Inf ineon ® P o w e r L E D D r i v e r TLD5095 / TLD5098 DC-DC Multitopology Controller IC Dimensioning and Stability Guideline - Theory and Practice Application Note Application Note V1.3, 2011-08-08 by Dieter Parth and Enrico Tonazzo Automotive Power TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Table of Contents Table of Contents 1 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 The 10-step approach for your TLD5095/98 application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 2.1 2.1.1 2.2 2.3 2.4 2.4.1 2.4.2 2.4.3 2.5 2.6 2.7 2.8 2.9 2.10 2.11 Calculation of external components for a TLD5095/98 application . . . . . . . . . . . . . . . . . . . . . . . . 7 Example: Automotive LED application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Application boundary conditions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Switching frequency definition fSW - calculation of RFREQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Calculation of the switching duty cycle - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Calculation of boost inductor LBO and current loop resistor RCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Calculation of the current sensing resistor - RCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Boost inductor LBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Boost inductor LBO if switching frequency fSW is provided by the µC . . . . . . . . . . . . . . . . . . . . . . . . 15 Calculation of the output capacitor - COUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Calculation of the input capacitance CIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Switching MOSFET considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Calculation of power resistor for LED current definition - RFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Calculation of over-voltage protection resistor divider - ROVL, ROVH . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Output diode selection - DBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Gate driver buffer capacitance selection - CIVCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 3 3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.5 Stability considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED resistance considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED forward voltage considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stability calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closed loop considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of the open loop gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of zeros and poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of the slope compensation parameters and quality factor Q . . . . . . . . . . . . . . . . . . . . . . Open loop gain calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculation of the phase margin: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 28 29 30 31 32 33 35 35 36 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 Power loss and system efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TLD5095/98 IC Power Losses - PIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power MOSFET - PMOSFET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED current feedback resistor power loss - PRFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch current sensing resistor power loss - PRCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inductor power loss - PLBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input capacitor power loss - PCIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output capacitor power loss - PCOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Freewheeling diode power loss - PDBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 39 40 40 40 40 41 41 41 5 5.1 5.2 5.3 5.4 5.5 Design-in tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Excel tool for fast evaluation of external components, efficiency and stability . . . . . . . . . . . . . . . . . . Electrical and thermal simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Demo boards for fast evaluation in the lab & onboard LED chain . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample layouts for small application boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMC test reports and results summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 42 43 44 45 46 6 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Application Note 2 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Introduction 1 Introduction Note: The following information is provided only as a guide for the implementation of the device and shall not be regarded as a description or warranty of a certain functionality, condition or quality of the device. The aim of this application note is to provide a dimensioning guideline for TLD5095/98 applications. A 10-step approach has been developed to guide the reader through the calculation of external components and stability considerations (Chapter 2 and Chapter 3). Furthermore, an efficiency and power loss summary (Chapter 4) completes the picture. To put the theory into practice, a typical example of application has been chosen, which should improve the understanding of the equations used. Chapter 5 provides an overview of tools and further information, which could be very valuable for design-in activities and detailed evaluation of TLD5095/98 applications. Note: The following considerations focus on the TLD5095/98 for a standard boost to GND application in constant current mode (CCM). 1.1 The 10-step approach for your TLD5095/98 application We have developed a 10-step approach to help you find your way through the maze of formulas and equations. We proceed step by step to develop a stable switching and energy-efficient application considering all the application-specific boundary conditions. Figure 1 displays the flow chart for the 10-step approach. Note: The “10-step approach” is the one used to dimension a TLD5095/98 boost application. To optimize and further improve the system response, the entire procedure may be repeated several times! Thus, it is clear that this is an iterative procedure and, at times, more than one dimensioning cycle is required. STEP 1: Get Application Information Get in touch with your customer and obtain the boundary conditions for the specific application. Think carefully about the worst case conditions and try to avoid mapping worst case scenarios over worst case scenarios. Very detailed knowledge about the real application ensures greater flexibility for the dimensioning of the system. In our example, the boundary conditions are defined in Chapter 2.1. STEP 2: Defining the Switching Frequency - fSW A DC/DC converter is also called a switched mode power supply (SMPS). Thus, switching is its main job. The selection of the system switching frequency is important for the selection of the external components (inductor and capacitor size). The system efficiency and the EMC performance are directly related to one another. The RF spectrum has some free areas in the 100 kHz to 500 kHz band. In our example, we switch at fSW = 400 kHz. The TLD5095/98 features two different control options for fixing the switching frequency fSW. Refer to Chapter 2.2 for more details. STEP 3: Calculating the Switching Duty Cycle - D The input and output power balance of a DC/DC converter is controlled by the ON and OFF timing of the switching MOSFET. The ratio of the ON and OFF phases is called the switching duty cycle (DC). The DC can be calculated using a simplified formula or a more detailed equation. Both approaches for calculating the DC are described in Chapter 2.3. Application Note 4 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Introduction STEP 4: Selection of the Boost Inductor - LBO An inductor is necessary to supply the output of a boost converter with the appropriate amount of power. To dimension the boost inductor LBO you need to calculate the current flowing trough the inductor depending on the required input voltage condition. A worst-case condition, which results in a higher inductor value, is the minimum value of input supply voltage VIN and a lower switching frequency fSW. The calculation of the proper boost inductor LBO for the TLD5095/98 ICs also depends on the current loop stability and the value of the current sensing resistor RCS that senses the current through the inductor. All the equations required for this purpose are furnished in Chapter 2.4. STEP 5: Calculation and Selection of Output Capacitor - COUT The output capacitor of a boost system is very important to maintain constant current flow through the load. The capacitance value at the given output voltage is crucial. The effect of a capacitor’s DC bias is often underestimated. For selection of the proper COUT please refer to Chapter 2.5. STEP 6: Calculation and Selection of Input Capacitor - CIN The value of the input capacitance CIN of a boost converter is generally selected to limit the input voltage ripple ΔVIN required by the specification. For proper dimensioning please refer to Chapter 2.6. STEP 7: Select Other External Components such as MOSFET, RFB, ROVL, ROVH, DBO The selection of the switching MOSFET, freewheeling diode DBO, load current defining shunt resistor RFB and the over-voltage protection resistors ROVL, ROVH plus gate buffer capacitance CIVCC is described in Chapter 2.7 to Chapter 2.11. STEP 8: Determine the Compensation Network - RCOMP, CCOMP1, CCOMP2 The external compensation network provides the flexibility to ensure a stable application with respect to various boundary conditions. The calculation of the open loop gain and the corresponding phase margin PM and the influence of the compensation network are explained in Chapter 3. STEP 9: Calculate Power Loss and System Efficiency After dimensioning the external components and the selection of the actual parts used to build up a TLD5095/98 application, the system power loss and efficiency can be determined. The method for this is illustrated in Chapter 4. STEP 10: Verify the Application with Simulations and Measurements Before building prototype hardware, it is useful to perform system simulations (e.g. SPICE simulations). A thermal system evaluation, too, could be beneficial. Infineon provides several design-in tools to simplify the usage of the TLD5095/98 products. A summary of the available design-in tools is presented in Chapter 5. Application Note 5 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Introduction 1 Get Application Information : VIN Range, VOUT, I OUT, fSW , ∆VIN , ∆VOUT 2 Switching Frequency definition f SW - Calculation of R FREQ 3 • Calculation of the Switching Duty Cycle – D Consider worst case when VIN is at it’s minimum Selection of the Boost Inductor - LBO • • • Calculation and selection of the current sense resistor – RCS • Select proper R CS value to protect L BO and MOSFET and keep in mind that the R CS value is important for the stability of the current loop and has influence on the dimensioning of the Boost inductor LBO 4 • • 5 6 8 Calculation and selection of Input Capacitor – CIN and max. ESR Select proper CIN to fullfill the input voltage ripple requirement ∆VIN Select other Components which meet the ratings and requirements : • Switching MOSFET • Power resistor for LED current definition – R FB • Overvoltage protection resistor divider - ROVL, ROVH • Output Diode selection – DBO • Gate Driver buffer capacitor - CIVCC Determine the compensation network – RCOMP, CCOMP1, CCOMP2 9 Figure 1 Calculation of Boost Inductor – LBO RCS, VOUT and fSW has influence on the size of L BO Perform some iteration steps here to find the best solution for the the size of the boost indctor L BO Calculation and selection of Output Capacitor – COUT and max. ESR • Select proper COUT to fullfill the output voltage ripple requirement ∆VOUT • 7 10 Inductor / Input current calculation : Average inductor current I L(AVG) Inductor ripple current ∆IL Min. and max. inductor current I L(min) , IL(peak) Calculate power loss and system efficiency - η Verify the application with simulations and measurements Proposed procedure for selecting external components Application Note 6 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application 2 Calculation of external components for a TLD5095/98 application The following chapter provides a detailed overview of the formulas that are used to achieve proper dimensioning of all external components used to build up a DC/DC boost application featuring the TLD5095/98. In addition, a sample calculation demonstrates the usage of these formulas. An Excel sheet including all formulas below can be provided on request. Refer to Chapter 5 to get an overview of other support tools and info material. Only constant current mode (CCM) is taken into account for further considerations. 1 2.1 Example: Automotive LED application A typical automotive exterior light application these days is the Daytime Running Light function. Most of the OEM’s introduce LED lights to establish brand recognition and achieve extraordinary headlamp design solutions. Figure 2 below illustrates an eye-catching OEM example of a DRL application. Figure 2 Daytime running light example - source: AUDI AG 2.1.1 Application boundary conditions: Note: The following example of an application boundary condition is independent of the picture illustrated in Figure 2. • • Sum of LED forward voltage = output voltage VOUT = 40 V. Supply input voltage VIN is specified in the range 8 V < VIN < 16 V. The typical value is usually 12 V. Note: Many calculations must consider the worst case input voltage condition to achieve a design that works properly over the entire input voltage range. Therefore, many calculations consider 8 V (= lowest input voltage is the worst case for boost converters). • • • LED current or output current IOUT should be 400 mA. Switching frequency fSW of the DC/DC converter is 400 kHz. Boost to GND application is used according to Figure 3 below. Application Note 7 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application VIN = 8V to 16V IL,AVE = I IN ID LBO CIN VREF DBO VOUT = 40V RFB ISW COUT 14 1 +5V CIVCC IN IOUT = 400mA TSW SWO 2 SWCS 4 D1 IVCC D2 R CS 10 SET SGND 3 OVFB 9 D3 ROVH D4 D5 D6 ROVL D7 PWM 13 EN / PWMI D8 D9 CCOMP2 11 FREQ / SYNC 8 COMP FBH 6 FBL 7 D11 CCOMP1 D12 PWMO RFREQ Figure 3 D10 5 PWM TDIM GND RCOMP 12 Example: B2G configuration A summary of the application boundary condition, which should be the basis of the values used in our example for better understanding of the upcoming equations, is presented in Figure 4 below. INPUTS Figure 4 Symbol Value Unit Name VIN 12,00 V Input Voltage Vo ut 40,00 V Output Voltage Io ut 0,40 A Output Current fsw 400,00 kHz Switching Frequency ∆VOUT 100,00 mV Max. allowable Ripple Voltage on VOUT ∆VIN 100,00 mV Max. allowable Ripple Voltage on VIN ∆IL% 20,00% % Pk-Pk Inductor Ripple Current VREF 300,00 mV Feedback reference voltage VREF Example: Typical input values Application Note 8 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application 2 2.2 Switching frequency definition fSW - calculation of RFREQ The regulator switching frequency fSW of the TLD5095/98 can be adjusted via: 1) a simple resistor RFREQ (for fSW between 100 kHz and 500 kHz) or 2) an external clock signal generated by a µC port (VCLK -> fCLK between 250 kHz and 500 kHz). The synchronization with an external clock signal can be beneficial if there are multiple DC/DC converters in a system. A defined phase shift strategy could improve EMC performance. Figure 5 illustrates the two options for controlling the switching frequency. Note: The value of the boost inductor LBO required is calculated differently for the two switching control methods. (Please refer to Section 2.4.2 and Section 2.4.3) Oscillator FREQ / SYNC 11 RFREQ VCLK Clock Frequency Detector Multiplexer PWM Logic Gate Driver 2 SWO 1 2 Figure 5 Two options for controlling the regulator switching frequency fSW The formula below expresses the mathematical relationship between the resistor RFREQ and the switching frequency fSW Figure 6 provides a diagram for fast evaluation. RFREQ = 1 −12 141⋅10 F ⋅ f SW R FREQ = 141 ⋅ 10 −12 − 3.5 ⋅103 (1) 1 − 3.5 ⋅ 10 3 = 14 .23 kΩ F ⋅ 400 kHz (2) Note: 141*10-12F: internal equivalent capacitance of the Oscillator Application Note 9 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application Figure 6 RFREQ f SW 67.42 kΩ 100 kHz 43.78 kΩ 150 kHz 31.96 kΩ 200 kHz 24.87 kΩ 250 kHz 20.14 kΩ 300 kHz 16.76 kΩ 350 kHz 14.23 kΩ 400 kHz 12.26 kΩ 450 kHz 10.68 kΩ 500 kHz Switching frequency fSW versus frequency selection resistor RFREQ to GND 3 2.3 Calculation of the switching duty cycle - D The first step is to determine the switching duty cycle, D, which is needed to generate a high output voltage VOUT from a low input voltage VIN. In principle, there are two approaches for calculating the duty cycle of the MOSFET boost switch. TSW = 2.5µs ton = 2µs VSW toff = 0.5µs VOUT = VLED = 40V VIN = 8V VRDS(on) t VSWO = VGS D = 0.80 VSWO = 5V SWITCH = ON Figure 7 SW=OFF SWITCH = ON SW=OFF t Switching MOSFET voltage VSW and the switching duty cycle - D Application Note 10 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application 1) Simplified equation: This calculation approach merely focuses on the input and output voltage relation. In most cases, these results are sufficient and can be used for further calculations. (All the following considerations are based on this simplified equation.) D≈ VOUT − VIN VOUT (3) The worst case evaluation considers the lowest input voltage VIN(min) and the highest output voltage VOUT(max) that can occur in a system. For further calculations, this worst case duty cycle is referred to as D(worst case). For some calculations, this parameter is required to ensure a proper dimensioning of the external passive components. D( worstcase) ≈ 40V − 8V ≈ 0.80 40V (4) The ON and OFF times of the switching MOSFET can be calculated on the basis of the duty cycle. The parameter TSW is the switching period time and can be calculated from the given switching frequency: TSW = 1 f SW = 1 = 2.5µs 400kHz (5) ton = D ⋅ Tsw (6) t on = 0.80 ⋅ 2.5µs = 2 µs (7) toff = (1 − D) ⋅ Tsw (8) t off = (1 − 0.80) ⋅ 2.5µs = 0.5µs (9) Application Note 11 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application 2) Detailed equation: The Equation (10) below also considers the freewheeling diode forward voltage VD and the voltage drop across the switching MOSFET in the ON-state VRDS(ON). During the initial evaluation stages of a DC/DC application, it is not known which switching MOSFET and freewheeling diode will be used. Therefore, it seems difficult to calculate a precise duty cycle at the initial stage. To complete the picture, some values have been chosen to demonstrate the difference between the two calculation approaches. Assumptions: • • RDS(ON) of switching MOSFET = 26 mΩ; VRDS(ON) = RDS(ON) * IRMS_SW = 30mΩ ∗ 1.79 A = 0.046 V forward voltage drop of freewheeling Schottky diode VD = 0.4 V D= VOUT + VD − VIN VOUT + VD − VRDS (ON ) (10) D= 40V + 0.4V − 8V = 0.803 40V + 0.4V − 0.046V (11) There is not much difference between the approaches 1 and 2. For worst case considerations it may be meaningful to evaluate the exact duty cycle. 4 2.4 Calculation of boost inductor LBO and current loop resistor RCS Note: The following description to calculate the appropriate boost inductor LBO is based on the current loop stability and the integrated slope compensation of the TLD5095/98, and differs from the standard booster equations. IIN = IL IL,peak = 2.2A IL,avg = IIN,avg = 2A IL,min = 1.8A ∆IL = 0.4A t SWITCH = ON Figure 8 SW=OFF SWITCH = ON SW=OFF Inductor current Application Note 12 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application The average current IL(AVG) that flows trough the boost inductor LBO is dependent on the output current IOUT required and the worst case duty cycle D(worst case). I L ( AVG ) = I OUT 1 − D( worstcase ) I L ( AVG ) = (12) 0 .4 A = 2A 1 − 0.80 (13) Referring to the inductor current slope of a boost converter in CCM operation (shown in Figure 5) the minimum inductor current IL(min) and the peak inductor current IL(Peak) can be calculated from the current ripple ΔIL specified. ΔI L = I L ( AVG) ⋅ ΔI L % (14) Δ I L = 2 A ⋅ 0 . 20 = 0 . 4 A (15) I L( peak) = I L( AVG) + ΔI L 2 I L ( peak ) = 2 A + 0 .4 A = 2 .2 A 2 (17) I L (min) = I L ( AVG ) − ΔI L 2 (18) I L (min) = 2 A − (16) 0 .4 A = 1 . 80 A 2 (19) The inductor peak current IL(Peak) calculated for the worst case, Equation (17), indicates the maximum current flowing through the inductor LBO, the MOSFET SW and the current loop sense resistor RCS. (See the application drawing in Figure 39 for details.) Application Note 13 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application An important factor for the calculation of the boost inductor LBO in Equation (22) is the value of the sensing resistor RCS. 2.4.1 Calculation of the current sensing resistor - RCS The RCS resistor has two functions: • • 1) Over-current protection: RCS is needed to limit the current through the external MOSFET switch SW and the inductor LBO. 2) Building up a current control loop for the boost regulator: RCS is needed to measure the current through the switch. The switch peak over-current threshold (VSWCS) in the datasheet is required to determine the proper value for RCS: The relationship is described in Equation (20) below. RCS = VSWCS I lim it (20) The limiting current Ilimit should be chosen according to the highest peak current IL(peak) that can occur in the system + a reasonable margin of safety. Furthermore, Ilimit should be higher than the max. peak inductor current IL(peak) and should be lower than the permissible current rating of the MOSFET SW selected and the boost inductor LBO. Based on the maximum peak current calculated in Equation (17), we must consider 2.2 A. The assumption for Ilimit = 3 A. RCS = 2.4.2 0 .15V = 0 .05 Ω 3A (21) Boost inductor LBO The equivalent circuit of an inductor consists of 3 components: • • • DCR: DC resistance of a coil. The DCR value is used to calculate the power loss in the inductor. L: total inductance of a coil. CW: winding capacitance (winding capacitance will be ignored in further considerations) L DCR CW Figure 9 Example: Equivalent circuit of a real inductor Application Note 14 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application Knowing the proper RCS resistance completes the device specific formula, which includes the integrated slope compensation consideration for control loop stability at duty cycles above 0.5. This formula considers VOUT>>VIN. The constant slope compensation is not dependent on the switching frequency fSW. LBO ≥ VOUT ⋅ RCS 106 ⋅10−3V ⋅ f SW L BO ≥ 40V ⋅ 0 .05 Ω = 47 .17 µH 106 ⋅ 10 − 3 V ⋅ 400 kHz (22) (23) Component selected: • Coilcraft MSS1278563MLD, L = 56 µH, DCR = 80.2 mW 2.4.3 Boost inductor LBO if switching frequency fSW is provided by the µC If the synchronization feature is used, the following formular should be applied to determine the proper inductor value. The constant slope compensation is fixed for a specific switching frequency (fSW = 250 kHz). LSYNC ≥ VOUT ⋅ RCS 106 ⋅ 10−3V ⋅ 250kHz (24) LSYNC ≥ 40V ⋅ 0.05Ω = 75.47µH 106 ⋅ 10−3V ⋅ 250kHz (25) Note: 106*10-3V: equivalent slope compensation voltage Tips for choosing the right inductor LBO • • • • • In fixed-frequency boost converters, the value of the inductor is based on the desired peak-to-peak ripple current ΔIL. Selection of the boost inductor is a trade-off between size and cost. Higher switching frequencies = lower inductance value = smaller component size = lower costs. Larger inductance means lower input ripple current. Ripple current between 20 % to 50 % of ILAVG are reasonable values to make calculations for CCM Check the maximum DC peak current ratings and maximum operating frequencies for the inductor selected. (In general, always try to remain within the max. ratings.) Application Note 15 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application 5 2.5 Calculation of the output capacitor - COUT The simplified equivalent circuit of a capacitor is shown in Figure 10 below. The resistive part of the capacitor is considered as equivalent to a series resistance ESR. The output capacitor is chosen such that it filters the switching ripple significantly. The parasitic resistance ESR, which is out of phase with its capacitance, causes additional voltage ripple. Ensure that capacitors are selected based on their maximum voltage, maximum ripple current and ESR ratings at the temperature and frequency of the application. The inductive portion LC shall be ignored in further considerations. ESR Figure 10 C LC Simplified equivalent circuit of a real capacitor The ESR value at the required switching frequency and the capacitance at the operating point (VOUT = 40 V) can be obtained from the datasheets of capacitors. The capacitor elected has 2 µF @ VOUT = 40 V although it is a device rated for 4.7 µF (Figure 11, diagram on the right hand side). Hence, the application requires 5 capacitors in parallel to achieve the required capacitance of >8µF. C @ 40V ~ 2µF ESR~2.5mΩ f SW =400kHz VOUT=40V Figure 11 COUT: ESR and DC bias of a 4.7 µF/50 V/X7R ceramic capacitor (source Murata: GRM32EB31H475KA87) Automotive type: GCM32ER71H475KA55 Application Note 16 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application When the switching MOSFET is ON the output capacitor COUT must supply the load. Therefore, the worst case duty cycle (D(worstcase)) divided by the switching frequency (fSW) is used in the formula to indicate the ON time (tON in Equation (6)). The ripple content due to the ESR of the capacitor is ignored in this formular. COUT ≥ I OUT ⋅ D( worstcase) C OUT ≥ (26) ΔVOUT ⋅ f SW 0.4 A ⋅ 0.80 ≥ 8 µF 100 mV ⋅ 400 kHz (27) It is good to know the mean current which is flowing through the output capacitor for the calculation of the power consumption of the output capacitor. I RMS _ COUT = I OUT 2 I RMS _ COUT = 0.4 A2 ⋅ ⋅ D ( worstcase 2 ) 1 − D ( worstcase + ) ΔI L ⋅ (1 − D ( worstcase 12 ) 2 ) (28) 0.80 0.20 2 2 + ⋅ (1 − 0.80) = 0.800013A 1 − 0.80 12 (29) A simplified formula can be used since the second term only has a small impact: I RMS _ COUT ≈ I OUT ⋅ I RMS _ COUT D ( worstcase ) (30) 1 − D ( worstcase ) ≈ 0 .4 A ⋅ 0 . 80 ≈ 0 .8 A 1 − 0 . 80 (31) ID = ICOUT I L,peak = 2.2A IL,min = 1.8A IRMS_D = IRMS_COUT = 0.8A t SWITCH = ON Figure 12 SW=OFF SWITCH = ON SW=OFF Diode current ID flowing trough COUT The maximum permissible voltage ripple on the output voltage should be known and specified by the application. In our example, the voltage output ripple should not exceed: ΔVOUT = 100 mV. Application Note 17 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application Output voltage ripple and ESR value: ΔVOUT = I L ( peak ) ⋅ ESR (32) The maximum permissible ESR value can be derived: ESR ≤ ΔVOUT I L ( peak ) (33) ESR ≤ 100mV = 45.45mΩ 2.2 A (34) Selection of the output capacitor: • • • Voltage Rating > 40 V: GCM32ER71H475KA55 = 50 V IRMS > 800 mA: GCM32ER71H475KA55 > 1 A ESR < 45.45 mOhm: GCM32ER71H475KA55 = 5 times 2.5 mΩ in parallel = 2mΩ The output capacitor system design could consider: 1) An electrolytic capacitor. This solution is suitable if the capacitance value required is relatively high (e.g. > 22 µF) and higher DC voltage classes are called for. Despite the advantage of higher capacitance values available, the electrolytic capacitor has some disadvantages such as: • • • • Higher ESR values = more power losses (those with low ESR are more expensive and, in any case, far less than ESR values for ceramic capacitors) Poor thermal conduction path (e.g. SMD versions have a plastic interface to the PCB) Less robust and less reliable Limited temperature range (those with high temperature ranges are more expensive) If an electrolytic capacitor is used in a system, it is a good practice to place a small (e.g. 100 nF) capacitor in parallel to bring down the ESR and achieve an additional filtering effect. 2) To overcome the issues with electrolytic capacitors, you can also use a bank of several ceramic capacitors connected in parallel. For the example under consideration, 5 times 4.7 µF/50 V capacitors can be placed in parallel, to fulfill the requirements. As shown in Figure 11, the capacitance value at 40 V is only 2 µF although the nominal rating is 4.7 µF. To be on the safe side, it is recommended to use 5*2 µT = 10 µF. The major advantage is the very low ESR value of 2 mΩ. 1 2 Electrolytic Capacitor Ceramic Capacitors VOUT VOUT C OUT Figure 13 100nF COUT_bank 1) Electrolytic capacitor with small parallel C and 2) Pure ceramic capacitor bank Application Note 18 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application Tips: • • • • • • • The output capacitance depends on the load and the converter configuration. In boost configurations, output capacitances are larger than in buck configurations to achieve the same load current ripple. Lower operating frequencies will require larger output capacitances. Output capacitors are selected based on their: capacitance; equivalent series resistance (ESR should be low); RMS or AC current rating and the DC bias voltage response. Note that a ceramic capacitor can have a very low capacitance value at the working voltage level! Hence, a reasonable margin of safety should be considered. X7R ceramic capacitances should be used: For automotive high-temperature applications, X8R ceramic capacitors are available. To improve the EMC, cost and thermal response, a parallel setup of ceramic capacitors is recommended. (Disadvantage: this is only possible in a reasonable µF range). 6 2.6 Calculation of the input capacitance CIN The value of the input capacitance CIN of a boost converter is generally selected to limit the input voltage ripple ΔVIN specified by the application. For continuous inductor current mode operation, the current flowing through CIN is primarily determined by the inductor ripple current ΔIL. The charge and discharge current of the capacitors is balanced, and thus, the root mean square (RMS) current flowing through the capacitor is zero. ICIN ∆IL = 0.4A + CCIN_RMS=0.115A 0A SWITCH = ON Figure 14 SW=OFF t SWITCH = ON SW=OFF Current flowing through input capacitor CIN Note: For the worst case calculation, VIN = 8 V has been considered. Hence, ΔL is at its maximum value. Application Note 19 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application C @ max.18V = 1.7µF ESR~5mΩ f SW=400kHz VIN=max.18V Figure 15 CIN: ESR and DC bias of a 2.2 µF/50 V/X7R ceramic capacitor (source Murata: GRM31CR71H225KA88) Automotive type: GCM31CR71H225KA55 The input capacitor CIN can be calculated as: C IN ≥ ΔI L ⋅ TSW 8 ⋅ ΔVIN (35) C IN ≥ 0 .4 A ⋅ 2 .5 µs = 1 .25 µF 8 ⋅ 100 mV (36) RMS current through CIN: I RMS _ CIN = I RMS _ CIN = ΔI L 12 (37) 0.4 A = 0.115 A 12 Application Note (38) 20 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application Input voltage ripple and ESR value: Δ V IN = Δ I L ⋅ ESR (39) The maximum permissible ESR value can be derived: ESR ≤ Δ V IN 100 mV = = 25 m Ω ΔI L 0 .4 A (40) Selection of input capacitor CIN: • • • Voltage rating > 18 V: GCM31CR71H225KA55 = 50 V IRMS > 115 mA: GCM31CR71H225KA55 > 1 A ESR < 25 mOhm: GCM31CR71H225KA55 = 5 mΩ Tips: • • SEPIC and boost converters require a lower input capacitance than buck converters Refer to remarks in the output capacitance section Application Note 21 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application 7 2.7 Switching MOSFET considerations The major parasitic components are show in the MOSFET equivalent circuit on the right hand side in Figure 16. Furthermore, the corresponding MOSFET gate charging steps are shown on the left hand side. Note: Parasitic MOSFET and freewheeling diode effects are not considered in this summary! Explanation of the different gate charging steps: • • • • • • • Before time t0 the gate source voltage VGS is zero and no current flows in the MOSFET. At time t0 the gate-source voltage VGS starts to increase. At time t1, the gate-source voltage VGS is equal to the threshold voltage VGS(th) and the current ID begins to flow in the MOSFET, and until time t2, all the current ID flows in the MOSFET. ( The input capacitance Cgs continues to charge during the time interval t1 - t2. After time t2 the drain voltage VDS begins to decrease while the drain current ID is constant. The drain voltage decreases during the interval t2 - t3. At t3 the drain voltage VDS reaches the value RDSon * ID (where RDSon is the power MOSFET ON resistance and the sum of Rd + Rs). Towards t3 the gate source voltage VGS can be increased furthermore to drive the ON resistance at an optimum value. VGS Qgate Qgs Q gd Qsw Drain Q g(TH) Id VGS(TH) C gd t t1 t2 t3 t ,Qgate Igd 5V VDS Ig Gate 0V Igs VDS VGS Cgs Drain Current Source ID Drain Voltage t Figure 16 t1 t2 t3 t MOSFET - Gate charge characteristic Application Note 22 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application Switch ON timing calculation for a MOSFET: t ON = t ON = Q gate (41) I SWO ,SRC 6.5 nC = 17 .22 ns 380 mA (42) Switch OFF timing calculation for a MOSFET: tOFF = t OFF = Qgate (43) I SWO,SNK 6.5nC = 11.82 ns 550 mA (44) Drain Voltage VDS t Drain Current ID t ID_rise tVDS_fall tVDS_rise t tOFF t ON Figure 17 t ID_fall MOSFET - Switching time definition Application Note 23 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application Tips for selecting the power MOSFET: For the application example under consideration, the Infineon OptiMOS®-T2 power transistor IPD25N06S4L-30 has been selected. Automotive applications require the use of AEC qualified robust MOSFETs with high operating temperature rating (Tj(max) = 175°C). The crucial MOSFET parameters are shown in Figure 18 below. • • • • • n-channel MOSFETs are used for boost configurations (advantage of simple gate drive), a 5 V gate voltage compatible device should be selected (example: VGS(th) of 1.7 V). The MOSFET should have an appropriate RDS(on) to handle the input current flow even during worst case conditions and to reduce the conduction losses PC. The MOSFET breakdown voltage V(BR)DSS should be greater than the maximum output voltage (example: VOUT = 40 V < VDS = 60 V). The MOSFET should have low value of gate input capacitances and gate charges since this will minimize the MOSFET’s switching losses PSW and power loss inside the TLD5095/98 PIC (example: QG = 6.5 nC). Lead-free automotive qualified MOSFETs from Infineon are recommended: Please browse the portfolio on Infineon’s website: www.infineon.com/automotivemosfet Figure 18 MOSFET datasheet abstract - IPD25N06S4L-30 Application Note 24 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application 2.8 Calculation of power resistor for LED current definition - RFB The typical reference voltage VREF is 300 mV (specified parameter in product datasheet). RFB = VREF I OUT (45) R FB = 0 .3V = 0 .75 Ω 0 .4 A (46) Tips: • Isabellenhuette power shunt resistors of the SMS series having 1 % tolerance can be recommended 2.9 Calculation of over-voltage protection resistor divider - ROVL, ROVH The maximum permissible voltage at the output (VOUT(max)) should be slightly higher than the desired operating voltage VOUT. To simplify the calculation, the lower value of the over-voltage resistor ROVL is fixed at 1 kΩ. The internal over-voltage feedback threshold VOVFB,TH is specified in the product datasheet. The typical value is: VOVFB,TH = 1.25 V. The current flowing through the over-voltage protection resistor divider is: I OV = I OV = VOVFB ,TH (47) ROVL 1 .25V = 1 .25 mA 1kΩ (48) Now, you can calculate the upper over-voltage protection resistance. The rough assumption is to apply a little voltage overhead of 3 V for this estimation VOUT(max) = 43 V. ROVH = R OVH = VOUT ,max (49) I OV 43V = 34 .4 k Ω 1 .25 mA (50) The over-voltage resistor divider protects the application at: V OUT _ OV = 1 . 25 V + 43 V = 44 . 25 V (51) The internal parameter VOVFB,TH has a spread of +/-3.2%. The external resistor divider should have a tolerance of 1 % (E96 series). This leads to a variation in the protected voltage VOUT_OV of +/-4.2%. Figure 19 below shows the variation of the protected output voltage. It is important that VOUT < VOUT_OVmin to ensure proper application according to the maximum output voltage desired. Application Note 25 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application VOVFB example: VOUT_OV = 44.25V VOVP,max 1.25mA ROVH TLD5098 OVFB Overvoltage Protection ACTIVE 43V 34.4kΩ VOVFB,TH 9 ROVL GND 1kΩ 1.25V 1.25V Overvoltage Protection is disabled 12 t ∆=±3.1% Min. Typ. Max. Resistor divider from E96 series = 1% tolerance = ±4.2% ∆VOUT_OV = ±3.2 % ±1% = 46.10V VOUT_Ovmax = 44.25V * 1.042 = 42.39V VOUT_Ovmin = 44.25V * 0.958 Figure 19 Description of over-voltage protection Tips: • E96 series (1%) resistors recommended 2.10 Output diode selection - DBO Diode selected for the example: Schottky diode: 1 A / 50 V Tips: • • • • • • The diode must handle the maximum DC output current = IOUT The minimum reverse voltage should be higher than the max. VOUT voltage Low leakage current at higher temperatures could be important Low forward voltage drop (use Schottky diodes) Diode should react fast (= fast switching) Package and thermal resistance considerations Application Note 26 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Calculation of external components for a TLD5095/98 application 2.11 Gate driver buffer capacitance selection - CIVCC The calculation of the gate buffer capacitance CIVCC is based on the standard capacitance equation: I =C⋅ dV dt (52) The current in this formula is specified in the TLD5095/98 datasheet and represented by the gate driver peak sourcing current ISWO,SRC = 380 mA. The value of dV is the voltage ripple on the regulator output voltage. Let’s assume dV = 20 mV. The value of dt is the switching ON time of the MOSFET, which is calculated in “Switching MOSFET considerations” on page 22. tON = 17.22 ns The buffer capacitance required can be calculated: C IVCC = I SWO , SRC ⋅ t ON dV = 380 mA ⋅ 17 . 22 ns = 327 nF 20 mV (53) Selection of gate driver buffer capacitance CIVCC: CIVCC = 1µF/6V Tips: • • • CIVCC should have a low ESR X7R ceramic capacitors should be used: For automotive high-temperature applications, X8R ceramic capacitors are available. The parasitic inductance of the capacitor should be as low as possible. Otherwise, the parasitic inductor could lead to decreasing the gate switch ON time and result in higher switching power losses. The slope control of the MOSFET should be done with a defined external resistor (e.g. 10 Ohm), if necessary. A parasitic inductance also creates more ringing on the voltage signal and thus influences the delta voltage on the regulator output. Application Note 27 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Stability considerations 8 3 Stability considerations The TLD5095/98 products feature an external compensation network (RCOMP, CCOMP1, CCOMP2), which can be adapted to a variety of application boundary conditions and ensure stable switching behavior. All the details for the dimensioning are explained in the following chapter. 3.1 LED resistance considerations One crucial parameter for the stability calculation is the output impedance. A resistor value for the LED load must be defined. This is explained in the figure below. RLED = ΔVF 0.4V = = 0.67Ω ΔI F 600mA (54) We assume LED forward drop voltage of 3.1 V to reach with 12 LEDs the VOUT = 12 * 3.1 = 40.72 V which is close to our example VOUT = 40 V. LW W5SN – OSRAM Platinum DRAGON ΔI F=600mA ΔVF =0.4V Figure 20 LED current versus LED forward voltage (LW W5SN – OSRAM Platinum DRAGON) Application Note 28 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Stability considerations 3.2 LED forward voltage considerations Figure 21 below gives an indication of the LED forward voltage variation of a high-brightness LED. In general, the LED forward voltage VF is dependent on the junction temperature Tj and the load current IF. At low temperatures, the LED forward voltage has its maximum value (e.g. 4.3 V). In many application specifications, where LEDs are connected in series, customers request the worst case forward voltage at low temperatures. This leads to relatively high output voltages and more expensive external components must be used as a consequence. Theoretically, this may be correct but it should be always cross-checked if it is really necessary to map worst case on worst case conditions. In a real application, the LEDs will heat up very fast and the Tj = -40°C is not a continuous operating condition. In our example, we select a continuous VF of 3.368V for one single LED (typ. value @ Room Temperature). The sample application consists of 12 LEDs in series, which results in a VOUT = 40.42V, which is very close to the output voltage initially assumed by us (VOUT = 40 V). Note: To be precise the contribution of VREF (0.3V) must be considered as well, to get the proper output voltage: VOUT = VLED + VREF = 40.42V + 0.3V = 40.72V LED Forward Voltage V F versus Temperature (IF=700mA) 4,5 VF [V] 4 3,5 VF,min 3 VF,typ 2,5 VF,max 2 ‐40 ‐20 0 20 40 60 80 100 120 Tj [°C] Figure 21 LED forward voltage VF over temperature Tj (LW W5SN – OSRAM Platinum DRAGON) Application Note 29 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Stability considerations 3.3 Stability calculation Figure 22 below shows the parameter input of a dedicated Excel calculation file. Especially for the stability calculation, it is more efficient to work with the tools provided to achieve faster results. Nevertheless, one sample calculation is shown to give a feel of the mathematical calculations used by the Excel tool. More information on the Excel tool is furnished in “Excel tool for fast evaluation of external components, efficiency and stability” on page 42. One way of using the compensation sheet could be: • • • • Fill in the yellow parameters such as “application input values”, “LED model characteristic values”, “output RC network values” according to the values determined by the application dimensioning process. Try to fill in some initial estimated values for the “compensation network values”. Use the values recommended in the TLD5095/98 product datasheet and view the stability results. If the phase margin parameter is below 60°, try to reduce the resistor value RCOMP and increase the value for CCOMP1 and view the stability results once again. Repeat this procedure until you have the desired phase margin of > 60° and cross-check the result for the entire input voltage range. Note: Sometimes it may be necessary to redefine the input values such as LBO, RSWCS, RESR to achieve optimized stability. Parameter Application Input Values Input Voltage DC/DC Boost Inductor SET Voltage Feedback Resistor Symbol Value VIN LBO VSET RFB 12 56,0 5 0,750 Over Current Resistor Rswcs Switching frequency fsw LED Model Characteristic Values number of LED n_LED LED threshold voltage Vth_LED single LED Resistor R_LED Output RC network Values Capacitor Cout Output Cap. Series Resistor Resr Compensation network Values Resistor Rcomp Capacitor Ccomp1 Capacitor Ccomp2 Output Characteristic Feedback Reference Voltage Vref LED Current ILED LED Voltage VLED Output Voltage Vout Duty Cycle D LED equivalent Resistor RL Load Resistor Rload DC Gain Values for small signal model Gain between VOUT and VFB beta_DC Error Amplifier Gain AEA_DC Current Mode Gain ACM_DC Stability results Open Loop DC Gain DC_Gain Cut Frequency fc Phase Margin PM Figure 22 Unit V µH V Ohm 0,05 Ohm 400000 Hz 12 3,10 V 0,67 Ohm 10,00 µF 0,01 Ohm 1000 Ohm 47,00 nF 0,00 nF 0,30 0,400 40,42 40,72 0,705 8,04 8,79 V A V V Ohm Ohm 0,09 1500,00 9,54 61,73 dB 1400 Hz 73,44 deg Inputs and numeric results of the Excel compensation sheet Application Note 30 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Stability considerations 3.4 Closed loop considerations The TLD5095/98 control logic consists of two control loops. A current control loop, defined by the shunt resistor RCS, and the voltage control loop, defined by the load current shunt resistor RFB. Internal slope compensation ensures the loop stability at duty cycles above 50%. The external compensation network RCOMP and CCOMP1 connected in series to ground, plus a parallel capacitor CCOMP2 is needed to achieve a stable application for the application boundary condition specified. The main contributors for the closed loop stability are displayed in Figure 23 below. These are primarily the boost inductor LBO, the output capacitor COUT and its ESR value, the feedback resistor RFB, and the output network RLED and VLED have an significant impact on the stability. The freewheeling diode parameters Vd and Rd may be ignored. Note: The ACM Equation (56) describes more than just the current loop amplifier. Current loop, slope compensation, logic and the booster network (consisting of: COUT and RLED, LBO) itself, are summarized as highlighted in the dotted area in Figure 23. RESRL=0Ω VIN LBO Vd =0V; Rd=0Ω RFB D RON =0Ω LOGIC Current Loop ACM COUT RESRC RSWCS RLED + I - Slope Comp VLED t AEA CCOMP1 CCOMP2 Voltage Loop RCOMP Figure 23 TLD5095/98 closed loop schematic Application Note 31 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Stability considerations 3.4.1 Definition of the open loop gain The poles of the open loop gain need to be obtained for the stability of a control system. The pole and zero map is often used to assess the stability of a control system. In general, it can be said that a system is stable if all the poles are located on the left hand side of the imaginary axis. Refer to Figure 24 to see more details. Note: Zeros are not influencing the stability of a system! im S X X re X Stable ! Figure 24 General overview of a pole and zero map T ≅ ACM ⋅ A EA ⋅ β (55) T = Open loop gain ACM = Amplification of current measurement amplifier (Current loop) AEA = Amplification of error amplifier (Voltage loop) β = Feedback network The feedback network describes the relation between the feedback signal and the output signal. A CM ≅ 0 . 2 ⋅ D ′ ⋅ R load (1 − τ z 1 ⋅ s ) ⋅ (1 + τ z 2 ⋅ s ) ⋅ − n ⋅ V th _ LED ⎞ V ⎛ ⎛ s s2 ⎜⎜ 1 + OUT ⎟⎟ ⋅ R swcs (1 + τ p 1 ⋅ s )⋅ ⎜ 1 + + ⎜ V OUT ωn ⋅Q ωn2 ⎝ ⎠ ⎝ A EA ≅ 0 . 0006 × R EA × (1 + τ (1 + τ z 3 p2 ⋅ s) ⋅ s ) ⋅ (1 + τ p3 ⋅ s) ⎞ ⎟ ⎟ ⎠ (56) (57) 0.0006 = gmEA "transconductance" of the error amplifier β≅ RFB Rload Application Note (58) 32 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Stability considerations 3.4.2 Definition of zeros and poles The following formulas require some parameters that are defined here: D = 1 − D′ (59) D′ = Vin Vout (60) D′ = Vin 12V = = 0.295 Vout 40 .72V (61) Rload ≅ RFB + n ⋅ R LED (62) Rload ≅ R FB + n ⋅ R LED = 0.75Ω + 12 ⋅ 0.67 Ω = 8.79 Ω (63) D’ = inverted switching duty cycle n = number of LEDs RLED = forward LED resistor The system displayed in Figure 3 includes three zeros which are defined as: τ z1 ≅ L BO Rload ⋅ D ′ 2 ⎛ VOUT − n ⋅ Vth _ LED ⋅ ⎜⎜ VOUT ⎝ ⎞ 56 µH ⎟⎟ = 8 . 79 Ω ⋅ 0 .295 2 ⎠ s ⎛ 40 .72V − 12 ⋅ 3 .1V ⎞ −7 ⋅⎜ ⎟ = 6 .33 ⋅ 10 40 . 72 V rad ⎝ ⎠ (64) τ z 2 ≅ C out ⋅ R ESR _ Cout = 10 µF ⋅ 0 .01Ω = 1 ⋅ 10 − 7 s rad (65) τ z 3 ≅ Ccomp1 ⋅ Rcomp = 47 nF ⋅ 1kΩ = 4.7 ⋅ 10 −5 s rad (66) Application Note 33 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Stability considerations Corresponding to the three zeros, the system includes three poles as well: τ p1 ≅ C out ⋅ ( R load + 2 ⋅ R ESR _ Cout ) 10 µF ⋅ (8 . 79 Ω + 2 ⋅ 0 . 01 Ω ) s = = 8 . 11 ⋅ 10 − 5 40 . 72 V − 12 ⋅ 3 . 1V ⎞ V OUT − n ⋅ V th _ LED ⎞ rad ⎛ ⎛ ⎜⎜ 1 + ⎟⎟ ⎜1 + ⎟ 40 . 72 V ⎝ ⎠ V OUT ⎝ ⎠ (67) REA = internal resistor of error amplifier REA ≅ 2.5 MΩ (for TLD5098) REA ≅ 47 MΩ (for TLD5095) REA >> RCOMP Note: CCOMP1 >> CCOMP2 τ p 2 ≅ (C comp 1 + C comp 2 )⋅ R EA = (47 nF + 0 nF ) ⋅ 2.5 M Ω = 1.18 ⋅10 −1 τ p 3 ≅ C comp 2 ⋅ Rcomp = 0 nF ⋅ 1kΩ = 0 Application Note s rad s rad (68) (69) 34 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Stability considerations 3.4.3 Definition of the slope compensation parameters and quality factor Q The slope compensation parameters (ωn, Q, mc, Se, Sn) for the current loop model is based on R.B. Ridley. [1] Reference: Ridley, R.B.; “A New Continuos Time Model for Current Mode Control”; IEEE Transaction on Power Electronics; Vol. 6; Issue 2; pp. 271-280; 1991. Note: For the stability of the system it is necessary that the quality factor Q is positive! Se = 50 ⋅ 10 − 6 A 50 ⋅ 10 − 6 A A = = 20 2 . 5 µs T SW s (70) TSW = switching period Se = internal slope compensation S n = 0 .001 ⋅ V IN 12V A ⋅ R swcs = 0 .001 ⋅ ⋅ 50 m Ω = 10 .71 56 µH L BO s (71) Sn = Slope of the ON period of the switch A 20 Se s = 2.87 mc = 1 + = 1+ A Sn 10.71 s Q≅ (72) 1 1 = = 0.92 π ⋅ (mc ⋅ D′ − 0.5) π ⋅ (2.87 ⋅ 0.295 − 0.5) (73) Q = Quality factor of the overshoot 3.4.4 Open loop gain calculations ACM (0) ≅ 0.2 ⋅ D ′ ⋅ Rload 0.2 ⋅ 0.295 ⋅ 8.79 Ω = = 9.54 ⎛ 40 .72V − 12 ⋅ 3.1V ⎞ ⎛ VOUT − n ⋅ Vth _ LED ⎞ 1 + ⋅ 0 . 05 Ω ⎟⎟ ⋅ R swcs ⎜ ⎟ ⎜⎜1 + 40 .72V ⎝ ⎠ VOUT ⎠ ⎝ AEA (0) ≅ 0.0006 ⋅ REA = 0.0006 ⋅ 2.5MΩ = 1500 β≅ (74) (75) RFB 0.75Ω = = 0.0853 Rload 8.79Ω (76) T ( 0) ≅ ACM ⋅ AEA ⋅ β = 9.54 ⋅1500 ⋅ 0.0853 = 1220 .64 (77) T (0) | dB = 20 ⋅ log(1220.64) = 61.73dB (78) Application Note 35 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Stability considerations 3.5 Calculation of the phase margin: Good practice for a proper phase margin value is > 60°. If the phase margin is lower, the system has a faster response time and oscillations can occur (the f cross-over is also higher in that case). A more gentle switching response can be achieved by increasing the phase margin. Systemspeed: Fast PM: 16° = Low Systemspeed: Medium PM: 73° = OK Systemspeed: Slow PM: 92° = OK 1 / fc Stability results Open Loop DC Gain Cut Frequency Phase Margin Gain Margin DC_Gain fc PM GM 61,73 5500 15,94 13,68 dB Hz deg dB RCOMP =1.1kΩ CCOMP1 = 4.7nF Figure 25 Stability results Open Loop DC Gain Cut Frequency Phase Margin Gain Margin DC_Gain fc PM GM 61,73 1400 73,45 27,39 dB Hz deg dB Stability results Open Loop DC Gain Cut Frequency Phase Margin Gain Margin RCOMP =1.0kΩ CCOMP1 = 47nF DC_Gain fc PM GM 61,73 760 92,48 27,42 dB Hz deg dB RCOMP =1.0kΩ CCOMP1 =100nF Response of fast and slow systems This can be achieved by changing the compensation network values. A dedicated Excel file for the stability estimation is of great help to figure out the proper compensation network values RCOMP, CCOMP1, CCOMP2. The Excel sheet itself features a built-in function which indicates a green label for the phase margin if it is in the proper range for a stable application. In addition, a Bode plot is provided to see the phase and gain slopes directly as illustrated in Figure 26 below. The crossover frequency fcross_over is defined as the value when the gain slope intersects the 0 dB line. The phase margin PM of the system is obtained at the fcross_over point. f cross _ over ≅ T (0) 1220 .64 = ≅ 1653 Hz 2 ⋅ π ⋅ C comp 1 ⋅ R EA 2 ⋅ π ⋅ 47 nF ⋅ 2 .5 M Ω ωc _ o = 2 ⋅ π ⋅ fcross _ over = 2 ⋅ π ⋅1653 Hz = 10386 (79) rad s (80) φm =180− tan−1(ωc0 ⋅τ p1 ) − tan−1(ωc0 ⋅τ p2 ) − tan−1(ωc0 ⋅τ p3 ) − tan−1(ωc0 ⋅τ z1 ) + tan−1(ωc0 ⋅τ z2 ) + tan−1(ωc0 ⋅τ z3 ) (81) φ m = 180 ° − 40 . 1 ° − 89 . 95 ° − 0 ° − 3 . 76 ° + 0 . 06 ° + 26 ° = 72 . 25 ° (82) Note: The deviations between the calculated values and the results in the Excel sheet are attributable to differences on account of rounding up! Application Note 36 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Stability considerations TLD5095/98 CCM Bode plot 90 60 30 0db - Line 0 -30 -60 -90 -120 -150 -180 -210 -240 -270 -300 -330 -360 0,01 fc=1400Hz PM=180°-106.56°=73.44° Open Loop Gain (dB) Open Loop Phase (deg) 0,1 1 10 100 1000 10000 100000 1000000 10000000 Frequency (Hz) Figure 26 Bode plot Application Note 37 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Power loss and system efficiency 9 4 Power loss and system efficiency After dimensioning and careful selection of the external components the overall power loss and system efficiency can be calculated. This chapter describes in detail how the power dissipation for each component can be obtained. The typical application input voltage VIN = 12 V is considered for the calculations. Figure 27 Power loss summary Figure 28 System efficiency and single power loss contribution slopes Application Note 38 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Power loss and system efficiency 4.1 TLD5095/98 IC Power Losses - PIC There are various power dissipating blocks integrated in the DC/DC controller IC. 1) Losses of the integrated voltage regulator - PLDO: It is necessary to calculate the average value of current required by the internal LDO. I VCC _ RMS = Qg ⋅ f SW (83) IVCC_ RMS = 6.5nC ⋅ 400kHz = 2.6mA (84) PLDO = (VIN − VIVCC ) ⋅ I VCC _ RMS (85) PLDO = (12V − 5V ) ⋅ 2.6mA = 18.2mW (86) 2) Gate charge losses: Pgate_charge: Pgate _ ch arg e = VIVCC ⋅ IVCC _ RMS (87) Pgate _ ch arg e = 5V ⋅ 2.6 mA = 13mW (88) 3) Quiescent current consumption losses - PQ: PQ = VIN ⋅ I q _ on (89) PQ = 12V ⋅ 7 mA = 0.084W (90) Total IC losses: PIC = PLDO + Pgate _ ch arg e + PQ = 115 .2 mW Application Note (91) 39 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Power loss and system efficiency 4.2 Power MOSFET - PMOSFET The power MOSFET losses are split up between: 1) Conduction losses PC: 2 PC = D ⋅ I IN ⋅ R DS ( on ) (92) PC = 0.70 ⋅ 1.33 A 2 ⋅ 30 m Ω = 37 .33 mW (93) 2) Switching losses PSW: PSW = 0.5 ⋅VOUT ⋅ I IN ⋅ (tON + tOFF ) ⋅ f SW (94) PSW = 0.5 ⋅ 40V ⋅1.33 A ⋅ (39.5ns + 27.3ns ) ⋅ 400 kHz = 308 .52 mW (95) The total MOSFET losses are: PMOSFET = PC + PSW = 37.33mW + 308.52mW = 345.85mW 4.3 (96) LED current feedback resistor power loss - PRFB 2 PRFB = I OUT ⋅ RFB (97) PRFB = 0 . 4 A 2 ⋅ 0 . 75 Ω = 0 . 12 W (98) 4.4 Switch current sensing resistor power loss - PRCS 2 PRCS = D ⋅ I IN ⋅ R CS (99) PRCS = 0.70 ⋅ 1.33 A2 ⋅ 0.05Ω = 0.062W 4.5 (100) Inductor power loss - PLBO 2 PLBO = I L, AVG ⋅ DCR (101) PLBO = 1.33A2 ⋅ 0.0802Ω = 142.58mW (102) Application Note 40 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Power loss and system efficiency 4.6 Input capacitor power loss - PCIN 2 PCIN = I RMS ⋅ ESR (103) PCIN = 0 . 115 A 2 ⋅ 0 . 005 Ω = 10 µW (104) 4.7 Output capacitor power loss - PCOUT 2 PCOUT = I RMS _ COUT ⋅ ESR (105) PCOUT = 0 .61 A 2 ⋅ 0 .01Ω = 3 .73 mW (106) 4.8 Freewheeling diode power loss - PDBO Pdiode = I OUT ⋅ VFW (107) Pdiode = 0.4 A ⋅ 0.4V = 160mW (108) Application Note 41 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Design-in tools 10 5 Design-in tools Dimensioning and design efforts could become a very time-consuming task, particularly for switched mode power supply applications. To reduce the development cycle, design-in tools are well appreciated by customers, and Infineon provides several tools and guidelines to ensure streamlined design-in activity for the TLD5095/98 DC/DC controller ICs. 5.1 Excel tool for fast evaluation of external components, efficiency and stability All the equations that have been summarized and described in this application note have been incorporated in a dedicated Excel sheet. This Excel tool supports the dimensioning, stability, and power loss and efficiency considerations very clearly. Last but not least, it is possible to export all results into a PDF document, which can be used as a design summary for permanent application documentation. The application note in combination with the Excel tool should provide a focused and fast approach for the proper design of a TLD5095/98 application. Figure 29 Excel sheet calculator for application dimensioning and stability Application Note 42 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Design-in tools 5.2 Electrical and thermal simulation A PSPICE model could be very beneficial to get an initial impression of the system response. After the dimensioning process, a quick crosscheck of the application response could save costs by reducing hardware development cycles. Stability and switching response can be investigated easily with the help of the PSPICE models of the TLD5095/98 ICs provided. A complete test bench including discrete components, the DC/DC converter and the MOSFET can be provided on request. It is also worth mentioning that the comprehensive Infineon MOSFET portfolio also features dedicated PSPICE models that could be included in such a test bench. Infineon website: www.infineon.com/automotivemosfet In addition to electrical simulation, it becomes increasingly important to estimate the thermal performance of a system. It is recommended to run thermal simulations (e.g. Flotherm) or other appropriate tools to study the thermal response of a rough layout. The maximum ratings of the components used must not be exceeded! Figure 30 Simulation tools and support Application Note 43 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Design-in tools 5.3 Demo boards for fast evaluation in the lab & onboard LED chain Another step in the evaluation of the TLD5095/98 products could be to conduct real measurements on a plug & play hardware such as the evaluation kit. The DC/DC layout has been reused from our EMC test PCB. All pins of the ICs can be easily connected with the help of banana cables to the measuring instruments, load and power supply equipment. The evaluation kit features onboard LEDs (max. 8 LEDs in series, reconfigurable to only 1 LED in series for buck boost configurations). In addition, there is the feature of driving real loads via dedicated ports (4 mm banana sockets). You can switch between onboard LEDs and the external load using a simple switch on the demo board. As illustrated in Figure 31 below, the Evaluation Kit can be ordered for two different configurations. 1. One demo board features the standard boost to GND application and a SEPIC configuration can be realized with simple adaptation of the external circuitry. In addition, both, the B2G and the SEPIC can be driven in a constant voltage mode. 2. The second demo board features a boost to battery configuration, which is needed to achieve a BUCK-BOOST response and connect a single LED or several LEDs in a string. Constant voltage mode regulation is also possible for this configuration after simple modification of the external components on the demo board. The TLD5095/98 demo boards enable quick evaluation of the products under real application conditions at the work bench level and can be ordered from our local sales team. Figure 31 Plug & play demo boards for getting started in the laboratory Application Note 44 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Design-in tools 5.4 Sample layouts for small application boards In addition to the evaluation kit for fast evaluation of the products, dedicated EMC and size-optimized application PCBs are available. These application boards are dedicated to one specific configuration such as the standard boost to GND or SEPIC configurations. The size of the application boards is 4.5 cm x 4 cm and the connections to the power supply and external load can be established with cables. To simulate real load conditions, Infineon has also developed a general purpose LED board. The LED load board features up to 20 LEDs in series or can be configured in parallel connection as well to simulate multi-channel light sources. The application boards in combination with real loads or the Infineon load board enable fast and realistic application prototyping and could be very beneficial for constructing initial system demonstrators. The layout of these boards is optimized for EMC and can be reused for customer applications. Figure 32 Small versatile application boards and EMC optimized layouts Application Note 45 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Design-in tools 5.5 EMC test reports and results summary The EMC behavior of switched mode power supplies is considered as one of the most crucial topics during the design-in activities. All OEMs specify different limits which must be complied with by the application. The Infineon EMC investigation clearly takes care of the OEM and customer specifications and provides comprehensive reports. The EMC reports consist of conducted and radiated emissions, immunity response, and ISO pulses. In some cases, dedicated filter and countermeasures are described to improve the EMC behavior further as well as to provide guidelines to the reader for a proper EMC design. Figure 33 • EMC test reports and results summary For further information, please contact http://www.infineon.com/ Application Note 46 V1.3, 2011-08-08 TLD5095 / TLD5098 Dimensioning and Stability Guideline - Theory and Practice Revision history 6 Revision history Revision History: V1.3, 2011-08-08 Previous version(s): 1.0, 1.1, 1.2 Page Subjects (major changes since last revision) all Editorial Changes Application Note 47 V1.3, 2011-08-08 Edition 2011-08-08 Published by Infineon Technologies AG 81726 Munich, Germany © 2011 Infineon Technologies AG All Rights Reserved. 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For information on the types in question, please contact the nearest Infineon Technologies Office. Infineon Technologies components may be used in life-support devices or systems only with the express written approval of Infineon Technologies, if a failure of such components can reasonably be expected to cause the failure of that life-support device or system or to affect the safety or effectiveness of that device or system. Life support devices or systems are intended to be implanted in the human body or to support and/or maintain and sustain and/or protect human life. If they fail, it is reasonable to assume that the health of the user or other persons may be endangered.