Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 1 Design Infineon LCD TV Power Solution with PowerEsim

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 2 Our junior Engineer Gary spend Input Voltage Vac Poweresim Measurement 3 days to build - Low cost 90% 150 W LCD power supply 1 days to design - Low cost 90% 150 W LCD power supply

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 3 Old VS New

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 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 ”

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 5 Old MOSFET VS Young MOSFET 47 ns vs 5 ns, 10 times different

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 6 Where is the ZVS ? Adaptor – A efficiency demanding product. How many of them are using ZVS circuit?

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 7 Where is the losses? 25 % 15 % 30 %10 % Example : 82% 10W loss

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 8 Do we need complicated circuit?

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 9 Why not use less copper? OldNew 50% losses come from magnetic circuit. Better design by using less copper

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 10 Why using diode? STPS20H100 2*7A 100 deg TO200 package USD ?? / pcs IRF540Z 22m Ohm 14A 100 deg TO200 package USD ?? / pcs OldNew

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 11 If TO220 has the same price... STPS20H100 2*7A 100 deg TO200 package USD ?? / pcs IPP05CN10 5m Ohm 14A 100 deg TO220 package USD ?? / pcs

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 12 fill in a value NOT design a circuit We are trained to

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 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

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 14 Then again... Replace 100pcs of components at bench

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 15 Fine, but no need to replace at the bench... Why not replace 100pcs of components at PowerEsim

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited It’s on-line It’s for everyone Worldwide access 100% server side simulation It’s free

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 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

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited W PFC – simulation vs measurement Input Votlage Vs Efficiency % W PFC Input Voltage Vac Measured PowerEsim

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited W Flyback – simulated vs measured I/P Votlage Vs Efficiency % W flybackInput Votlage Vdc Measured PowerEsim

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 20 Loss and Temp.

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 21 Component Based Approach Find MOSFET Find Diode Find Capacitor Find Core Find Wire  Rds*Crss  Vf*trrm  CV  k1, k2, k3  Current density Real componentsAbstract Concept

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 22 PowerEsim vs Traditional Design result oriented adaptive iteration instead of skill of knowledge application PowerEsim turn design into

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 23 Why Power E sim ?? 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 Design Prototype Design Verify PowerEsim Trim R1 PowerEsim Redesign PowerEsim SPICE Design Prototype Design Verify

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 24 But first... Find a circuit that has closest specification to your need, e.g. 160W TDA4863 for PFC front end.

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 25 Ask our expert Enter the input & output specification Chose an application Click “Recommend Design”

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 26 If you like more freedom Click “Topologies” Chose the topology you like Enter the input & output specification

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 27 Click the main MOSFET

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 28 How we model component?

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 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

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 30 Other than loss, Stress is important

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 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

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 32 Search more MOSFET Extend to higher current range is usually needed Extend the body diode’s trrm can find more MOSFET

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 33 Select a better Sync Rect. 2.54W SCK loss 0.5W Active Diode loss

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 34 Which component is more critical? Why M1, D3 & T1 Loss Analysis – the most useful page It rank the loss and it’s details

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 35 Click T1 and go to Magnetic Builder

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 36 Step 1 – select the core you like Chose the range of Ae Select Core shape Select Manufacturer

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 37 Instant preview winding when thing change Click the “preview winding” Corresponding winding cross section will be shown Supported on Core, N and Wire.

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 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.

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 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.

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 40 Don’t forget preview winding Click the “Preview Winding” button Observe how winding structure change with number of turn.

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 41 Step 4 – need more copper? Click the “Change Wire” button Click the “No. of Parallel Wire” Add more parallel wire as you like.

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 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

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 43 DVT – check the stresses DVT Report check every components stress and also circuit design constraint.

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 44 Connecting Power Supplies

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 45 Thermal – knowing Temp. at day 1

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 46 MTBF – how long it last

Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited 47 It’s Done and On PowerEsim Enjoy using PowerEsim