600W Halfbridge LLC Evaluation Board EVAL 12V 600W LLC analog EVAL 12V 600W LLC digital Table of Contents General Description Efficiency Results Design Concept 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 2 Table of Contents General Description Efficiency Results Design Concept 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 3 Example of System Understanding: Infineon Demo Solution for Titanium HV DC/DC stage Half Bridge LLC with synchronous rectification in center tap configuration Vin 350-410VDC Vin_nom 380VDC Vout_nom 12VDC Iout 50A Po 600W fres=f0 157kHz fmin 90kHz fmax 210kHz Transformer turns ratio 16:1 Cr 66nF Lr 15.5uH Lm 195uH 2014-11-04 Primary HV MOSFETs CoolMOSTM IPP60R190P6 Reduced Gate Charge (Qg) Reduced Eoff High body diode ruggedness LLC analog controller ICE2HS01G or digital controller XMC4200 HB Gate Drive IC 2EDL05N06PF SR MOSFETs OptiMOSTM BSC010N04LS New generation Best FOM RDS(on) x Qg Best FOM RDS(on) x Qoss Bias QR Flyback controller ICE2QR2280Z SR MOSFETs BSC010N04LS Resonant inductor Transformer PQ35/35 core RM12 core Copyright © Infineon Technologies AG 2014. All rights reserved. Page 4 PCB Boards Layout: Main Power Board and Control and Bias Daughter Boards Power Density>20W/inch3 Controller Board 2014-11-04 Bias Board Copyright © Infineon Technologies AG 2014. All rights reserved. Page 5 Main Power Board Schematic 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 6 Bias Board Schematic 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 7 Analog Control Board Schematic 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 8 Digital Controller XMC 4200 Digital Control Daughter Board Schematic 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 9 PCB structure 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 10 Table of Contents General Description Efficiency Results Design Concept 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 11 Automated Efficiency Measurement Efficiency Combination of converter Proper selection of SR LV design (resonant tank, device and secondary side transformer) and proper HV design device selection 0,99 0,985 97.8% peak efficiency! 0,98 0,975 0,97 0,965 Highest Efficiency standard 0,96 0,955 in Computing applications 0,95 (HV DC/DC stage) 0,945 0,94 0,935 0,93 0,925 0,92 0,915 0,91 0,905 0,9 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 0.1% IOUT [A] 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. P6 190mOhm Total Accuracy Page 12 10%Pmax Vin=380Vdc 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 13 50%Pmax Vin=380Vdc 1,2 1 0,8 Turn-off losses 0,6 Body diode losses Driving losses 0,4 Conduction Losses 0,2 0 Losses spread on each device at 50%Pmax [W] 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 14 100%Pmax Vin=380Vdc 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 15 Table of Contents General Description Efficiency Results Design Concept 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 16 Design Procedure: Input Data Vin _ nom n 2 Vout _ nom n Vo _ min M min K min(Q, m, Fx ) Vin _ max 2 M max 2014-11-04 n Vo _ max K max (Q, m, Fx ) Vin _ min 2 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 17 Resonant Tank Components and Related Resonant Frequencies n=Vin_nom/(2xVo)=380/(2*12)≈16 Lm=195µH Lr=15.5µH Ln=Lm/Lr=12.5 Cr=66nF 1 fo 157kHz 2 Lr Cr 2014-11-04 fp 1 42.7kHz 2 ( Lr Lm) Cr Copyright © Infineon Technologies AG 2014. All rights reserved. Page 18 Gain Curves dc-gain curve (600W LLC hardware revision E02) 1,2 M max 1,1 n Vo _ max Vin _ min 2 1 gain 5A 0,9 0,8 M min 15 A n Vo _ min Vin _ max 2 25 A 35 A 50 A 0,7 0,6 frequency [Hz] 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 19 Energy Related Calculations (Ref. IPP60R190P6 Device Parameters) Im ag _ min 2 2 n Vo 0.672 A 2 fsw _ max Lm 1 Enres _ min ( Lm Lr ) I ² mag _ min 95.1J 2 Enres _ min Encap _ max 1 Encap _ max (2Co(er )) V ² DS _ max 9J 2 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 20 Qoss, Imag,pk, tdead,min, tecs Relationship Im,pk IQ2 IQ 2(t ) Im, pk (1 IQ 2(t ) 0 t tecs ) t tecs t tecs Cds ) Cgd ICHB Im,pk tdead , min ICHB(t )dt 0 VHB VBULK 1 tecs 2014-11-04 tecs f ( Rg , tot,Vgs, th, tdead,min 1 Im, pk tecs Im, pk (tdead, min tecs ) 2 Qoss, @ 400V 2 tecs 2 Qoss, @ 400V tdead, min 2 Im, pk Copyright © Infineon Technologies AG 2014. All rights reserved. Page 21 Time Related Calculations (Ref. IPP60R190P6 Device Parameters) Im ag _ min Im ag _ max 2 2 2 2 n Vo 0.672 A 2 fsw _ max Lm n Vo 1.66 A 2 fsw _ min Lm tecs 2 Qoss, @ 400V tdead, min 130n sec 2 Im ag, max tdead, max 2014-11-04 tecs 2 Qoss, @ 400V 311n sec 2 Im ag, min Copyright © Infineon Technologies AG 2014. All rights reserved. Page 22 Main Transformer Structure: PQ35/35 Core with TDK PC95 Ferrite Material 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 23 Resonant Choke: RM12 Core, Material N87 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 24 Support Slides 600W LLC Evaluation Board Evaluation Board Page Technical Description Datasheets Parameters Related material Videos www.infineon.com/600w-llc-evaluationboard-a www.infineon.com/600w-llc-evaluationboard-d Product Family Pages Product Brief Application Notes Selection Guides Datasheets and Portfolio Videos Simulation Models 2014-11-04 www.infineon.com/p6 www.infineon.com/xmc Resonant Mode Controller www.infineon.com/optimos5-40v60v Copyright © Infineon Technologies AG 2014. All rights reserved. Page 25 Support Slides Online Tools and Services 1 2 3 1 Find your Local Distributor 2 Tools, Finders and Selectors 3 Support 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 26