poweresim 上作 150W LED 电源的优化 Design Optimization by PowerEsim 1

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1 poweresim 上作 150W LED 电源的优化 Design Optimization by PowerEsim 1 1

2 Power e lab Design, Software, Licensing, Consultancy We make design for wide range of products e.g. AC-DC power supply, DC-DC converter, EV charger, HF electronic ballast, LED driver, battery charger, DC-AC Inverter, etc. Design Optimization by PowerEsim 2 2

3 Our Free Product... It s on-line. It s for everyone. Worldwide access. 100% server side simulation. It s FREE!! But 80% featured. Design Optimization by PowerEsim 3 3

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5 Need more common component? Ask your component manufacture to contact us. It is free! Component supplier should provide a free tool for you! Design Optimization by PowerEsim 5 5

6 From sponsor s Web site Make it as virtual FAE. Engineers all over the world can freely use this tool and sponsor s products. Much better than the worksheet solution. Design Optimization by PowerEsim 6 6

7 Your private free account User can apply for a 7 days private free full features account by each address. Design Optimization by PowerEsim 7 7

8 Follow the crowd.... Almost 500 visitors come every days all around the world. Design Optimization by PowerEsim 8 8

9 The crowd are % users are post graduates. 20% users have over 20 years experiences. 60% users are non power supply expert. 80% users are technical people. Design Optimization by PowerEsim 9 9

10 It s highly accurate Input Votlage Vs Efficiency % W PFC Input Voltage Vac Measured Measured Cu rre n t RM S (A ) Measured 0.4 Mea sured 0.3 Cla ss D L imi ts Harmoni c nu mber I/P Votlage Vs Efficiency % W flybackinput Votlage Vdc Simulated Simulated Simulated No pressing run button anymore! 0.1 s for a simulation. Design Optimization by PowerEsim

11 Why needed - Saving knowledge transferring cost Traditional Method Web 2.0 solution Design Optimization by PowerEsim

12 Design in real life - Try and Error Replacing 398 pcs of components at bench during design. Smoke a converter 5 times during design. Design Optimization by PowerEsim

13 Fine, do it in virtual world... Why not replace 398 pcs of components at PowerEsim. Design Optimization by PowerEsim

14 What make us different speed is everything <0.05s <0.1s SPEED is everything. Overall losses Xformer modeling SPEED is everything. <0.2s <3s SPEED is everything. Waveform Thermal simulation Design Optimization by PowerEsim 14 SPEED is everything. 14

15 No expert knowledge needed! Traditional design Rds*Crss Vf*trrm CV k1, k2, k3 Current density PowerEsim Find MOSFET Find Diode Find Capacitor Find Core Find Wire No equations needed! Simple pick and place components. Or build real Xformer in virtual space. Design Optimization by PowerEsim

16 Select any real core you like Chose the range of Ae Select Core shape Select Manufacturer Design Optimization by PowerEsim

17 poweresim is... PowerEsim turn design into result oriented adaptive iteration instead of knowledge oriented design approach Design Optimization by PowerEsim

18 PowerEsim vs Traditional Design Traditional PowerEsim Design Prototype Design Verify Mathcad Excel Paper & Pen SPICE Trim R1 Redesign Excel T1 drawing Rewind T1 Mathcad Optimize T2 Optimize fs Optimize R3 Redesign Mathcad Excel SPICE Design Prototype Design Verify PowerEsim Trim R1 PowerEsim Redesign Redesign PowerEsim SPICE Save up to 30% Design Time Design Optimization by PowerEsim

19 Start a design Ask our expert system Type in your basic requirement and application. Click Recommend Design. Design Optimization by PowerEsim

20 Start a design Ask our expert system Recommendation will be ranked. Pick one as you like. Design Optimization by PowerEsim

21 Default design will be given first General performance, e.g. Eff., Losses, Vo, flux level, duty cycle, switching frequency, etc. at different input voltage are shown. Design Optimization by PowerEsim

22 New design with new specification Click New Design Enter new input and output Spec. A preliminary design will be ready. Design Optimization by PowerEsim

23 Change different PWM controller circuit Double click the PWM block. Select the PWM controller. Another PWM circuit will appear. Design Optimization by PowerEsim

24 Change transformer and component Construct any transformer you like. Select other MOSFET to fit design. Design Optimization by PowerEsim

25 Background - What else we consider for a transformer H Leakage inductance L k uo 2 = H dv I k m=2 Proximity effect ( 2 1) Pd m 2 sinh cosh ( ξ ) sin( ξ ) ( ξ ) + cos( ξ ) Skin effect Fringing flux Core losses π d ξ = 2 D ski n Pd 2 f B l wire d wire ρ wire 4 D skin = u o ρ π f ( meter) f Pd Vol a b + k 1 B B k 2 c + B k d f B Design Optimization by PowerEsim

26 Losses and it s details Loss Analysis the first page to click. It give total losses at a practical operating condition. It also shows losses breakdown at each component. Design Optimization by PowerEsim

27 The most important page Component Finder Best Try and Error tool. Design Optimization by PowerEsim

28 Click, click, click and select Previous selection total & individual loss Present s selection total, individual loss and stress Future selection total, individual loss and stress Design Optimization by PowerEsim

29 Other than loss, Stress is important Stress of each component can be known immediately. Design Optimization by PowerEsim

30 How we model component? The component modeled characteristic can be seen. Design Optimization by PowerEsim

31 Features are same for all component Design Optimization by PowerEsim

32 Save a Design all the time, please... Click the save button can save the design in your own computer or your company s network storage. Both Transformer and Design can be saved, and use as a template. Design Optimization by PowerEsim

33 Start optimization - 160W 95% PFC PFC choke first -Now click L4 on the schematic and go to the Magnetic Builder. Design Optimization by PowerEsim

34 Choice the ferrite core first PQ2625 is chosen. Winding window cross section can be seen when changing different core. Design Optimization by PowerEsim

35 Search and Destroy! Core is saturated Less inductance or more turns Core loss is low Increase fs. DC Cu loss is high Less turns or More copper. AC Cu loss is high Thinner wire or Less turns. Design Optimization by PowerEsim

36 Less turn Less cost... DC Cu loss is high Less turns More copper. Core is saturated Less L0 + same turn Same L0 + more turn Less less L0 + less turn Try and Error method. Smallest Xformer losses at 50T. 75 T to 50 T makes 3.9 W to 2.9. Design Optimization by PowerEsim

37 How much less inductance? Core is saturated Less L0 More turns Try and Error method. No saturation beginning at 380 uh. 2.9 W to 2.9 W Design Optimization by PowerEsim

38 Smaller wire & more copper? DC copper loss is high Less turns More copper. AC copper loss is high Thinner wire Less turns. Try and Error method. AWG30x2 to AWG34x14 wires to thinner wire and increase copper. 2.9 W to 1.6 W. Design Optimization by PowerEsim

39 Can it be Optimize thermistor Try and Error method. Replace thermistor TH1 by 0 Ohm parts. 1.2 W to 0W, 94.4% Efficiency. Design Optimization by PowerEsim

40 Can it be Optimize MOSFET Try and Error method. Change M1 to IPP60R199CP. 1W to 0.78W, 94.56% Efficiency. Design Optimization by PowerEsim

41 Can it be Aux. series resistor Try and Error method. ChangeAux. winding from 3T to 2T. 94.9% Efficiency. Design Optimization by PowerEsim

42 Can it be Snubber capacitor Try and Error method. Reduce snubber to virtually zero. Design Optimization by PowerEsim % Efficiency. Done! 42

43 Now the DC-DC part Go back to front page. Click All topologies. Select Flyback DC-DC. Design Optimization by PowerEsim

44 A design on virtual bench first Click New Design Enter new input and output Spec. A preliminary design will be ready. Design Optimization by PowerEsim

45 You can choice before Initialize Double click the PWM block. Select the PWM controller. Another PWM circuit will appear. Design Optimization by PowerEsim

46 85% only, what next? Optimize T1 : : Optimize M1 Optimize D3 : : : Optimize R2 Optimize R8 : Design Optimization by PowerEsim

47 Start optimization - 150W 95% Flyback Transformer first Now click T1 on the schematic and go to the Magnetic Builder. Design Optimization by PowerEsim

48 Triple Insulated Wire more power & lower cost Try and Error method. Use Triple Insulated Wire at secondary side can cut the creepage tape so more room for cooper wires to boost the power of the Xformer. Design Optimization by PowerEsim

49 Choice the preferred ferrite core PQ2625 is chosen. Winding window cross section can be seen when changing different core. Design Optimization by PowerEsim

50 Search and Destroy! Core loss is low Reduce fs. DC Cu loss is high Less turns or More copper. AC Cu loss is high Thinner wire or Less turns. Design Optimization by PowerEsim

51 Less turn Less cost... DC Cu loss is high Less turns More copper. Design Optimization by PowerEsim 51 Try and Error method. Click Keep Turn Ratio. 36 T is minimum of no saturation 42 T to 36 T makes 7.3 W to 5.4 W. 51

52 How much less inductance? Core Less isturns enough by less inductance Less L0first give more Bs margin Try and Error method. 260 uh is next L0 that away saturation. Design Optimization by PowerEsim

53 Less turns, Less turns, Less turns, Less turns, Less turns... DC Cu loss is high Less turns More copper. AC Cu loss is high Thinner wire Less turns. Design Optimization by PowerEsim 53 Try and Error method. 30T is minimum non-saturated No. 4.9 W to 4.5 W. 53

54 More copper, more copper, more copper, more copper... DC Cu loss is high Less turns More copper. AC Cu loss is high Thinner wire Less turns. Try and Error method. Primary AWG28x1 to AWG28x2 Secondary AWG24x1 to AWG27x4 4.5 W to 3.1 W. Design Optimization by PowerEsim

55 Can it be 95% Optimize MOSFET Try and Error method. Change M1 to IPP60R199CP. 5 W to 1.9 W, 91.4% Efficiency. Design Optimization by PowerEsim

56 Can it be 95% stupid choice Try and Error method. Sometimes the recommend part is not the best. 4.2 W to 2.6 W, 92.4% Efficiency. Design Optimization by PowerEsim

57 Can it be 95% Optimize snubber circuit Design Optimization by PowerEsim 57 Try and Error method. Reduce snubber to virtually zero. 0.8 W to 0.2 W 92.8% Efficiency. 57

58 Can it be 95% Optimize dummy load Try and Error method. Increase dummy load resistor. 0.75W to 0.05W 93.26% Efficiency. Design Optimization by PowerEsim

59 Can it be 95% Optimize gate drive resistor Try and Error method. Reduce gate drive resistor. -1W 93.26% to 93.81% Efficiency. Design Optimization by PowerEsim

60 Can it be 95% Optimize winding layer configuration Try and Error method. Better sandwiches winding % to 93.93% Efficiency. Design Optimization by PowerEsim

61 Can it be 95% Better output diode Try and Error method. Find a better diode % to 94.18% Efficiency. Design Optimization by PowerEsim

62 Can it be 95% More output diodes Try and Error method. Parallel more diodes % to 94.25% Efficiency. Design Optimization by PowerEsim

63 Can it be 95% take a break here 80% of losses depend on 4 components... T1 are get almost 98%... RCD clamper is bad. Change topology for better efficiency. Design Optimization by PowerEsim

64 System of power supplies 150W 90% 48 V with PFC An almost 90% efficiency 150W power supply with PFC front end and 48V output is done. More complex system can be build. Design Optimization by PowerEsim

65 Magnetic Builder - Build a single transformer alone User can build a single transformer by pressing the button Magnetic Builder Design Optimization by PowerEsim

66 Design a single Xformer Where it apply? Choose the application of the magnetic component, e.g. it is a Flyback Xformer or Input Choke Design Optimization by PowerEsim

67 Design a single Xformer Operating conditions? Design Optimization by PowerEsim 67 Enter the simple operating condition of the application, e.g. the operating condition of the Flyback converter Press Recommend Design, a preliminary Xformer with core, wire, tape and winding sequence, will be recommended. 67

68 Design a single Xformer Full version Magnetic Builder Click the Advanced button will go to the full version Magnetic Builder and do whatever you like. Design Optimization by PowerEsim

69 Virtual Transformer Test Bench Click the Estimate Loss button will go to the dedicated testing bench to test the loss of a individual transformer under defined excitation. Design Optimization by PowerEsim

70 Select any real core you like Chose the range of Ae Select Core shape Select Manufacturer Design Optimization by PowerEsim

71 Instant preview winding when thing change Click the preview winding Corresponding winding window cross section will be shown Supported on Core, N and Wire. Design Optimization by PowerEsim

72 Seeking the best values Change inductance, result changed immediately. Change No. of Turn, result changed immediately. Change No. of. Parallel wires, result changed immediately. Design Optimization by PowerEsim

73 Copper foil can be used Click the Use copper foil button Enter the copper foil size That s all. Design Optimization by PowerEsim

74 Faraday shield can be added Click the Add Pri Wdg or Add Sec Wdg button Click the check box Faraday Shield Click the combo box W x to arrange for the layer of the Faraday shield You may go to Winding Construction page to further arrange for the shield. Design Optimization by PowerEsim

75 Arrange each winding layer you like Design Optimization by PowerEsim

76 The dot of a winding User can define whether the winding is started at dot sign or not. Design Optimization by PowerEsim

77 Where to start winding User can define whether the winding is started at upper end or lower end of the winding layer. Design Optimization by PowerEsim

78 How to wind a winding User can define the location of a winding at the center, lower part or upper part of the winding layer. Distribute the winding all over the layer is also possible. Design Optimization by PowerEsim

79 Layer to layer winding method A winding may occupy more than 1 layer. Choose Tight will ensure wires to full up all space in it s layer before go to the next layer. Choose Shared will resulting in even distribution on each layers Design Optimization by PowerEsim

80 Inner tape between each layer Inner tape can be placed between each layer of Multilayers winding. Design Optimization by PowerEsim

81 Customize different bobbins type Design Optimization by PowerEsim 81 Thickness of each wall and the type of split bobbin can be defined in Bobbin Setting. 81

82 You can make a transformer like this.. Design Optimization by PowerEsim 82 You can change the number of wire used. You can change the size of the wire. You can control how you place the wire. You can use copper foil to replace magnet wire. You can split the bobbin. You can add Faraday shield. You can do anything you like

83 Most helpful - Transformer drawing Transformer drawing will be automatically generated by pressing the Generate Drawing button. Details testing methods, P/N, material can be edit before printing. Design Optimization by PowerEsim

84 Thermal Final Thermal Result It will only take a few seconds to see the thermal result. No need to build library! Design Optimization by PowerEsim

85 DVT check the stresses DVT Report check every components stress and also circuit design constraint. Design Optimization by PowerEsim

86 MTBF how long it last Design Optimization by PowerEsim

87 Loop Analysis how stable the system Gain and phase margin will be immediately known with after any change or circuit component. Design Optimization by PowerEsim

88 Loop Analysis automatic compensation Enter the expected DC gain, phase margin and cross over frequency. Press Automatic Compensation button. Design Optimization by PowerEsim 88 System will iteration to best fit the points by changing the component marked with Enable for Automatic Loop Compensation 88

89 Loop Analysis transient loading Design Optimization by PowerEsim 89 Define step loading waveform and corresponding output transient loading response will be shown. 89

90 Harmonic knowing input current harmonics content All input current parameters, e.g. PF, THD, harmonic content can be seen. Design Optimization by PowerEsim

91 Monte Carlo knowing production distribution Monte Carlo analysis can estimate real mass production distribution. Design Optimization by PowerEsim

92 Waveform the least important tools Critical component s waveform will be illustrated. Design Optimization by PowerEsim

93 Magnetic Builder build any transformer You can build any kind of transformer on your own wish and press a button to print the corresponding transformer drawing. Design Optimization by PowerEsim

94 BOM Builder BOM is always ready to print out BOM is always ready to print and will be updated automatically. It save a lot of preparing document time for engineer. Design Optimization by PowerEsim

95 Report Builder Generate all documents with a click Simple a click - All result from analysis or tools can be exported to Excel file for engineering documentation. Design Optimization by PowerEsim

96 Download a lot of document is ready to download A lot of document and publication are ready to download. It is helpful to becomes a PowerEsim expert. Design Optimization by PowerEsim

97 Design Optimization by PowerEsim