/60Hz, 88 to 264 Vac


Power Stage

Vds

t Currents

t

Vr

Vr

Llk&Cd

Lp&Cd

Ipeak

Secondary

Vin

Primary Demagnetization

Ton

Llk+Lp

Cd

Llk+Lp

Vout1: 105 V ± 5%

Iout1: 0.1 to 0.35 A

Vripple1: 1%

Vout2: 14 V ± 10%

Iout2: 0.1 to 1 A

Vripple2: 1%

Discontinuous Conduction Mode

Peak Current Mode Control

Vout3: 5 V ± 5%

Iout3: 50 mA

Vripple3: <1%


Vin: 50/60Hz, 88 to 264 Vac


Power Stage

Vds

t Currents

t

Ipeak

Vin

Ton Toff

Valley

Switching

Vout1: 105 V ± 5%

Iout1: 0.1 to 0.35 A

Vripple1: 1%

Vout2: 14 V ± 10%

Iout2: 0.1 to 1 A

Vripple2: 1% Vr

Vr

Vout3: 5 V ± 5%

Iout3: 50 mA

Vripple3: <1%


Vin: 50/60Hz, 88 to 264 Vac


Power Stage

Vds

t Currents

t

Ipeak

Vin

Ton Toff

ZVS

Vr

Vin < Vr

Vout1: 105 V ± 5%

Iout1: 0.1 to 0.35 A

Vripple1: 1%

Vout2: 14 V ± 10%

Iout2: 0.1 to 1 A

Vripple2: 1%

Vout3: 5 V ± 5%

Iout3: 50 mA

Vripple3: <1%


Vin: 50/60Hz, 88 to 264 Vac


Power Stage

Vds

t Currents

t

Ipeak

Vin

Ton Toff

Skip Cycle

Vout1: 105 V ± 5%

Iout1: 0.1 to 0.35 A

Vripple1: 1%

Vout2: 14 V ± 10%

Iout2: 0.1 to 1 A

Vripple2: 1%

Vout3: 5 V ± 5%

Iout3: 50 mA

Vripple3: <1%


RCD

Clamp

Output Voltage Regulation Feedback

Vin: 50/60Hz, 88 to 264 Vac

Vout1: 105 V ± 5%

Iout1: 0.1 to 0.35 A

Vripple1: 1%

Vout2: 14 V ± 10%

Iout2: 0.1 to 1 A

Vripple2: 1%


Power Stage

Vcc

start-up

self-supply

Vout3: 5 V ± 5%

Iout3: 50 mA

Vripple3: <1%


Agenda





–Controller Chip

–MOSFET

–Transformer


–EMI



Current Sense and Primary Voltage

Full Load, Vin = 100 V

4µs 4µs

1V

100V



Full Load, Vin = 380 V

2µs 2µs

1V

100V



Half Load, Vin = 100 V

4µs 4µs

1V

100V



Half Load, Vin = 380 V

2µs 2µs

0.5V

100V


Cycle Skipping / Frequency Foldback

Light Load, Vin = 300 V

5µs 5µs

0.5V

100V



Standby, Vin = 380 V Burst Mode

100µs 100µs

0.5V

100V


Agenda





–Controller Chip

–MOSFET

–Transformer


–EMI



Modeling

Controller IC


Modeling

Controller IC

Turn-on

Valley detection model

with StateAMS tool Blanking time

model with TLU tool

Frequency foldback


Modeling

Controller IC

Turn-on

Turn-off

Line voltage feedforward

function implemented in MAST

Limits power capability

at high line voltage


Modeling

Power MOSFET


Modeling

Power MOSFET

• DC Characteristics

Characterized

Temperatures


Modeling

Power MOSFET


• Interelectrode Capacitances


Modeling

Power MOSFET


• Interelectrode Capacitances

• Gate Charge Characteristic


Modeling

Transformer


Modeling

Transformer

• Ferrite Core 3C85

–Hysteresis (major and minor BH loops)

–Frequency dependent losses (hysteresis

and eddy currents)


Modeling

Transformer




and eddy currents)


Modeling

Transformer




and eddy currents)

• Core geometry

–Air gap

– Lamination


Modeling

Transformer




and eddy currents)

• Core geometry

–Air gap

– Lamination

• Windings (Cauer - 1D Model)

–Flux leakage

–Frequency dependent loss (skin and

proximity effects)

–Winding capacitances


Agenda





–Controller Chip

–MOSFET

–Transformer


–EMI



LISN


Experiment Editor Basic Tasks


Parallel

Computing


Loss breakdown

report


Converter

efficiency


Most dissipative

components


Conduction Losses Switching Losses


Conduction Losses Switching Losses

Rac = 50kΩ added across primary

to account for air gap fringing field

losses

NTC thermistor

adjusted to 2.5Ω


Rac = 50kΩ added across primary

to account for air gap fringing field

losses

NTC thermistor

adjusted to 2.5Ω


Conclusion

• High fidelity models characterized from datasheets

• Automated design verification / regression testing over broad

operating conditions

–Experiment Analyzer

–Fault Injection

–Worst Case Analysis / Extreme Value Analysis

–Statistical variations (Monte Carlo)

• Scalable solution

–Capacity for large designs (network of power converters)

–User or site (company wide) model library management

–Distributed/grid iterative analysis (parametric Vary, Monte-Carlo,

Worst-Case Analysis, Fault)


Thank You

• Flyback design available on Synopsys Forum

• Improved IGBT Tool in 2016.03

Thank you to Sophia LI, Min ZHANG and Balaji EMANDI for their contributions.

Special thanks to Claudio ADRAGNA and Giovanni GRITTI from ST for their valuable feedback.

quasi-resonant flyback converter simulations with saber - apec 2016

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