PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 1 PowerEsim FACT sheet

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 2 Hardware Prototype Implementation Topology: AC/DC Flyback Dual-output Converter Input range: VAC/50Hz Outputs: O/P1 – 5V/6A; O/P2 – 12V/2.5A

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 3 Critical waveforms Input voltage at 85VAC Drain Voltage Waveform Analysis Primary MOSFET switching waveform Ch1 – M1 drain source voltage waveform; Ch2 – M1 drain current waveform Simulation peak voltage from Power e Sim = 300V Actual peak voltage approx. = 285V

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 4 Critical waveforms Input voltage and bulk capacitor voltage waveforms Bulk Capacitor Voltage Waveform Analysis Ch1 - Input AC voltage waveform Ch2 - Rectified bulk capacitor voltage Similar intersection point SimulationMeasurement

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 5 Critical waveforms Input voltage and current Input Current Waveform Analysis Ch1 - Input AC voltage waveform Ch2 - Input current waveform SimulationMeasurement

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 6 Line Regulation SimulationMeasurement Output at full load

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 7 Load Regulation Input voltage at 85VAC Simulation Measurement

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 8 Power Loss Analysis Efficiency comparison at full load

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 9 Closed-loop Analysis (Bode plot) Input voltage at 115VAC full load Measurement Cut-off freq Simulation

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 10 Closed-loop Analysis (Transient Response) Conditions: Input voltage at 162VDC O/P1: 0.2A-6A O/P2: 12V at 1A SimulationMeasurement CH1: Load current CH2: Output voltage of O/P1

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 11 Input Current Harmonics Analysis Measurement Input voltage at 230VAC/50Hz Simulated bar charts showed in good agreement with measurement.

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 12 Thermal Analysis Measurement Simulation 94

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 13 Transformer Design Leakage inductance: Measurement = 2.787uH Simulation = 2.982uH

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 14 DVT Report – SMPS from other factory

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 15 DVT Report – 100 times faster to know the design fault Measurement Simulation

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 16 Saturation current observed in experimental measurement DVT Report – Every component checked include Xformer Measurement Simulation

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 17 A simulated drain voltage of 75W flyback converter with 3 outputs – result = ~580V DVT Report – MOSFET Stress MeasurementSimulation

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 18 Evaluation Design Measurement Simulation

PowerEsim FACT sheets Prepared by Franki Poon PowerELab Limited 19 After 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