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PowerEsim FACT sheetPowerEsim FACT sheet

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Hardware Prototype ImplementationHardware Prototype Implementation

Topology: AC/DC Flyback Dual-output ConverterInput range: 85-264VAC/50HzOutputs: O/P1 – 5V/6A; O/P2 – 12V/2.5A

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Critical waveformsInput voltage at 85VAC

Drain Voltage Waveform AnalysisDrain Voltage Waveform Analysis

Primary MOSFET switching waveformCh1 – M1 drain source voltage waveform; Ch2 – M1 drain current waveform

Simulation peak voltage from PowereSim = 300V

Actual peak voltage approx. = 285V

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Critical waveformsInput voltage and bulk capacitor voltage waveforms

Bulk Capacitor Voltage Waveform AnalysisBulk Capacitor Voltage Waveform Analysis

Ch1 - Input AC voltage waveform Ch2 - Rectified bulk capacitor voltage

Similar intersection point

Simulation Measurement

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Critical waveformsInput voltage and current

Input Current Waveform AnalysisInput Current Waveform Analysis

Ch1 - Input AC voltage waveform Ch2 - Input current waveform

Simulation Measurement

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Line RegulationLine Regulation

Simulation Measurement

Output at full load

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

80.00 130.00 180.00 230.00 280.00

Input voltage RMS (V)

Outpu

t volt

age (

V)

+5V @ 6A

+12V @ 2.5A

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

80.00 130.00 180.00 230.00 280.00

Input voltage RMS (V)

Outpu

t volt

age (

V)

+5V @ 6A

+12V @ 2.5A

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Load RegulationLoad Regulation

Input voltage at 85VACSimulation Measurement

Input voltage at 85VAC

0.00

5.00

10.00

15.00

20.00

25.00

0.00 0.50 1.00 1.50 2.00 2.50

Output current (A)

Outpu

t volt

age (

V)

+12V @ 5V/1A

+12V @ 5V/3A

+12V @ 5V/6A

+5V @ 1A

+5V @ 3A

+5V @ 6A

Input voltage at 85VAC

0.00

5.00

10.00

15.00

20.00

25.00

0.00 0.50 1.00 1.50 2.00 2.50

Output current (A)

Outpu

t volt

age (V

)

+12V @ 5V/1A

+12V @ 5V/3A

+12V @ 5V/6A

+5V @ 1A

+5V @ 3A

+5V @ 6A

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Power Loss AnalysisPower Loss Analysis

Efficiency comparison at full load

Conversion Efficiency

01020304050607080

70 120 170 220 270

Input voltage RMS (V)

Effici

ency

(%)

Measurement

Simulation

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Closed-loop Analysis (Bode plot)Closed-loop Analysis (Bode plot)

Input voltage at 115VAC full loadMeasurement

1 10 100 1 103

1 104

1 105

40302010

010203040506070

70

40

Gaini

3 1041 f i

1 10 100 1 103

1 104

1 105

200

150

100

50

0

50

100

150

200200

200

Phasei

3 1041 f i

Cut

-off

freq

Cut

-off

freq

Simulation

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Closed-loop Analysis (Transient Response)Closed-loop Analysis (Transient Response)

Conditions:Input voltage at 162VDCO/P1: 5V @ 0.2A-6AO/P2: 12V at 1A

Simulation Measurement

CH1: Load current CH2: Output voltage of O/P1

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-0.1

0

0.1

0.2

0.3

0.4

3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

Harmonic number

Cur

rent

RM

S (A

)

Measured

Class D Limits

Input Current Harmonics AnalysisInput Current Harmonics Analysis

Measurement

Input voltage at 230VAC/50Hz

Simulated bar charts showed in good agreement with measurement.

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Thermal AnalysisThermal Analysis

Measurement

123.1

65

94

62

66

7870

52

103

93

68

52

Simulation

94

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Transformer DesignTransformer Design

Leakage inductance:

Measurement = 2.787uHSimulation = 2.982uH

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DVT Report – SMPS from other factoryDVT Report – SMPS from other factory

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DVT Report – DVT Report – 100 times faster to know the design fault100 times faster to know the design fault

Stress Percentage176.62%

Rated Current0.77

Measured Current1.36

Measurement

Simulation

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Saturation current observed in experimental measurement

DVT Report – DVT Report – Every component checked include XformerEvery component checked include Xformer

Measurement

Simulation

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Stress Percentage96.00%

Rated Voltage600

Measured Voltage576

A simulated drain voltage of 75W flyback converter with 3 outputs – result = ~580V

DVT Report – DVT Report – MOSFET StressMOSFET Stress

Measurement Simulation

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Evaluation Design Evaluation Design

Measurement Simulation

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After ALLAfter ALL

Traditional Engineer Daily Work

•Day 1 – PowerEsim calculation

•Day 2 – Bench Work::

Day x – PowerEsim recalculation:

:::

•Day30 - FINISH

•Day 1 – start paper calculation•Day 2 – collect data sheets•Day 3 – collect data sheets•Day 4 – find equations•Day 5 – understand equations•Day 6 – start calculation•Day 14 – finish calculation•Day 15 – Bench Work•Day 21 – fs changed•Day 22 – re-calculate design•Day 25 – finish re-calculation•Day 26 – redesign Xformer•Day 27 – MOSFET overstress•Day 28 – redesign Xformer•Day 29 – OP diode overstress

:•Day60 - FINISH

PowerEsim Engineer Daily Work