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

2. Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited www.powerEsim.com 2 Our junior Engineer Gary spend... 0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00 85110230265 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

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

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

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

7. Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited www.powerEsim.com 7 Where is the losses? 25 % 15 % 30 %10 % Example : 12V@4A 82% 10W loss

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

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

10. Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited www.powerEsim.com 10 Why using diode? STPS20H100 0.6V @ 2*7A 100 deg TO200 package USD ?? / pcs IRF540Z 22m Ohm 0.54V @ 14A 100 deg TO200 package USD ?? / pcs OldNew

11. Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited www.powerEsim.com 11 If TO220 has the same price... STPS20H100 0.6V @ 2*7A 100 deg TO200 package USD ?? / pcs IPP05CN10 5m Ohm 0.08V @ 14A 100 deg TO220 package USD ?? / pcs

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

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

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

16. Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited www.powerEsim.com 16 www.powerEsim.com It’s on-line It’s for everyone Worldwide access 100% server side simulation It’s free

17. Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited www.powerEsim.com 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. Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited www.powerEsim.com 18 160 W PFC – simulation vs measurement Input Votlage Vs Efficiency % 0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00 85110230265 160W PFC Input Voltage Vac Measured PowerEsim

19. Design Infineon LCD TV Power Solution with PowerEsim 31/Aug/07 Prepared by Dr. Franki Poon PowerELab Limited www.powerEsim.com 19 150 W Flyback – simulated vs measured I/P Votlage Vs Efficiency % 0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00 300350405 150W flybackInput Votlage Vdc Measured PowerEsim

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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