Design Infineon LCD TV Power Solution with PowerEsim

1. Design Infineon LCD TV Power Solution with PowerEsim

2. 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 3 days to build - Low cost 90% 150 W LCD power supply Input Voltage Vac

3. Old VS New

4. Old engineer vs Young 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 ”

5. Old MOSFETVS Young MOSFET 47 ns vs 5 ns, 10 times different

6. Where is the ZVS ? Adaptor – A efficiency demanding product. How many of them are using ZVS circuit?

7. Where is the losses? Example : 12V@4A 82% 10W loss 15 % 30 % 10 % 25 %

8. Do we need complicated circuit?

9. Why not use less copper? • 50% losses come from magnetic circuit. • Better design by using less copper Old New

10. STPS20H100 0.6V @ 2*7A 100 deg TO200 package USD ?? / pcs Why using diode? Old New • IRF540Z 22m Ohm • 0.54V @ 14A 100 deg • TO200 package • USD ?? / pcs

11. STPS20H100 0.6V @ 2*7A 100 deg TO200 package USD ?? / pcs If TO220 has the same price . . . • IPP05CN10 5m Ohm • 0.08V @ 14A 100 deg • TO220 package • USD ?? / pcs

12. We are trained to fill in a value NOT design a circuit

13. 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

14. Then again . . . • Replace 100pcs of components at bench

15. Fine, but no need to replace at the bench . . . • Why not replace 100pcs of components at PowerEsim

16. www.powerEsim.com • It’s on-line • It’s for everyone • Worldwide access • 100% server side simulation • It’s free

17. Build virtual and real converter PFC Developed under Infineon TDA4863 Evaluation Design DC-DC Developed under Infineon ICE3DS01 Evaluation Design 150W 90% LCD Converter

18. Input Votlage Vs Efficiency % 100.00 90.00 80.00 70.00 60.00 50.00 40.00 30.00 20.00 160W PFC Input Voltage Vac 10.00 0.00 85 110 230 265 160 W PFC – simulation vs measurement Measured PowerEsim

19. I/P Votlage Vs Efficiency % 100.00 90.00 80.00 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 150W flybackInput Votlage Vdc 300 350 405 150 W Flyback – simulated vs measured Measured PowerEsim

20. Loss and Temp.

21. Find MOSFET Find Diode Find Capacitor Find Core Find Wire Component Based Approach Real components Abstract Concept • Rds*Crss • Vf*trrm • CV • k1, k2, k3 • Current density

22. PowerEsim vs Traditional Design PowerEsim turn design into result oriented adaptive iteration instead of skill of knowledge application

23. 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 Why PowerEsim ?? Design Design • PowerEsim • Trim R1 • PowerEsim • Redesign • Redesign • PowerEsim • SPICE Prototype Design Verify Prototype Design Verify

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

25. Ask our expert • Enter the input & output specification • Chose an application • Click “Recommend Design”

26. If you like more freedom • Click “Topologies” • Chose the topology you like • Enter the input & output specification

27. Click the main MOSFET

28. How we model component?

29. Click, click, click and select • A particular one – total & individual loss • Highlighted one – total, individual loss and stress • Selected one – total individual loss and stress

30. Other than loss, Stress is important

31. Now 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

32. Search more MOSFET • Extend to higher current range is usually needed • Extend the body diode’s trrm can find more MOSFET

33. Select a better Sync Rect. • 0.5W Active Diode loss • 2.54W SCK loss

34. Which component is more critical? • Why M1, D3 & T1 • Loss Analysis – the most useful page • It rank the loss and it’s details

35. Click T1 and go to Magnetic Builder

36. Step 1 – select the core you like • Chose the range of Ae • Select Core shape • Select Manufacturer

37. Instant preview winding when thing change • Click the “preview winding” • Corresponding winding cross section will be shown • Supported on Core, N and Wire.

38. Step 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.

39. Step 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.

40. Don’t forget preview winding • Click the “Preview Winding” button • Observe how winding structure change with number of turn.

41. Step 4 – need more copper? • Click the “Change Wire” button • Click the “No. of Parallel Wire” • Add more parallel wire as you like.

42. Finally – 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 + • . . . . .

43. DVT – check the stresses • DVT Report check every components stress and also circuit design constraint.

44. Connecting Power Supplies

45. Thermal – knowing Temp. at day 1

46. MTBF – how long it last

47. It’s Done and On PowerEsim • Enjoy using PowerEsim