Design Better Power Supply

Getting Start on PowerEsim PowerELab LimitedPowerELab Limited www.powerEsim.com 11


It’s Free . . . It’s Free . . .

• It’s on-line

• It’s for everyone

• Worldwide access

• 100% server side simulation

• It’s FREE!!


Free accounts from sponsorsFree accounts from sponsors

• Some sponsors provide a full features PowerEsim for public user.


Your private free account Your private free account

• User can apply for a 7 days private free full features account by email address.


It’s highly accurateIt’s highly accurateI/P Votlage Vs Efficiency %

0.0010.0020.0030.0040.0050.0060.0070.0080.0090.00

100.00

300 350 405

150W flybackInput Votlage Vdc

Input Votlage Vs Efficiency %

0.0010.0020.0030.0040.0050.0060.0070.0080.0090.00

100.00

85 110 230 265160W PFC Input Voltage Vac


No expert knowledge neededNo expert knowledge needed

• Find MOSFET

• Find Diode

• Find Capacitor

• Find Core

• Find Wire

Rds*Crss

Vf*trrm

CV

k1, k2, k3

Current density

PowerEsim need Traditional design need

• No equations needed!• Simple pick and place components• Or build real Xformer in virtual space


PowerEsim vs Traditional DesignPowerEsim vs Traditional Design

result oriented adaptive iteration

instead of

skill of knowledge application

PowerEsim turn design into


Start a design – Design from ReferenceStart a design – Design from Reference

• Find a circuit that has closest specification to your need, e.g. 160W TDA4863 for PFC front end.


Reference design will be loadedReference design will be loaded

• Reference design will be loaded within a few seconds

• No need to read application notes

• Change component for your own requirements


Remember, it’s other people design . . .Remember, it’s other people design . . .

As in a real bench, change Vo by

changing feedback resistor to suit for your own output

voltage requirement


Or click the main MOSFETOr click the main MOSFET

• Select other component for cost or performance reasons.


Re-define specification Re-define specification

• Click “Detail Spec.”• Change specification

as you like


Start a design - Ask our expertStart a design - Ask our expert

• Enter the simple input & output specification

• Chose an application

• Click “Recommend Design”


How our expert inside the server workHow our expert inside the server work

Specification Search for closest reference design

Search for best topologies

• Fuzzy logic is used to rank the topologies or reference design according to user’s requirements


Start a design - more freedomStart a design - more freedom

• Click “Topologies”• Chose the topology you like• Then chose for PWM controller too


Chose a PWM controller circuitChose a PWM controller circuit

• Double click the PWM block• Select the PWM controller• Another PWM circuit will appear


Finally . . .Finally . . .

Enter the input and output specification

then click“Initialize Design”


Preliminary design will be initializedPreliminary design will be initialized

• Preliminary design of real components will be initialized within a few seconds

• A virtual power supply is on the your bench

• Click LosseSIM


Losses and it’s detailsLosses 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


Losses and operating conditionsLosses and operating conditionsFrom To

Vin 85 V 240 V

Io 3.75 A 2 A

Pd 14.7 W 7.7 W


The most important pageThe most important page

• Component Finder – Best optimize tool for cost and performance


Change the rangeChange the range

• Extend the range can select more suitable components

• Choose different Manufacturer can refine the list too


Click, click, click and selectClick, click, click and select

• A particular one – total & individual loss

• Highlighted one – total, individual loss and stress

• Selected one – total individual loss and stress


Other than loss, Stress is importantOther than loss, Stress is important


How we model component?How we model component?


Features are same for all componentFeatures are same for all component


More clever method – More clever method – Smart OptimizerSmart Optimizer

Click “Select All”

All MOSFET will dump into a

optimizer pool


Smart Optimizer – just a clickSmart Optimizer – just a click

• Click “Smart Optimizer”

• Enter maximum iterations

• Wait a few seconds


Multi dimensional optimizationMulti dimensional optimization

:

1

2

10

10 resistorx

10 MOSFET

10 diode

x

x:

= 1010 combination

= 31 years simulation


Smart Optimizer – how it workSmart Optimizer – how it work

Data set Smart ScanSearch for good component

Genetic Algorithm

SPD07N60C3 BU60

SPN04N60C2

IPP50R520CP

SPB07N60S5

SPD07N60C3 BU60

SPN04N60C2

IPP50R520CPSPB07N60S5


Sorted one by oneSorted one by one

• Result will be ranked• Click to view each result• Optimized Component will be shown


Diode or Active DiodeDiode or Active Diode

• Click the diode you like to replace by Active Diode or Sync Rect.

• In the Component Finder, change it’s “Rectifier Type” to

Active Diode


Search more MOSFETSearch more MOSFET

• Extend to higher current range is usually needed

• Extend the body diode’s trrm can

find more MOSFET


Select a better Sync Rect.Select a better Sync Rect.

• 2.54W SCK loss

• 0.5W Active Diode loss


Now click T1 and go to Magnetic BuilderNow click T1 and go to Magnetic Builder


dvHIu

Lk

ok

2H

Background Background - - What else we consider for a transformerWhat else we consider for a transformer

Leakage inductanceLeakage inductance

coscoshsinsinh12 2

mPd

m=2

Proximity effectProximity effect

meterfu

Do

skin

Skin effectSkin effect

skinDd

2

wire

wirewire dlBf

Pd

42

Fringing flux Fringing flux

22

321

Bfd

Bc

Bb

Ba

fVolPd

kkk

Core lossesCore losses


Magnetic Builder - Build a single Magnetic Builder - Build a single transformer alonetransformer alone

• User can build a single sand alone transformer by pressing the button “Magnetic Builder”


Design a single Xformer – Where it Design a single Xformer – Where it apply?apply?

• Choose the application of the magnetic component, e.g. it is a “Flyback Xformer” or “Input Choke”


Design a single Xformer – Design a single Xformer – Operating conditions?Operating conditions?

• 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.


Design a single Xformer – Design a single Xformer – Full version Magnetic BuilderFull version Magnetic Builder

• Click the “Advanced” button will go to the full version Magnetic Builder and do whatever you like.


Any real core you likeAny real core you like

• Chose the range of Ae

• Select Core shape

• Select Manufacturer


Instant preview winding when thing changeInstant preview winding when thing change

• Click the “preview winding”

• Corresponding winding cross section will be shown

• Supported on Core, N and Wire.


Seeking the best LmSeeking the best Lm

• Click the “Inductance” button

• Enter the range of inductance

• Highlight each in the list, select according to total loss and stress.

• Double check OCP is not be triggered.


Find the best number of turnFind the best number of turn

• Click the “Number of turn” button

• Enter the range of turn

• Highlight each in the list, select according to total loss and stress.

• Double check OCP is not be triggered.


No. of turn is not just an abstract number !No. of turn is not just an abstract number !

• Click the “Preview Winding” button

• Observe how winding structure change with number of turn.


Add more copper?Add more copper?

• Click the “Change Wire” button• Click the “No. of Parallel Wire”• Add more parallel wire as you like.


Copper foil can be usedCopper foil can be used• Click the “Use copper foil”

button• Enter the copper foil size


Faraday shield can be addedFaraday 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.


Arrange each winding layer you likeArrange each winding layer you like


The dot of a windingThe dot of a winding

• User can define whether the winding is started at dot sign or not


Where to start windingWhere to start winding

• User can define whether the winding is started at upper end or lower end of the winding layer


How to wind a windingHow 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.


Layer to layer winding methodLayer 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


Inner tape between each layerInner tape between each layer

• Inner tape can be placed between each layer of Multi-layers winding.


Customize different bobbins typeCustomize different bobbins type

• Thickness of each wall and the type of split bobbin can be defined in “Bobbin Setting”.


You can make a transformer like this . .You can make a transformer like this . .• 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 . . . .


Transformer drawing will be followedTransformer drawing will be followed

• Transformer drawing will be automatically generated by pressing the “Generate Drawing” button.

• Details testing methods, P/N, material can be edit before printing.


Thermal – knowing Temp. at day 1Thermal – knowing Temp. at day 1


Thermal – Pick and PlaceThermal – Pick and Place• Highlight the component

on left bottom side, pick and place them on PCB

• Or, select the component you like at left upper corner combo box


• Click the side view button to touch up the vertical location of components

• User may click back to “Nor-mal” button when finish vertical alignment

Thermal – Side ViewThermal – Side View


• Highlight the heatsink and click the blue component button below

• You will go to the component page and then select different heatsink type

Thermal – Different Heatsink shapeThermal – Different Heatsink shape


• Highlight the heatsink and “shift+highlight” on the MOSFET

• Press the horizontal group and attach button to attach the MOSFET to the heatsink

Thermal – Attach componentsThermal – Attach components


Thermal – Final Thermal ResultThermal – Final Thermal Result

• It will only take a few seconds to see the thermal result


DVT – check the stressesDVT – check the stresses

• DVT Report check every components stress and also circuit design constraint.


MTBF – how long it lastMTBF – how long it last


Use thermal result check boxUse thermal result check box• Once this check box is clicked, all simulation, e.g.

DVT, MTBF, etc, will be base on junction Temp. from thermal simulation result, otherwise default value will be used


Loop Analysis– how stable the systemLoop Analysis– how stable the system

• Gain and phase margin will be immediately known with after any change or circuit component


Loop Analysis– Loop Analysis– automatic compensationautomatic compensation

• Enter the expected DC gain, phase margin and cross over frequency

• Press “Automatic Compensation” button

• System will iteration to best fit the points by changing the component marked with “Enable for Automatic Loop Compensation”


Loop Analysis– transient loadingLoop Analysis– transient loading

• Define step loading waveform and corresponding output transient loading response will be shown


Harmonic – Harmonic – knowing input current harmonics contentknowing input current harmonics content

• All input current parameters, e.g. PF, THD, harmonic content can be seen


Waveform – Waveform – the least important toolsthe least important tools

• Critical component’s waveform will be illustrated


Magnetic Builder – Magnetic Builder – build any transformer build any transformer

• You can build any kind of transformer on your own wish and press a button to print the corresponding transformer drawing.


BOM Builder – BOM Builder – BOM is always ready to print outBOM 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.


Report Builder – Report Builder – Generate all documents with a clickGenerate all documents with a click

• Simple a click - All result from analysis or tools can be exported to Excel file for engineering documentation.


Download – Download – a lot of document is ready to downloada 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.


Documents

Design Better Power Supply