Design and Simulation of Power Converters using the Ansoft Power ...
Design and Simulation of Power Converters using the Ansoft Power ...
Design and Simulation of Power Converters using the Ansoft Power ...
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“<strong>Design</strong> <strong>and</strong><br />
<strong>Simulation</strong> <strong>of</strong><br />
<strong>Power</strong> <strong>Converters</strong><br />
<strong>using</strong> <strong>the</strong> Ans<strong>of</strong>t<br />
<strong>Power</strong> Suite”<br />
Presenter: Roberto Prieto<br />
Universidad Politécnica de Madrid (UPM). Spain
The application: Interleaved converters<br />
Outline<br />
<strong>Design</strong> <strong>of</strong> magnetic components for power conv erters <strong>using</strong><br />
converters <strong>using</strong> PExprt<br />
Advantages <strong>of</strong> Integrated magnetics in Interleaved<br />
<strong>Converters</strong><br />
Integrated magnetics component design <strong>using</strong> PExprt<br />
Converter design, including regulation loop: from PExprt to<br />
PExprt to Simplorer<br />
Digital control implementation with Simplorer<br />
System design: from <strong>the</strong> circuit level to <strong>the</strong> system level<br />
level
Ans<strong>of</strong>t <strong>Power</strong> Suite
Paralleling<br />
+<br />
Shift<br />
+<br />
Packaging<br />
Interleaved <strong>Converters</strong> Features<br />
Load
Advantages <strong>of</strong> Interleaved <strong>Converters</strong> (I)<br />
L 1<br />
L 2<br />
IL1 L1<br />
IL2 L2<br />
Ripple cancellation<br />
Small C OUT<br />
IL1 L1<br />
IL2 L2<br />
IL1 L1<br />
IL2 L2<br />
2 converters d = 50%<br />
4 converters d = 25%<br />
I C<br />
I C
Advantages <strong>of</strong> Interleaved <strong>Converters</strong> (II)<br />
V s = 9V, I s = 10A<br />
V s = 24V, I s = 10A
Advantages <strong>of</strong> Interleaved <strong>Converters</strong> (III)<br />
Load<br />
I IN /N
<strong>Power</strong> Converter<br />
Control<br />
Application <strong>of</strong> Interleaved <strong>Converters</strong><br />
Filter<br />
Amp<br />
RF
High Low<br />
Interleaved converters: Automotive<br />
application<br />
DC-DC<br />
42V<br />
400V<br />
DC-DC<br />
DC-DC<br />
12V<br />
12V
Automotive Application: Multi-phase converters.<br />
36 phases<br />
Very small size<br />
SMD<br />
Output components capacitors<br />
Phase currents (A)<br />
Efficiency (%)<br />
2<br />
1.5<br />
1<br />
0.5<br />
0<br />
100.00<br />
97.50<br />
95.00<br />
92.50<br />
90.00<br />
87.50<br />
85.00<br />
82.50<br />
Only power stage<br />
<strong>Power</strong> stage + control<br />
Phase currents<br />
-0.5<br />
0.0E+00 5.0E-06 1.0E-05 1.5E-05 2.0E-05 2.5E-05 2.5E-05<br />
t (s)<br />
SMD is possible<br />
80.00<br />
0 10 20 30 40 50 60 70<br />
Output current (A)
Interleaved <strong>Converters</strong> design with<br />
Simplorer (I)<br />
SMPS Library elements
SMPS library contains a<br />
wide list <strong>of</strong> averaged<br />
<strong>and</strong> switch level models<br />
Simplorer SMPS library
1.00<br />
500.00m<br />
0<br />
6.00<br />
5.00<br />
2.50<br />
0<br />
2.00<br />
Efficiency ~86%<br />
0 5.00<br />
10.00<br />
Output Voltage<br />
0 500.00u<br />
1.02m<br />
Interleaved <strong>Converters</strong> design with<br />
Simplorer (II)<br />
Current at each phase (1.6A p-p)<br />
5.00<br />
4.00<br />
3.00<br />
2.00<br />
9.95m 9.96m 9.98m<br />
10.00m
Magnetic Component design with PExprt (I)
<strong>Design</strong> with PExprt. Step 1: <strong>Design</strong>
PExprt. Step 2: Select & Compare
PExprt. Step 2: Select & Compare
PExprt. Step 3: Optimize
PExprt. Step 4: Circuit level simulation with<br />
Simplorer
Comparison <strong>of</strong> models at circuit level with Simplorer<br />
1.00<br />
500.00m<br />
5.00<br />
4.00<br />
3.00<br />
86%<br />
0<br />
0 5.00<br />
10.00<br />
1.6A p-p<br />
2.00<br />
9.95m 9.96m 9.98m<br />
10.00m<br />
Efficiency<br />
1.00<br />
500.00m<br />
0<br />
0 5.00<br />
10.00<br />
1.00<br />
-1.00<br />
Current at each phase<br />
0<br />
max 84%<br />
Efficiency<br />
Decrease due to<br />
parasitic effects<br />
Phase Currents<br />
1.5A p-p<br />
949.27u 960.00u 980.00u<br />
999.90u
Integrated Magnetics<br />
5.23<br />
4.00<br />
2.00<br />
0<br />
2.00<br />
0<br />
-2.00<br />
Output Voltage<br />
0 500.00u 800.00u<br />
Phase Currents<br />
360.08u 370.00u 380.00u 390.00u 400.00u<br />
Integrated Magnetics vs Discrete<br />
Components<br />
4.94<br />
4.00<br />
2.00<br />
0<br />
13.98<br />
10.00<br />
0<br />
-12.27<br />
Discrete Components<br />
Output Voltage<br />
0 500.00u 800.00u<br />
Phase Currents<br />
360.05u 370.00u 380.00u 390.00u 400.00u
Multiphase<br />
converters<br />
Integrated Magnetics Features in Interleaved<br />
<strong>Converters</strong> (I)<br />
v 1<br />
v 2<br />
v 3<br />
Magnetic<br />
integration<br />
i 1<br />
i 2<br />
i 3<br />
i 4<br />
i 0<br />
Load<br />
Coupling<br />
Multiphase transformer<br />
(several implementations)
Integrated Magnetics Features in Interleaved<br />
<strong>Converters</strong> (II)<br />
v 1<br />
v 2<br />
v 3<br />
i 2<br />
i 3<br />
i O Load<br />
St<strong>and</strong>ard cores
Core A Core B<br />
Winding<br />
phase 2<br />
Phase 3<br />
Core B<br />
Integrated Magnetics Features in Interleaved<br />
<strong>Converters</strong> (III)<br />
Winding<br />
phase 4<br />
Phase 2<br />
Phase 4<br />
Core A<br />
Phase 1<br />
Core B<br />
Winding phase 3<br />
125%<br />
100%<br />
Winding phase 4<br />
75%<br />
50%<br />
25%<br />
0%<br />
Volume comparison<br />
Decoupled<br />
inductor<br />
Core A<br />
Winding phase 1<br />
Integrated Integrated<br />
transformer transformer +<br />
additional inductor
<strong>Design</strong> <strong>of</strong> Integrated Magnetics with PExprt<br />
Features<br />
Frequency dependent<br />
Capacitive effects<br />
Nonlinear core
Simple procedure to define Integrated Magnetics in<br />
PExprt
Flexible Winding Setup Definition for each core leg
PExprt Model: Simplorer link
Different bobbins can be assigned to each core leg
Planar Integrated can also be defined
Circuit level simulation with Simplorer<br />
E1<br />
pwm<br />
pwm1<br />
pwm<br />
pwm2<br />
pwm<br />
pwm3<br />
M1<br />
p<br />
MOSFET_LEG<br />
M2<br />
M1<br />
n<br />
p<br />
MOSFET_LEG<br />
M2<br />
M1<br />
n<br />
p<br />
MOSFET_LEG<br />
M2<br />
n<br />
m<br />
m<br />
m<br />
A<br />
AM1<br />
A<br />
AM2<br />
A<br />
AM3<br />
PExprtLink1<br />
PEX<br />
STEP1<br />
R1<br />
C1
Comparison <strong>of</strong> models at circuit level with Simplorer<br />
1.00<br />
500.00m<br />
0<br />
0 5.00<br />
10.00<br />
1.00<br />
0<br />
-1.00<br />
6.00<br />
5.00<br />
2.50<br />
0<br />
MOSFET_LEG<br />
pwm<br />
m<br />
A<br />
pwm1<br />
M2<br />
AM1<br />
PExprtLink1<br />
n<br />
p<br />
M1<br />
Discrete Integrated<br />
MOSFET_LEG<br />
Efficiency<br />
pwm<br />
m<br />
A<br />
M2<br />
Efficiency<br />
pwm2<br />
AM2<br />
1.00<br />
n<br />
max 84%<br />
1.5A p-p<br />
949.27u 960.00u 980.00u<br />
999.90u<br />
2.00<br />
0 500.00u<br />
1.02m<br />
E1<br />
pwm<br />
pwm3<br />
M1<br />
M1<br />
MOSFET_LEG<br />
m<br />
M2<br />
p<br />
p<br />
n<br />
A<br />
AM3<br />
PEX<br />
500.00m<br />
STEP1<br />
84%<br />
More stable behavior<br />
0<br />
0 5.00<br />
10.00<br />
2.00<br />
0<br />
2.00<br />
6.00<br />
5.00<br />
2.50<br />
0<br />
R1<br />
C1<br />
Integrated<br />
2.2A p-p<br />
949.27uThe 960.00u currents are 980.00u in phase 999.90u<br />
Faster than <strong>the</strong> uncoupled version<br />
2.00<br />
0 500.00u<br />
1.02m
Particular geometries might require Maxwell 3D<br />
2D is feasible<br />
3D is necessary
Automotive Application: Multi-phase converters.<br />
36 phases<br />
Digital control is m<strong>and</strong>atory
1<br />
2<br />
3<br />
Control Implementation: Alternatives<br />
Analog<br />
Continuous blocks: S-Transfer function<br />
Digital<br />
Discrete blocks: Z-Transfer function<br />
Discrete Fixed-Point : Syn<strong>the</strong>sized VHDL code<br />
G(z)<br />
G(s)<br />
Discrete_PID
Digital Control for multiphase <strong>Converters</strong><br />
f = 3kHz
Duty Cycle<br />
Digital Control Implementation<br />
Analog PID<br />
Simplorer blocks<br />
Analog<br />
Implementation<br />
Output Voltage<br />
S<strong>of</strong>t Start<br />
(Electric circuit)
Digital Control Implementation<br />
Discrete PID<br />
(VHDL-AMS block)<br />
Duty Cycle<br />
Digital<br />
Implementation<br />
Output Voltage<br />
Simplorer blocks<br />
S<strong>of</strong>t Start<br />
(Electric circuit)
3.50<br />
3.00<br />
2.50<br />
3.50<br />
3.00<br />
2.50<br />
Digital Control Implementation: Simplorer Results<br />
Output Voltage<br />
250.00u 300.00u 400.00u 450.00u<br />
Output Voltage<br />
250.00u 300.00u 400.00u 450.00u<br />
Continuous time PID (Analog)<br />
20.00<br />
10.00<br />
0<br />
-10.00<br />
Discrete time PID (Digital): sampling = 600kHz<br />
20.00<br />
10.00<br />
0<br />
-10.00<br />
Phase Currents<br />
250.00u300.00u 400.00u450.00u<br />
Phase Currents<br />
250.00u 300.00u 400.00u 450.00u
Digital Control Implementation: Simplorer based<br />
design<br />
Overshot <strong>and</strong> settling time<br />
measurement<br />
Performance evaluation<br />
(better when settling time is short)<br />
Initial simulations<br />
Tendency <strong>of</strong><br />
<strong>the</strong> parameters<br />
Fitness function
Complete system <strong>Power</strong> system<br />
The power system can not be<br />
modeled as an ideal system<br />
The power system inv olves:<br />
involves:<br />
Losses<br />
Dynamic limitations<br />
Temperature issues<br />
Failures<br />
System <strong>and</strong> Sub-System levels
Switch level models<br />
Are based directly on <strong>the</strong> structure<br />
Provide information for each<br />
component in every switching<br />
cycle<br />
Averaged models<br />
Switching information is lost but<br />
structure is kept<br />
There are several techniques like:<br />
State space averaging<br />
Averaged switch modeling<br />
Behavioral models<br />
Based on <strong>the</strong> input-output<br />
behavior<br />
The model is a black box, <strong>the</strong> real<br />
structure is lost<br />
Modeling approaches
SubsistemaGenerad<br />
Vp<br />
+<br />
V<br />
Vm<br />
VMin<br />
Vinp<br />
Vinm<br />
Vinp<br />
Vinm<br />
Vp<br />
Buck<br />
Regulado<br />
42V/28V<br />
Buck<br />
Regulado<br />
42V/28V<br />
Vop A<br />
+<br />
AMbat<br />
V<br />
VMbat<br />
Vom<br />
Vop<br />
Vom<br />
+<br />
V<br />
Vm<br />
SubsistemaCargasNoRe<br />
Vp<br />
VM28<br />
Vm<br />
SubsistemaCargasNoReg2<br />
Vinp<br />
Vinn<br />
Vinp<br />
Vinn<br />
Vinp<br />
Vinn<br />
SubsistemaBaterias<br />
Vinp<br />
Vinm<br />
Half Bridge<br />
Regulado<br />
28V/1.8V<br />
Half Bridge<br />
Regulado<br />
28V/1.8V<br />
Half Bridge<br />
Regulado<br />
28V/1.8V<br />
Voutp<br />
Voutn<br />
Voutp<br />
Voutn<br />
Voutp<br />
Voutn<br />
+<br />
V<br />
+<br />
Vp<br />
V<br />
VMc<br />
Vm<br />
SubsistCargasReg<br />
VMc2<br />
Vp<br />
Vm<br />
SubsistCargasReg2<br />
<strong>Simulation</strong> time<br />
<strong>Simulation</strong> time<br />
-Averaged models -> 157 seconds<br />
-Behavioral models -> 29 seconds<br />
43.00<br />
30.00<br />
20.00<br />
10.00<br />
0<br />
5 times faster!!!<br />
0 25.00m 50.00m 75.00m 100.00m 150.00m
Problems designing power systems<br />
The lack <strong>of</strong> models for each DC/DC converter<br />
The lack <strong>of</strong> information on commercial converters<br />
Difficulty to develop <strong>the</strong> models<br />
Long simulation time<br />
SMPS Library: PTool<br />
All above problems multiplied by <strong>the</strong> number <strong>of</strong> converters<br />
Get optimized VHDL-AMS VHDL AMS models for DC/DC<br />
converters in minutes
PTool converter’s converter s features:<br />
•Input Input characteristics<br />
•Output Output characteristics<br />
•Dynamic Dynamic response<br />
•Static Static response<br />
•Remote Remote control<br />
•Thermal Thermal behavior<br />
•Protections<br />
Protections<br />
•<strong>Power</strong> <strong>Power</strong> sharing<br />
•Cross Cross regulation<br />
SMPS Library: PTool
Simplorer System Level Models<br />
vi_p<br />
vi_n<br />
vo1_p<br />
Behavioral<br />
vo1_n
100.00<br />
50.00<br />
0<br />
Efficiency comparison<br />
Behavioral<br />
Switch level<br />
0 5.00<br />
10.00<br />
Simplorer System Level Models<br />
3.40<br />
2.00<br />
0<br />
vi_p<br />
vi_n<br />
vo1_p<br />
Behavioral<br />
vo1_n<br />
System Level <strong>and</strong> Switch<br />
Total simulation time: 700us<br />
0 200.00u 400.00u 520.00u<br />
Behavioral: 0.992s Switch level: 352.54s
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