PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 1 PowerEsim FACT sheet.
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Transcript of PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 1 PowerEsim FACT sheet.
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 11
PowerEsim FACT sheetPowerEsim FACT sheet
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 22
Hardware Prototype ImplementationHardware Prototype Implementation
Topology: AC/DC Flyback Dual-output ConverterInput range: 85-264VAC/50HzOutputs: O/P1 – 5V/6A; O/P2 – 12V/2.5A
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 33
Critical waveformsInput voltage at 85VAC
Drain Voltage Waveform AnalysisDrain Voltage Waveform Analysis
Primary MOSFET switching waveformCh1 – M1 drain source voltage waveform; Ch2 – M1 drain current waveform
Simulation peak voltage from PowereSim = 300V
Actual peak voltage approx. = 285V
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 44
Critical waveformsInput voltage and bulk capacitor voltage waveforms
Bulk Capacitor Voltage Waveform AnalysisBulk Capacitor Voltage Waveform Analysis
Ch1 - Input AC voltage waveform Ch2 - Rectified bulk capacitor voltage
Similar intersection point
Simulation Measurement
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 55
Critical waveformsInput voltage and current
Input Current Waveform AnalysisInput Current Waveform Analysis
Ch1 - Input AC voltage waveform Ch2 - Input current waveform
Simulation Measurement
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 66
Line RegulationLine Regulation
Simulation Measurement
Output at full load
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
80.00 130.00 180.00 230.00 280.00
Input voltage RMS (V)
Outpu
t volt
age (
V)
+5V @ 6A
+12V @ 2.5A
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
80.00 130.00 180.00 230.00 280.00
Input voltage RMS (V)
Outpu
t volt
age (
V)
+5V @ 6A
+12V @ 2.5A
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 77
Load RegulationLoad Regulation
Input voltage at 85VACSimulation Measurement
Input voltage at 85VAC
0.00
5.00
10.00
15.00
20.00
25.00
0.00 0.50 1.00 1.50 2.00 2.50
Output current (A)
Outpu
t volt
age (
V)
+12V @ 5V/1A
+12V @ 5V/3A
+12V @ 5V/6A
+5V @ 1A
+5V @ 3A
+5V @ 6A
Input voltage at 85VAC
0.00
5.00
10.00
15.00
20.00
25.00
0.00 0.50 1.00 1.50 2.00 2.50
Output current (A)
Outpu
t volt
age (V
)
+12V @ 5V/1A
+12V @ 5V/3A
+12V @ 5V/6A
+5V @ 1A
+5V @ 3A
+5V @ 6A
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 88
Power Loss AnalysisPower Loss Analysis
Efficiency comparison at full load
Conversion Efficiency
01020304050607080
70 120 170 220 270
Input voltage RMS (V)
Effici
ency
(%)
Measurement
Simulation
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 99
Closed-loop Analysis (Bode plot)Closed-loop Analysis (Bode plot)
Input voltage at 115VAC full loadMeasurement
1 10 100 1 103
1 104
1 105
40302010
010203040506070
70
40
Gaini
3 1041 f i
1 10 100 1 103
1 104
1 105
200
150
100
50
0
50
100
150
200200
200
Phasei
3 1041 f i
Cut
-off
freq
Cut
-off
freq
Simulation
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1010
Closed-loop Analysis (Transient Response)Closed-loop Analysis (Transient Response)
Conditions:Input voltage at 162VDCO/P1: 5V @ 0.2A-6AO/P2: 12V at 1A
Simulation Measurement
CH1: Load current CH2: Output voltage of O/P1
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1111
-0.1
0
0.1
0.2
0.3
0.4
3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Harmonic number
Cur
rent
RM
S (A
)
Measured
Class D Limits
Input Current Harmonics AnalysisInput Current Harmonics Analysis
Measurement
Input voltage at 230VAC/50Hz
Simulated bar charts showed in good agreement with measurement.
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1212
Thermal AnalysisThermal Analysis
Measurement
123.1
65
94
62
66
7870
52
103
93
68
52
Simulation
94
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1313
Transformer DesignTransformer Design
Leakage inductance:
Measurement = 2.787uHSimulation = 2.982uH
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1414
DVT Report – SMPS from other factoryDVT Report – SMPS from other factory
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1515
DVT Report – DVT Report – 100 times faster to know the design fault100 times faster to know the design fault
Stress Percentage176.62%
Rated Current0.77
Measured Current1.36
Measurement
Simulation
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1616
Saturation current observed in experimental measurement
DVT Report – DVT Report – Every component checked include XformerEvery component checked include Xformer
Measurement
Simulation
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1717
Stress Percentage96.00%
Rated Voltage600
Measured Voltage576
A simulated drain voltage of 75W flyback converter with 3 outputs – result = ~580V
DVT Report – DVT Report – MOSFET StressMOSFET Stress
Measurement Simulation
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1818
Evaluation Design Evaluation Design
Measurement Simulation
PowerEsim FACT sheetsPowerEsim FACT sheetsPrepared by Franki Poon Prepared by Franki Poon PowerELab LimitedPowerELab Limited www.powerEsim.comwww.powerEsim.com 1919
After ALLAfter ALL
Traditional Engineer Daily Work
•Day 1 – PowerEsim calculation
•Day 2 – Bench Work::
Day x – PowerEsim recalculation:
:::
•Day30 - FINISH
•Day 1 – start paper calculation•Day 2 – collect data sheets•Day 3 – collect data sheets•Day 4 – find equations•Day 5 – understand equations•Day 6 – start calculation•Day 14 – finish calculation•Day 15 – Bench Work•Day 21 – fs changed•Day 22 – re-calculate design•Day 25 – finish re-calculation•Day 26 – redesign Xformer•Day 27 – MOSFET overstress•Day 28 – redesign Xformer•Day 29 – OP diode overstress
:•Day60 - FINISH
PowerEsim Engineer Daily Work