High density, high efficiency, light weight MIL-COTS DC-DC solutions. Arthur Jordan [email protected] , +44 1276 678 8222 CMSE’08, 6-10th -12th 2008 CMSE’08, Portsmouth UK, June 10th-12th 2008 • • • • • • • • • • • • Scope: DC-DC power conversion from 270V or 28V down to 0.8V-50V, from 30W to 3kW. Data-processing, communications and solid-state lighting solutions. Air-, ship-, vehicle-borne systems or man-carried / -wearable applications. Content: The separation – or ‘factorization’ - of regulation & voltage transformation functions in a DC-DC converter creates new high power, small size power components which can be arranged in a variety of configurations to reduces distribution losses, reduce duplicated functions and reduce power dissipation at the Point-of-Load while increasing total system efficiency. These flexible building blocks, known as V•I Chips provide key advantages to the power designer with their industry leading power density, high efficiency, design flexibility, speed (fast response) and size. Several packaging options allow for optimum mechanical / thermal design. The paper will introduce the topologies used within the new building block power components (Sine Amplitude Converter and Non-isolated Buck-Boost) and present system application comparisons between traditional and ‘Factorized Power’ architectures. For example: 28VIN to 3.3V, 40A MIL-COTs DC-DC converter with 20% more power and 2/3 less space than the original design. ‘Single-slot’ MIL-COTS 28VIN VME power card with 50% more power in ½ the size and 2/3 weight reduction. 100W at 3.3V from 270VDC with MIL-STD 704 performance Efficiency, transient response and EMI filter performance will be presented. CMSE’08, 6-10th -12th 2008 Abstract 2 Vicor & V•I Chip • Headquarters & manufacturing: – Andover, MA – 1,100 employees worldwide • Sales and Technical Support Centers: • • • • 100+ patents 8,000 active customers $200M revenue (2007) V•I Chip Inc. is a wholly owned subsidiary of Vicor CMSE’08, 6-10th -12th 2008 – US (CA, TX, IL), France, Hong Kong, Germany, Italy, UK, Japan 3 Product Milestones MIL-COTS V I Chips Factorized Power Architecture introduced 1984 1988 Full-brick 600 W 1997 1997 ¼ brick 150 W 1998 2003 2005 2007 CMSE’08, 6-10th -12th 2008 First Full-brick 100 W First ½-brick 100 W ½ brick 300 W V I Chips 300 W 4 Factorized Power Architecture (FPA) and V•I Chips • Factorized Power Architecture – Separation of power conversion stages: Regulation & Voltage Transformation • Reduces distribution losses in a system • Reduces duplicated functions in the DC-DC conversion path • Reduces power dissipation at the load while increasing total system efficiency – A holistic approach vs. traditional design compromises Flexible building blocks: V•I Chips • Small, powerful components for DC-DC conversion • Provide key advantages to the power designer – – – – Industry leading power density (size & weight) High Efficiency Design flexibility Speed (fast response) CMSE’08, 6-10th -12th 2008 • 5 Sine Amplitude Converter (SAC) • Resonant Full Bridge Primary – ZVS, ZCS, >1 Mhz switching frequency Synchronous Secondary Rectification D +IN D D P P SAC Control D P -OUT Cres D -IN D • +OUT Operates as: D P=Power Transformer D=Drive Transformer – Isolated, unregulated voltage transformer / current multiplier – Output voltage determined by transformer K-factor • Used in – Bus Converter Module (BCM) – Voltage Transformation Module (VTM) U.S. and Foreign Patents and Patents Pending CMSE’08, 6-10th -12th 2008 • 6 SAC Performance (Bus Converters) • • Proprietary topology allows high efficiency and extremely small size Size – 1.28 x 0.87 x 0.26 in • Weight – 0.5 oz / 15 g each Bus Converter performance: * * MIL-COTS meets MIL-STD-704D-F (125 - 350V, 50ms ride-through) CMSE’08, 6-10th -12th 2008 • 7 Buck-Boost Regulator • Non-isolated buck-boost • Creates: – Regulated DC output from wide range unregulated input • Used in – Pre-Regulator Module (PRM) U.S. and Foreign Patents and Patents Pending CMSE’08, 6-10th -12th 2008 – ZVS, >1 Mhz switching frequency 8 • Same size and weight as SAC • Buck-Boost Regulator performance: CMSE’08, 6-10th -12th 2008 Buck-Boost Performance (Pre-Regulators) 9 • • Same size and weight as BCMs / PRMs Output of Pre-Regulator (PRM) is the input to the Voltage Transformer (VTM) • Voltage Transformer performance: CMSE’08, 6-10th -12th 2008 SAC Performance (Voltage Transformers) 10 DC-DC Conversion • Unregulated = BCM (Bus Converter) Load Source OR POL Source Load CMSE’08, 6-10th -12th 2008 • Regulated = PRM (Regulator) + VTM (Transformer) 11 PRM & VTM: Operation & Regulation Unregulated Wide Range Input Source Regulated Factorized Bus K-factor Regulated Vf • K Load • • • PRM controls the “Factorized Bus” voltage (Vf) to regulate the VTM input VTM transforms and isolates at the POL Result: Efficient distribution, regulation, transformation and isolation CMSE’08, 6-10th -12th 2008 Vf 12 PRM & VTM: Operation & Regulation Unregulated Wide Range Input Source Regulated Factorized Bus K-factor Regulated Vf • K Load 3 – 5% Vf • • • PRM controls the “Factorized Bus” voltage (Vf) to regulate the VTM input VTM transforms and isolates at the POL Result: Efficient distribution, regulation, transformation and isolation CMSE’08, 6-10th -12th 2008 Local Loop 13 PRM & VTM: Operation & Regulation Unregulated Wide Range Input Source Regulated Factorized Bus K-factor Regulated Vf • K Load 1 – 2% Vf • • • PRM controls the “Factorized Bus” voltage (Vf) to regulate the VTM input VTM transforms and isolates at the POL Result: Efficient distribution, regulation, transformation and isolation CMSE’08, 6-10th -12th 2008 Adaptive Loop 14 PRM & VTM: Operation & Regulation Unregulated Wide Range Input Source Regulated Factorized Bus K-factor Regulated Vf • K Load 0.2% Vf • • • PRM controls the “Factorized Bus” voltage (Vf) to regulate the VTM input VTM transforms and isolates at the POL Result: Efficient distribution, regulation, transformation and isolation CMSE’08, 6-10th -12th 2008 Remote Loop 15 Closed Loop with MIL-COTS PRM (Dependent Outputs) e.g. K=1/24 1.5 Vdc Load 1 Vf = 36 Vdc 16-50 Vdc +/- x% e.g. K=1/3 12 Vdc Load 2 • Multiple VTMs from a single PRM – See Application Note AN: 003 CMSE’08, 6-10th -12th 2008 +/- x% 16 Closed Loop (Independently Regulated Outputs) e.g. K=1/12 1.8 Vdc Load 1 Vf = 43.2 Vdc +/- x% 16-50 Vdc e.g. K=1/8 Vf = 40 Vdc +/- y% • • Use one VTM per PRM for independently regulated outputs Use different grounding point for negative voltages Load 2 CMSE’08, 6-10th -12th 2008 -5 Vdc 17 Load Bulk Capacitance Elimination / Reduction • VTM ‘voltage transformer’ is also a low impedance ‘current multiplier’ – <1 mOhm from DC to 1MHz Bulk capacitance at the load can be eliminated / reduced Move POL Capacitance to input of VTM – Reduce capacitance by 1/K^2 – Additional space and cost savings e.g. K=1/32 Source Load 1,000uF here Source Load CMSE’08, 6-10th -12th 2008 • • 1uF here 18 Load step with 100 μF input capacitance and no output capacitance (MV036F120M010) CMSE’08, 6-10th -12th 2008 Fast Transient Response 19 MIL-COTS Application Example: 3.3V, 30A from 28V Unregulated 28 V (4 A, 112 W) 95% Vf 39.6 V K=1/12 94.5% (2.7 A, 106 W) Load Regulated 3.3 V ( 30.3 A, 100 W ) – With reduction in bulk capacitors, heatsinks, etc. • Powertrain pcb area only 2.23 in2 CMSE’08, 6-10th -12th 2008 • 100W load draws only 112W from the main distribution bus • Overall efficiency = 89.3% 20 MIL-COTS Application Example: 3.3V, 30A from 270V Unreg. 270V (0.44 A, 118 W) • K=1/8 95% Unreg. 33.75V (3.3A, 112W) 95% Vf 39.6V K=1/12 94.5% Load Reg. 3.3V (30.3A, 100W) (2.7A, 106W) 100W load draws only 118W from the main 270V (aircraft) distribution bus – MIL-STD-704D/F (125V – 350V ride-through) Overall efficiency = 85.3% from 270V to 3.3V Powertrain pcb area only 3.4 in2 – With reduction in bulk capacitors, heatsinks, etc. • • As the HV BCM is capable of 240W (i.e. only 50% utilized), a second PRM+VTM combination could be added for an additional output / load HV distribution benefits (270V vs. ~28V) – 99% reduction in I2R loss – Smaller connectors, etc. – Place VTM directly at load and factorize (place) the PRM at the HV BCM CMSE’08, 6-10th -12th 2008 • • 21 MIL-COTS V•I Chip – EMI (no filter) Military COTS V●I Chips tested to MIL-STD-461E levels, CE102 (no filter) • Out of tolerance at frequencies above 1 MHz (V•I Chip switching frequency) Out of Tolerance CMSE’08, 6-10th -12th 2008 MIL-STD-461E, CE 102 Threshold 22 MIL-COTS V•I Chip – EMI (with filter) MIL-COTS V I Chips tested to MIL-STD-461E levels, CE102 with filter and Y-capacitors ● • Greatly reduced EMI signature Within Tolerance CMSE’08, 6-10th -12th 2008 MIL-STD-461E, CE 102 Threshold 23 Filter Waveforms (M-FIAM7 + V•I Chips, MIL-STD-1275A/B/D) 100 V surge as per MIL-STD-1275B Output from the M-FIAM7 shuts off after 50 mS CMSE’08, 6-10th -12th 2008 100 V surge clamped to 50 V 24 MIL-COTS Application Example: Single-Slot 550W VME • • • • • • 28 VIN, 4 Outputs = 550 W (+66%) POUT Efficiency = 85% (+7% pts) Weight = 2.4 lbs (-30%) Size = Single VME (-50%) Meets: – – – MIL-STD-461E (EMI) MIL-STD-704F (28VIN) MIL-STD-810 F (516.5/1) (Vibration) CMSE’08, 6-10th -12th 2008 6x PRMs, 6 VTMs & 2x MFIAM Filters Photographs courtesy of Aegis. Unit available for purchase - contact William H. Dockery of Aegis Power Systems Inc., 805 Greenlawn Road, Murphy, NC 28906. Tel: 828-837-4029 x102, [email protected], www.aegispower.com 25 Conclusion • Factorized Power Architecture (FPA) • • • ‘Factorization’ (separation) of regulation & voltage transformation functions in a DC-DC converter Enables reduction of distribution losses, reduction of duplicated functions, reduced power dissipation at the load while increasing total system efficiency. V•I Chips • Flexible power components which provide key advantages: • Power density, high efficiency, design flexibility, speed (fast response) and size. Topologies: • • • MIL-COTS Application examples • • • • Sine Amplitude Converter Non-isolated Buck-Boost Improved efficiency Light weight Smaller size Thank You – Comments / Questions? CMSE’08, 6-10th -12th 2008 • 26