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Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com

Next 2. 5 hours • • 2: 30 – 2: 45 – 3: 15 Next 2. 5 hours • • 2: 30 – 2: 45 – 3: 15 3: 00 – 3: 15 – 3: 45 – 4: 00 – 4: 45 – 5: 00 Old vs New Active Diode & IC EMI Cancellation & IC Design Methodology – How we trained? Tea Break Designed by Power. Esim – New design procedure Q&A Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 2

Old VS Designing a 90% efficiency 150 W power supply with PFC in hours Old VS Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited New www. power. Esim. com 3

Old engineer vs Young engineer 20 years ago. . 20 years old. . “ Old engineer vs Young engineer 20 years ago. . 20 years old. . “ “ For a MOSFET Conduction loss = 1/3 Conduction loss = 2/3 Switching loss = 1/3 ” ” Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 4

Old MOSFET VS Young MOSFET 47 ns vs 5 ns, 10 times different Designing Old MOSFET VS Young MOSFET 47 ns vs 5 ns, 10 times different Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 5

Where is the ZVS ? Adaptor – A efficiency demanding product. How many of Where is the ZVS ? Adaptor – A efficiency demanding product. How many of them are using ZVS circuit? Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 6

Where is the ZVS ? Active Clamp 2 Switch Forward Full Bridge Phase Shift Where is the ZVS ? Active Clamp 2 Switch Forward Full Bridge Phase Shift Bridge Asym. Half-Bridge Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 7

Where is the losses? Example : 12 V@4 A 82% 10 W loss 30 Where is the losses? Example : 12 V@4 A 82% 10 W loss 30 % Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited 10 % 15 % 25 % www. power. Esim. com 8

Where money can buy • • • Pay for ZVS Pay for lower Rds Where money can buy • • • Pay for ZVS Pay for lower Rds Pay for lower tr, tf. . 10 % • After all, it is only 10% Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 9

Where money can’t buy Copper Loss Designing a 90% efficiency 150 W power supply Where money can’t buy Copper Loss Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited Copper & Ferrite Band Gap Loss www. power. Esim. com 10

Why not use less copper? • Active EMI Filter • WT 6001 Y -Cap Why not use less copper? • Active EMI Filter • WT 6001 Y -Cap Booster • Next section Old New Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 11

Why not of not using diode? Old • • STPS 20 H 100 0. Why not of not using diode? Old • • STPS 20 H 100 0. 6 V @ 2*7 A 100 deg TO 200 package USD ? ? / pcs Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited New • • IRF 540 Z 22 m Ohm 0. 54 V @ 14 A 100 deg TO 200 package USD ? ? / pcs www. power. Esim. com 12

If TO 220 has the same price. . . • Active Diode • WT If TO 220 has the same price. . . • Active Diode • WT 6002 active diode IC • • STPS 20 H 100 0. 6 V @ 2*7 A 100 deg TO 200 package USD ? ? / pcs • Next section Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited • • IPP 05 CN 10 5 m Ohm 0. 08 V @ 14 A 100 deg TO 200 package USD ? ? / pcs www. power. Esim. com 13

Transformer design calculation • After all those mathematics, how will it perform ? Designing Transformer design calculation • After all those mathematics, how will it perform ? Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 14

Mathematics for the loss • Do you calculate it every time on your design Mathematics for the loss • Do you calculate it every time on your design stage? Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 15

What exactly you are doing? Do=? Np = ? Co=? Wire =? Ns = What exactly you are doing? Do=? Np = ? Co=? Wire =? Ns = ? Wire=? M 1=? • Just simple fill in the blank Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 16

Transformer – core and wire only • Power. Esim – It is not giving Transformer – core and wire only • Power. Esim – It is not giving parameters for play with design, It is a tool to build the design. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 17

98% VS 99% - not 1% different • 98% efficiency • 2% loss • 98% VS 99% - not 1% different • 98% efficiency • 2% loss • 30 W loss • 99% efficiency • 1% loss • 15 W loss • Efficiency is not just a figure, it does matter. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 18

98% VS 99% - 200% different • 98% efficiency • 2% loss • 150 98% VS 99% - 200% different • 98% efficiency • 2% loss • 150 W converter • 99% efficiency • 1% loss • 300 W converter • Selling price double by 1% losses cut Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 19

What is all about • Active Diode vs Diode – almost same cost. • What is all about • Active Diode vs Diode – almost same cost. • EMI IC vs filter – greatly improve efficiency. • Power. Esim vs Paper design – no cost. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 20

Active Diode & EMI IC Designing a 90% efficiency 150 W power supply with Active Diode & EMI IC Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 21

EMI solutions: Passive filter § Conventional EMI solutions depend on passive filter using inductors EMI solutions: Passive filter § Conventional EMI solutions depend on passive filter using inductors and capacitors: § Inductors: CMC, DMC § Capacitors: X-cap, Y-cap § There are limitations when using passive filters: § Inductors: Large size and high conduction loss § Capacitors: leakage current specifications Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 22

Active EMI cancellation IC WT 6001: An effective EMI solution – Y-cap booster WT Active EMI cancellation IC WT 6001: An effective EMI solution – Y-cap booster WT 6001 § A patented technology developed in Power. ELab. § An SO-8 IC WT 6001 developed with W 2. § Equivalent to a Y-cap with very large value within the EMI concerned frequency range only. § No boosting effect in the leakage current test concerned frequency range (50 – 800 Hz). § Greatly reduce the common mode inductor size and requirements. § Reduce converter size and improve conversion efficiency. § Provide effective and efficient EMI solution. § Built-in electrical surge protection which can easily pass the EN 610004 -4 and EN 61000 -4 -5 immunity standard. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 23

Applications: Replace passive Y-cap Replaced by Y-cap booster LISN Designing a 90% efficiency 150 Applications: Replace passive Y-cap Replaced by Y-cap booster LISN Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 24

Effect measurable by oscilloscope when using Ycap booster Noise voltage across Y-cap in switching Effect measurable by oscilloscope when using Ycap booster Noise voltage across Y-cap in switching converter Noise voltage across Y-cap booster in switching converter More application examples can be found in the datasheet of WT 6001 Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 25

Practical application examples § The original EMI filter design cannot pass the EN 55022 Practical application examples § The original EMI filter design cannot pass the EN 55022 class B limit. § Filter component: § 2 x 20 mm high mu toroid for common mode filters § 2 x 0. 15 u. F X – cap § 1 x 1 n Y 1 -cap connected between primary and secondary Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 26

Practical application examples: Original filter schematic • It is a commonly used filter configuration Practical application examples: Original filter schematic • It is a commonly used filter configuration • L 2 B is wound with many turns which intends to suppress the low to mid-frequency common mode noise. Its leakage inductance together with C 1 also provides differential mode noise filtering • L 1 B is a single layer, bi-filer wound common mode choke for high frequency common mode noise filtering Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 27

Practical application examples: EMI measurement DM noise Y-cap: From 1 n to 3 n Practical application examples: EMI measurement DM noise Y-cap: From 1 n to 3 n 3 CM noise Improved but not enough Failure was identified to be caused by: • Insufficient leakage inductance of the common mode choke for DM noise attenuation. • The two common mode choke cannot effectively block out the common mode current. • Further increase of Y-cap can reduce CM noise but fail to meet leakage current specifications. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 28

Practical application examples: Solution using Y-cap booster § Y-cap booster is used to replace Practical application examples: Solution using Y-cap booster § Y-cap booster is used to replace the primary to secondary Y-cap § After using the Y-cap booster, L 2 B is replaced by a small differential mode filter and L 1 B is reduced to a 9 mm toroid with only a few turns to tackle the high frequency common node noise. The test results pass the required limit lines Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 29

Practical application examples: Filter comparison: Before and After. . . Failed design even with Practical application examples: Filter comparison: Before and After. . . Failed design even with more cost, loss and bigger size for the filter Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited Passed design using Y-cap booster with much smaller filter size that saves cost, power and space www. power. Esim. com 30

Another practical application examples: Filter comparison: Before and After. . . Original EMI solution Another practical application examples: Filter comparison: Before and After. . . Original EMI solution using passive filter in ATX converter Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited New EMI solution using Y-cap booster in ATX converter www. power. Esim. com 31

Conclusion § Y-cap booster breaks the relationship between the Y-cap values and leakage current Conclusion § Y-cap booster breaks the relationship between the Y-cap values and leakage current requirement. § Greatly reduce product design period and resources. § It can be applied to any position with conventional Y-cap. § Significantly reduce the size and loss of common mode choke implies higher power density and efficiency. § EMI less sensitive to transformer winding capacitance implies more rooms for improving transformer coupling. § Very suitable for equipment required low leakage current like medical equipment. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 32

Active Diode – An easy to use and high efficiency rectifier suitable for all Active Diode – An easy to use and high efficiency rectifier suitable for all converters Stringent requirements of nowadays converters: § § § Compact size Low heat generation and high conversion efficiency High output power and output current Low cost ………!!! Conventional technologies cannot meet the requirements!! Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 33

Synchronous rectifier § Use MOSFETs to replace diode rectifiers. 0. 24 V K 9 Synchronous rectifier § Use MOSFETs to replace diode rectifiers. 0. 24 V K 9 m A Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited K 7. 8 m A www. power. Esim. com 34

Synchronous rectifier § Provides low conduction loss. § Can operate at higher high current Synchronous rectifier § Provides low conduction loss. § Can operate at higher high current without heatsink. SCK 2. 8 W losses @ 10 A MOSFET 0. 7 W losses @ 10 A Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 35

Synchronous rectifier § Usage not limited to converters with high profit margin. § Price Synchronous rectifier § Usage not limited to converters with high profit margin. § Price of nowadays low RDSon MOSFETs comparable to schottky diodes using the state of the art technology. § Provide even lower converter cost because of reduced heatsink, more output power, higher conversion efficiency…. . § Emerge in low cost converter like adaptors, standard open frame converters, ATX ……. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 36

Synchronous rectifier AD AD § Problematic for some conventional topologies § Special and sometimes Synchronous rectifier AD AD § Problematic for some conventional topologies § Special and sometimes complicated driving circuits SR are needed for different topologies § Performance sensitive to transformer leakage inductance and operating conditions § Converter cannot be paralleled – Reverse current § Poor efficiency at low load § Simple circuit § Discontinuous mode is allowed § Good low load efficiency § Converter can be paralleled § High conversion efficiency § Works just like a diode § Limited input voltage range Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 37

Active diode – Operating principle A K A 1 N 2 N 3 D Active diode – Operating principle A K A 1 N 2 N 3 D 1 N 4 D 2 n n n N 1 is the current sense winding N 2 provides MOSFET driving signals A 1 driver circuit (IC WT 6002) N 1 N 3 & D 1 form energy recovery circuit N 4 & D 2 form reset circuit Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 38

Active diode – Operating principle Voltage across winding N 2 or gate drive voltage Active diode – Operating principle Voltage across winding N 2 or gate drive voltage Von of SR depends on ratio of N 2 to N 3 and voltage Vo Toff A K Ii Von VN 2 A 1 N 1 Voltage source Vo can be any voltage source in a converter, e. g. output voltage Vo N 2 VN 3 Vo N 3 D 1 VN 4 D 2 Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 39

Application of Active Diode in different topologies Co Vin Vo - S - Lf Application of Active Diode in different topologies Co Vin Vo - S - Lf + + Vin Flyback SR - Flyback Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited Freewheel SR Magnetic Reset Co Vo - S Forward SR Forward www. power. Esim. com 40

Application of Active Diode in different topologies + S 1 C 1 SR 1 Application of Active Diode in different topologies + S 1 C 1 SR 1 Vin - Lf 1 Lf S 2 C 2 + Co Vo - SR 2 Half Bridge centre tap Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited + S 1 C 1 S 2 C 2 SR 1 Co Vin + Vo - SR 2 Lf 2 Current Doubler www. power. Esim. com 41

Application of Active Diode in different topologies SR 1 Co + Vo - ISIN Application of Active Diode in different topologies SR 1 Co + Vo - ISIN SR 2 and many others…. Resonant converter Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 42

Successful application of Active Diode in converter products AD on 150 W ACDC AD Successful application of Active Diode in converter products AD on 150 W ACDC AD on 120 W ACDC AD on 300 W ACDC Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited AD on 1. 5 V 200 A ACDC AD on 60 W ACDC AD on 100 W DCDC www. power. Esim. com 43

Conclusion § A new “Active Diode” technology is presented. § A kind of current Conclusion § A new “Active Diode” technology is presented. § A kind of current driven synchronous rectifier technology that provides high conversion efficiency and eliminates many conventional synchronous rectifier application problems. § Patented technologies. § An Active Diode driver IC WT 6002 for easy implementation of the technology. § Well proven by many converter product design. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 44

References • Liu, J. C. P. ; Poon, F. N. K. ; Xuefei Xie; References • Liu, J. C. P. ; Poon, F. N. K. ; Xuefei Xie; Pong, M. H. ; current driven synchronous rectifier with energy recovery sensor Power Electronics and Motion Control Conference, 2000. Proceedings. PIEMC 2000. The Third International , Volume: 1 , 2000, page(s): 375 -380 vol. 1 • Xuefei Xie; Liu, J. C. P. L. ; Poon, F. N. K. ; Man Hay Pong; Current-driven synchronous rectification technique for flyback topology, Power Electronics Specialists Conference, 2001. PESC. 2001 IEEE 32 nd Annual , Volume: 1 , 2001, Page(s): 345 350 vol. 1 • Xuefei Xie; Liu, J. C. P. ; Poon, F. N. K. ; Man Hay Pong; A novel high frequency current-driven synchronous rectifier for low voltage high current applications, Applied Power Electronics Conference and Exposition, 2001. APEC 2001. Sixteenth Annual IEEE , Volume: 1 , 2001, Page(s): 469 -475 vol. 1 • Liu, J. C. P. ; Xuefei Xie; Poon, F. N. K. ; Pong, B. M. H. ; Practical solutions to the design of current-driven synchronous rectifier with energy recovery from current sensing, Applied Power Electronics Conference and Exposition, 2002. APEC 2002. Seventeenth Annual IEEE , Volume: 2 , 2002, Page(s): 878 -884 vol. 2 • Xuefei Xie; Joe Chui Pong Liu; Poon, F. N. K. ; Man Hay Pong; A novel high frequency current-driven synchronous rectifier applicable to most switching topologies, Power Electronics, IEEE Transactions on , Volume: 16 Issue: 5 , Sep 2001, Page(s): 635 -648 • Xie Xuefei; Liu, J. C. P. ; Poon, F. N. K. ; Pong, B. M. H. ; Two methods to drive synchronous rectifiers during dead time in forward topologies, Applied Power Electronics Conference and Exposition, 2000. APEC 2000. Fifteenth Annual IEEE , Volume: 2 , 2000, Page(s): 993 -999 vol. 2 • US patent "Current driven synchronous rectifier with energy recovery" patent number 6, 134, 131 • US patent “Self-driven synchronous rectifier by retention of gate charge” patent number 6, 377, 477 • US patent “Current driven synchronous rectifier with energy recovery using hysterisis driver”, patent number 6, 597, 587 Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 45

We are trained to fill in a value NOT design a circuit Designing a We are trained to fill in a value NOT design a circuit Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 46

Fill in values by experience. . . Vi=100 Vo=12 Vo=Vi*D*Ns / (1 -D)*Np Vi+Vo*Np/Ns=0. Fill in values by experience. . . Vi=100 Vo=12 Vo=Vi*D*Ns / (1 -D)*Np Vi+Vo*Np/Ns=0. 8 Vds_max Vo=Ns*0. 3*fs/(1 -D) 0. 5*Vo_ripple=Q/Co Vds_max_M 1=lowerest cost in stock IF_max_Do=2*Io VR_max_Do=1. 2*(Vi*Ns/Np+Vo) Core_T 1=recommended table from ferrite manufacturer Wire_Np=fully filled Wire_Ns=fully filled Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 47

Then again. . . • Replace 100 pcs of components at bench Designing a Then again. . . • Replace 100 pcs of components at bench Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 48

Fine, but no need to replace at the bench. . . • Why not Fine, but no need to replace at the bench. . . • Why not replace 100 pcs of components at Power. Esim Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 49

www. power. Esim. com • It’s on-line • It’s for everyone • Worldwide access www. power. Esim. com • It’s on-line • It’s for everyone • Worldwide access • 100% server side simulation • It’s free Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 50

Build virtual and real converter PFC Developed under Infineon TDA 4863 Evaluation Design DC-DC Build virtual and real converter PFC Developed under Infineon TDA 4863 Evaluation Design DC-DC Developed under Infineon ICE 3 DS 01 Evaluation Design 150 W 90% LCD Converter Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 51

160 W PFC – simulation vs measurement Input Votlage Vs Efficiency % 100. 00 160 W PFC – simulation vs measurement Input Votlage Vs Efficiency % 100. 00 90. 00 80. 00 70. 00 60. 00 50. 00 40. 00 30. 00 20. 00 10. 00 Measured 85 110 230 265 160 W PFC Input Voltage Vac Power. Esim Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 52

150 W Flyback – simulated vs measured I/P Votlage Vs Efficiency % 100. 00 150 W Flyback – simulated vs measured 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 Measured 300 350 405 150 W flyback. Input Votlage Vdc Power. Esim Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 53

Loss and Temp. Designing a 90% efficiency 150 W power supply with PFC in Loss and Temp. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 54

Component Based Approach Real components Abstract Concept • Find MOSFET ý Rds*Crss • Find Component Based Approach Real components Abstract Concept • Find MOSFET ý Rds*Crss • Find Diode ý Vf*trrm • Find Capacitor ý CV • Find Core ý k 1, k 2, k 3 • Find Wire ý Current density Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 55

Power. Esim vs Traditional Design Power. Esim turn design into result oriented adaptive iteration Power. Esim vs Traditional Design Power. Esim turn design into result oriented adaptive iteration instead of skill of knowledge application Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 56

But first. . . • Find a circuit that has closest specification to your But first. . . • Find a circuit that has closest specification to your need, e. g. 160 W TDA 4863 for PFC front end. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 57

Ask our expert • Enter the input & output specification • Chose an application Ask our expert • Enter the input & output specification • Chose an application • Click “Recommend Design” Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 58

How our expert system work. Specification Search for closest evaluation design Designing a 90% How our expert system work. Specification Search for closest evaluation design Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited Search for best topologies www. power. Esim. com 59

If you like more freedom • Click “Topologies” • Chose the topology you like If you like more freedom • Click “Topologies” • Chose the topology you like • Enter the input & output specification Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 60

Re-define specification • Click “Detail Spec. ” • Change specification as you like Designing Re-define specification • Click “Detail Spec. ” • Change specification as you like Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 61

Click the main MOSFET Designing a 90% efficiency 150 W power supply with PFC Click the main MOSFET Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 62

How we model component? Designing a 90% efficiency 150 W power supply with PFC How we model component? Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 63

Click, click and select • A particular one – total & individual loss • Click, click and select • A particular one – total & individual loss • Highlighted one – total, individual loss and stress • Selected one – total individual loss and stress Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 64

Other than loss, Stress is important Designing a 90% efficiency 150 W power supply Other than loss, Stress is important Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 65

More clever method – Smart Optimizer Click “Select All” All MOSFET will dump into More clever method – Smart Optimizer Click “Select All” All MOSFET will dump into a optimizer pool Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 66

Smart Optimizer – just a click • Enter maximum iterations • Wait a few Smart Optimizer – just a click • Enter maximum iterations • Wait a few seconds • Click “Smart Optimizer” Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 67

Multi dimensional optimization 1 10 resistor 2 10 MOSFET x : 10 Designing a Multi dimensional optimization 1 10 resistor 2 10 MOSFET x : 10 Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited x : x 10 diode = 1010 combination = 31 years simulation www. power. Esim. com 68

Smart Optimizer – how it work Data set SPD 07 N 60 C 3 Smart Optimizer – how it work Data set SPD 07 N 60 C 3 Smart Scan BU 60 SPN 04 N 60 C 2 SPB 07 N 60 S 5 IPP 50 R 520 CP Genetic Algorithm Search for good component BU 60 SPD 07 N 60 C 3 SPN 04 N 60 C 2 SPB 07 N 60 S 5 IPP 50 R 520 CP Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 69

Sorted one by one • Result will be ranked • Click to view each Sorted one by one • Result will be ranked • Click to view each result • Optimized Component will be shown Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 70

Now Active Diode • Click the diode you like to replace by Active Diode 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 Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 71

Search more MOSFET • Extend to higher current range is usually needed • Extend Search more MOSFET • Extend to higher current range is usually needed • Extend the body diode’s trrm can find more MOSFET Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 72

Select a better Sync Rect. • 0. 5 W Active Diode loss • 2. Select a better Sync Rect. • 0. 5 W Active Diode loss • 2. 54 W SCK loss Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 73

Which component is more critical? • • Loss Analysis – the most useful page Which component is more critical? • • Loss Analysis – the most useful page • Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited Why M 1, D 3 & T 1 It rank the loss and it’s details www. power. Esim. com 74

Follow the step • Follow the tips from the header is a good practice. Follow the step • Follow the tips from the header is a good practice. • Just click the box, it will redirect you to other tools • Go through each box step by step Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 75

Click T 1 and go to Magnetic Builder Designing a 90% efficiency 150 W Click T 1 and go to Magnetic Builder Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 76

Step 1 – select the core you like • Chose the range of Ae Step 1 – select the core you like • Chose the range of Ae • Select Core shape • Select Manufacturer Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 77

Instant preview winding when thing change • Click the “preview winding” • Corresponding winding Instant preview winding when thing change • Click the “preview winding” • Corresponding winding cross section will be shown • Supported on Core, N and Wire. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 78

Step 2 – find the best Lm • Click the “Inductance” button • Enter 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. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 79

Step 3 – find the best N 0 • Click the “Number of turn” Step 3 – find the best N 0 • 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. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 80

Don’t forget preview winding • Click the “Preview Winding” button • Observe how winding Don’t forget preview winding • Click the “Preview Winding” button • Observe how winding structure change with number of turn. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 81

Step 4 – need more copper? • • • Click the “Change Wire” button Step 4 – need more copper? • • • Click the “Change Wire” button Click the “No. of Parallel Wire” Add more parallel wire as you like. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 82

160 W PFC – simulation vs measurement Input Votlage Vs Efficiency % 100. 00 160 W PFC – simulation vs measurement Input Votlage Vs Efficiency % 100. 00 90. 00 80. 00 70. 00 60. 00 50. 00 40. 00 30. 00 20. 00 10. 00 Measured 85 110 230 265 160 W PFC Input Voltage Vac Power. Esim Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 83

150 W Flyback – simulated vs measured I/P Votlage Vs Efficiency % 100. 00 150 W Flyback – simulated vs measured 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 Measured 300 350 405 150 W flyback. Input Votlage Vdc Power. Esim Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 84

DVT – check the stresses • DVT Report check every components stress and also DVT – check the stresses • DVT Report check every components stress and also circuit design constraint. Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 85

Thermal – knowing Temp. at day 1 Designing a 90% efficiency 150 W power Thermal – knowing Temp. at day 1 Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 86

MTBF – how long it last Designing a 90% efficiency 150 W power supply MTBF – how long it last Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 87

Designing a 90% efficiency 150 W power supply with PFC in minutes • Live Designing a 90% efficiency 150 W power supply with PFC in minutes • Live Demonstration Designing a 90% efficiency 150 W power supply with PFC in hours Prepared by Dr. Franki Poon & Dr. Joe Liu Power. ELab Limited www. power. Esim. com 88