Saber Tutorial. Quasi-resonant Flyback Converter Simulation. Alan Courtay. March 7, 2016
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1 Saber Tutorial Quasi-resonant Flyback Converter Simulation Alan Courtay March 7, 2016
2 Agenda Quasi-Resonant Flyback Converter (AN1326) Principles of Operation Simulation vs. Measurement Accurate Datasheet-Driven Modeling Controller Chip MOSFET Transformer Automated Verification EMI Loss / Efficiency 2016 Synopsys, Inc. 2
3 L6565-Based 50W QR ZVS Flyback Vout1: 105 V ± 5% Iout1: 0.1 to 0.35 A Vripple1: 1% Vin: 50/60Hz, 88 to 264 Vac Vout2: 14 V ± 10% Iout2: 0.1 to 1 A Vripple2: 1% 2016 Synopsys, Inc. 3
4 L6565-Based 50W QR ZVS Flyback Power Stage Vout1: 105 V ± 5% Iout1: 0.1 to 0.35 A Vripple1: 1% Llk+Lp Vin: 50/60Hz, 88 to 264 Vac Vds Vin Llk&Cd Vr Vr Lp&Cd Cd Vout2: 14 V ± 10% Iout2: 0.1 to 1 A Vripple2: 1% Currents T on Secondary Discontinuous Conduction Mode Peak Current Mode Control t Ipeak Primary Demagnetization t 2016 Synopsys, Inc. 4
5 L6565-Based 50W QR ZVS Flyback Power Stage Vout1: 105 V ± 5% Iout1: 0.1 to 0.35 A Vripple1: 1% Vin: 50/60Hz, 88 to 264 Vac Vds Vin Vr Vr Valley Switching Vout2: 14 V ± 10% Iout2: 0.1 to 1 A Vripple2: 1% Currents T on T off t Ipeak t 2016 Synopsys, Inc. 5
6 L6565-Based 50W QR ZVS Flyback Power Stage Vout1: 105 V ± 5% Iout1: 0.1 to 0.35 A Vripple1: 1% Vin: 50/60Hz, 88 to 264 Vac Vds Vin Vr ZVS Vin < Vr Vout2: 14 V ± 10% Iout2: 0.1 to 1 A Vripple2: 1% Currents T on T off t Ipeak t 2016 Synopsys, Inc. 6
7 L6565-Based 50W QR ZVS Flyback Power Stage Vout1: 105 V ± 5% Iout1: 0.1 to 0.35 A Vripple1: 1% Vin: 50/60Hz, 88 to 264 Vac Vds Vin Skip Cycle Vout2: 14 V ± 10% Iout2: 0.1 to 1 A Vripple2: 1% Currents T on T off t Ipeak t 2016 Synopsys, Inc. 7
8 L6565-Based 50W QR ZVS Flyback RCD Clamp Power Stage Vout1: 105 V ± 5% Iout1: 0.1 to 0.35 A Vripple1: 1% Vin: 50/60Hz, 88 to 264 Vac start-up self-supply Vout2: 14 V ± 10% Iout2: 0.1 to 1 A Vripple2: 1% Vcc 2016 Synopsys, Inc. 8 Output Voltage Regulation Feedback
9 L6565-Based 50W QR ZVS Flyback 2016 Synopsys, Inc. 9
10 Agenda Quasi-Resonant Flyback Converter (AN1326) Principles of Operation Simulation vs. Measurement Accurate Datasheet-Driven Modeling Controller Chip MOSFET Transformer Automated Verification EMI Loss / Efficiency 2016 Synopsys, Inc. 10
11 Current Sense and Primary Voltage Full Load, Vin = 100 V 1V 4µs 4µs 100V 2016 Synopsys, Inc. 11
12 Current Sense and Primary Voltage Full Load, Vin = 380 V 1V 100V 2µs 2µs 2016 Synopsys, Inc. 12
13 Current Sense and Primary Voltage Half Load, Vin = 100 V 1V 100V 4µs 4µs 2016 Synopsys, Inc. 13
14 Current Sense and Primary Voltage Half Load, Vin = 380 V 0.5V 100V 2µs 2µs 2016 Synopsys, Inc. 14
15 Cycle Skipping / Frequency Foldback Light Load, Vin = 300 V 0.5V 100V 5µs 5µs 2016 Synopsys, Inc. 15
16 Current Sense and Primary Voltage Standby, Vin = 380 V Burst Mode 0.5V 100V 100µs 100µs 2016 Synopsys, Inc. 16
17 Agenda Quasi-Resonant Flyback Converter (AN1326) Principles of Operation Simulation vs. Measurement Accurate Datasheet-Driven Modeling Controller Chip MOSFET Transformer Automated Verification EMI Loss / Efficiency 2016 Synopsys, Inc. 17
18 Modeling Controller IC 2016 Synopsys, Inc. 18
19 Modeling Controller IC 2016 Synopsys, Inc. 19
20 Modeling Controller IC Frequency foldback Turn-on Valley detection model with StateAMS tool 2016 Synopsys, Inc. 20 Blanking time model with TLU tool
21 Modeling Controller IC Turn-on Turn-off Line voltage feedforward function implemented in MAST Limits power capability at high line voltage 2016 Synopsys, Inc. 21
22 Modeling Power MOSFET 2016 Synopsys, Inc. 22
23 Modeling Power MOSFET Characterized Temperatures DC Characteristics 2016 Synopsys, Inc. 23
24 Modeling Power MOSFET DC Characteristics Interelectrode Capacitances 2016 Synopsys, Inc. 24
25 Modeling Power MOSFET DC Characteristics Interelectrode Capacitances Gate Charge Characteristic 2016 Synopsys, Inc. 25
26 Modeling Transformer 2016 Synopsys, Inc. 26
27 Modeling Transformer Ferrite Core 3C85 Hysteresis (major and minor BH loops) Frequency dependent losses (hysteresis and eddy currents) 2016 Synopsys, Inc. 27
28 Modeling Transformer Ferrite Core 3C85 Hysteresis (major and minor BH loops) Frequency dependent losses (hysteresis and eddy currents) 2016 Synopsys, Inc. 28
29 Modeling Transformer Ferrite Core 3C85 Hysteresis (major and minor BH loops) Frequency dependent losses (hysteresis and eddy currents) 2016 Synopsys, Inc. 29
30 Modeling Transformer Ferrite Core 3C85 Hysteresis (major and minor BH loops) Frequency dependent losses (hysteresis and eddy currents) Core geometry Air gap Lamination 2016 Synopsys, Inc. 30
31 Modeling Transformer Ferrite Core 3C85 Hysteresis (major and minor BH loops) Frequency dependent losses (hysteresis and eddy currents) Core geometry Air gap Lamination Windings (Cauer - 1D Model) Flux leakage Frequency dependent loss (skin and proximity effects) Winding capacitances 2016 Synopsys, Inc. 31
32 Modeling Transformer Ferrite Core 3C85 Hysteresis (major and minor BH loops) Frequency dependent losses (hysteresis and eddy currents) Core geometry Air gap Lamination Windings (Cauer - 1D Model) Flux leakage Frequency dependent loss (skin and proximity effects) Winding capacitances 2016 Synopsys, Inc. 32
33 Agenda Quasi-Resonant Flyback Converter (AN1326) Principles of Operation Simulation vs. Measurement Accurate Datasheet-Driven Modeling Controller Chip MOSFET Transformer Automated Verification EMI Loss / Efficiency 2016 Synopsys, Inc. 33
34 2016 Synopsys, Inc. 34
35 2016 Synopsys, Inc. 35 LISN
36 2016 Synopsys, Inc. 36
37 2016 Synopsys, Inc. 37
38 2016 Synopsys, Inc. 38
39 2016 Synopsys, Inc. 39 Experiment Editor Basic Tasks
40 2016 Synopsys, Inc. 40
41 2016 Synopsys, Inc. 41 Parallel Computing
42 2016 Synopsys, Inc. 42
43 2016 Synopsys, Inc. 43 Most dissipative components
44 Conduction Losses Switching Losses 2016 Synopsys, Inc. 44
45 NTC thermistor adjusted to 2.8Ω Rac = 35kΩ added across primary to account for air gap fringing field losses Conduction Losses Switching Losses 2016 Synopsys, Inc. 45
46 NTC thermistor adjusted to 2.8Ω Rac = 35kΩ added across primary to account for air gap fringing field losses 2016 Synopsys, Inc. 46
47 Conclusion High fidelity models characterized from datasheets Automated design verification / regression testing over broad operating conditions Experiment Analyzer Fault Injection Worst Case Analysis / Extreme Value Analysis Statistical variations (Monte Carlo) Scalable solution Capacity for large designs (network of power converters) User or site (company wide) model library management Distributed/grid iterative analysis (parametric Vary, Monte-Carlo, Worst-Case Analysis, Fault) 2016 Synopsys, Inc. 47
48 Thank You Flyback design available on Synopsys Forum Improved IGBT Tool in Thank you to Sophia LI, Min ZHANG and Balaji EMANDI for their contributions. Special thanks to Claudio ADRAGNA and Giovanni GRITTI from ST for their valuable feedback Synopsys, Inc. 48
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