Design and Analysis Artificial Intelligence (AI) research for Power Supply - Power Electronics Expert System (PEES)

Wei Li, Jianping Ying

Delta Power Electronics R&D Center 238 Minxia Road, Caolu Industry Zone, Pudong, Shanghai, 201209, China

Tel: 86-21-68723988-8243, Fax: 86-21-68723996, Email: li.wei@deltaww.com.cn

Abstract This paper introduces design and analysis artificial intelligence (AI) research for power supply named power electronics expert system (PEES). The paper will demonstrate expert system feasibility and summary the architecture. Purpose, main function blocks and runtime performance will be reviewed. Optimized design and analysis models with Delta experts experience knowledge as rules are applied in the system. Rules dynamic check refresh engine ensures they can be changed or updated and extension when needed anytime. Power loss of semiconductor devices and magnetic components, control loop small signal analysis, virtual standard hardware circuit, close loop circuit electrical performance simulation, rapid thermal simulation are integrated into the system. Components reuse technique, Object oriented programming (OOP), ActiveX controls, Dynamic link library (DLL) are widely used in tools software development. The system is stable, flexible and extensible. I. INTRODUCTION Now, Business Intelligence (BI) [1] is in full swing when Enterprise Resource Planning (ERP) is not enough for company growth. Why it focus on Intelligence and is there some tips for power supply field? Lets review. In power supply products development, what bother us? All power supply manufactures face such problems: Time is very tight to do the pre-evaluation because the customers requirements are complex, changeable and stringent. Lack of enough experienced engineers. On the other words, Lack of components optimal design and loss analysis; Shortage of AC small signal design and system stability; Difficulties in system optimization; Construct different simulation modeling; Thermal managements. These will obviously increase the cost. [3], [4] But we cant find a design tool which gives total solution for all of the problems. Challenge means chance, We want to build up artificial intelligence (AI) [2] tool research for design and analysis named Power Electronics Expert System (PEES) as problems terminator. AI means the science and engineering of making intelligent machines. Expert system is an import branch of AI research. An expert system is a computer program that simulates the judgement and behavior of a human or an organization that has expert knowledge and experience in a particular field. Typically, such a system contains a

knowledge base containing accumulated experience and a set of rules for applying the knowledge base to each particular situation that is described to the program. Reduce costs, Time to market, PEES aims at shortening power supply design period with existing expert experience knowledge and saving debug resource through virtual standard hardware. PEES allows user to design a power supply in only few minutes without searching parameters from component datasheets. PEES can show efficiency report in different loads or different input voltage and gives loss distribution without user calculation. PEES can complete optimized design compensator parameters with small signal analysis and show all kinds of gain or phase characteristic bode plot curves. PEES can support circuit transient and small signal simulation in SIMPLIS with self_created models. PEES use experienced standard hardware parts to build up prototype and selects an experienced placement to run rapid thermal simulation. Patent system, Technical marketing information, Technical BBS, Projects managements are developed in Simplified Chinese or Traditional Chinese as PEES auxiliary systems. The user only input power supply specifications and click, all of these function blocks will be realized. [3],[4] We can also seen PEES as a BI system for the power supply engineers based on Specialist knowledge. PEES can self study based on data dinning and statistic. General views as [Fig. 1].

Fig. 1 PEES profile view

978-1-4244-1874-9/08/$25.00 2008 IEEE

2009

II. DEMONSTRATE SYSTEM FEASIBILITY AI system should simulate human intelligence. In order to develop PEES, firstly, we should summary actual power supply unit iteration design or analysis process with specialists brainstorm. [See Fig. 2] Then PEES should include following function blocks: [3], [4] Expert engine. 1) Experience knowledge as rules work well. 2) Ensures the experience rules can be updated by specialists when needed anytime. 3) Self study with data dinning and statistic. Expert knowledge BASE 1) Common topologies with diode rectifier,SR 2) Semi-conductor loss evaluation algorithm 3) Magnetic loss evaluation algorithm 4) Optimized components design models 5) Control models and stability analysis 6) Optimized design controller 7) EMI filter design and analysis 8) Virtual standard hardware circuit 9) Simulation models 10)Thermal management guide placement. Core driver engine Ensures knowledge base, expert engine,

Fig. 2 PEES process Secondly, accumulate experts experience as rules to guide how to select topology, how to select components, etc. We must check and build core algorithm models for optimized design as knowledge base. [See Fig. 3].

Fig. 3 Visualize Expert system Finally, abstract the concept class and summary the Expert System architecture. [See Fig. 4]

GUIs and databases cooperate well to satisfy user engineers operation. Database maintenance tools

Fig. 4 PEES architecture Now, Expert system architecture had been achieved.

Ensures databases parameters can be added removed, modified to meet the latest RFQ.

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III. MAIN FUNCTION BLOCKS IMPLEMENT 1. Expert engine How to select topology? Take this as a sample to demo the same engine principle. [See Fig. 5] The close loop rules check method to ensure update and self study. When more than 3 specialist role users check in, audit the self study results. If successful, new rules will be sent to all PEES client computers, if not successful, expert engine self update study logic to avoid next same error. The expert engine also ensures that specialist role users can put in new rules manually as another way, the rule can be used in specialist own computer. Only after check by the other two specialists, the rule will be sent to all clients.

Same way, PEES builds standard class model to calculate semiconductor loss, make the switching on and off waveform for users understanding. Specialist three ports model for Mosfet and reverse recovery Diode model are works well in the background calling by core driver engine. [5][6][7] [See Fig. 7]

Fig. 7 Mosfet switching off waveform and loss After optimized design components, PEES can optimize the other work conditions with keep the same components; PEES can analysis loss breakdown and efficiency at different load or input voltage. PEES is not only a design tool but also analysis tool with user input power components by manual. [See Fig. 8]

Fig. 5 Experience engine self study 2. Expert knowledge BASE The expert knowledge BASE is the core algorithm libraries which are developed into DLLs. DLL means dynamic link library who is working only when user use this function library. Take an example: Almost every topology will design inductor optimization. We package the inductor trade off optimized algorithm model into a standard class in a DLL, the input parameters are current waveform etc. [8][9][10][See Fig. 6]

Fig. 8 Loss breakdown and optimize work frequency Here we use two design samples to check the accuracy of loss and efficiency. We do the comparison between analyzed by PEES and experimentation test result. Fig. 9 is the efficiency comparison of a 65W Flyback adapter. PEES analyzed results and sample tested results at various input voltage and at various output load are compared respectively.

Fig.9a. Flyback efficiency vs. input voltage @Full load Fig. 6 Inductor standard class optimized model

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Specialists knowledge is integrated into all kinds of dynamic link algorithm classes with different ID. Class ID name rule is Topology_Mode_Block. The core driver engine will dynamic call the class to meet users selection and operation. Take PSFB_CMC_Gvd as an example to show block cycle . [See Fig.12]

Fig.9b. Flyback efficiency vs. output current@150dc input Fig.10 is the efficiency comparison of a 1000W PFC. PEES analyzed results and sample tests results at various input voltage and at various output load are compared respectively.

Fig.10a. Efficiency vs. input voltage@Full load

Fig. 12 Phase shift full bridge (PSFB) block cycle models PEES shows bode plot characteristic curves to help user understand small signal in frequency domain. PEES can analysis user actual sample compensator performance in bode plot. Let user import AP200 test loop curves to compare. On the other hand, PEES can design compensator automatically and optimize the design result meet users specification. [See Fig. 13]

Fig.10b. Efficiency vs. output current@220 ac input From the verification, the error at light load is little more than at heave load, the light load algorithm modeling BASE should be improved next step. PEES complete power plant design very well and quickly. How to optimize compensator with small signal model? How to analysis stability? [11][12][13][14][15] PEES provides a very good solution, user only click with mouse and input the specifications follow the design steps flow. [See Fig. 11]

Fig. 11 Controller design steps

Fig. 13 Optimized design compensator flow chart

2012

Here we use a 1000W phase shift full bridge(PSFB) total loop gain and phase characteristic bode plot comparison between PEES analyzed results and tested results by AP200. The pink curves are PEES analyzed results and blue curves are tested results in actual sample which were imported by From AP200 button. [See Fig.14]

Example: Flyback common mode and differential mode original noise models and runtime analysis results.

Fig. 16 Flyback CM,DM models and noise analysis In order to save debug time and guide components placement, PEES builds virtual standard hardware circuits functions block. It is undergoing, here only show the idea. Use PFC UCC3818 control parts to explain. First step: cut the function blocks;
CT111 R845 CT1+ R817 0 REF 100 R851 D836 1000P C842 1SS355 DRV1 VCP 390pF C853 SF1 MOUT UDZS TE-17 5.1B ZD808 IA C RLZTE-11 3.3A ZD809 R852 C843 100P 12K R862 16K C849 2.2u 2.2u C845 47P C865 OV_LIMIT C885 2.2u/16V C850 2.2u/16V D837 1SS355 16K R856 MMBT4403 2.2u/25V C820 1u C848 0.01u C840 IC831 UCC3818DTR 0.022u C846 0.068u C847 R859 10.5K R854 75K R857 34.8K V/SENSE 100P C856 2.2u/25V C855 Q865 SF1 27K R853 C852 100P R858 47 PFC_ENA /OVP 1 R846 270 R847 26.1KF R848 5.6K R849 2.2M R825 2.2M R826

470P C841 27.4KF R855

100P C844

Fig. 17 PFC UCC3818 control circuit

Second step: form the integrated parts (IP);

Fig. 14 1kw PSFB sample machine total loop comparison. PEES can complete control circuit design or analysis very well and quickly. EMI filter will be considered. Design filter with experienced modeling based on noise models analysis. Also provides analysis function.

Fig. 18 Virtual standard block for UCC3818 control Third step: build the layout standard blocks as PCB IP;

Fig. 15 EMI filter design and analysis implement

Fig. 19 Standard block in PCB

2013

R878 22.6K

Final step: design power supply with the standard blocks. PCB blocks placement rules will limit other components.

Fig. 20 Standard parts form power supply In order to convince customers, PEES builds special simulate BASE to do electrical performance automatically simulation and simplified thermal simulation with commercial simulation tool such as PSPICE, SIMPLIS and Flotherm. PEES automatically start up the simulation tool, PEES automatically provide expert simulation models from specialist simulation BASE. Then PEES run script program to update all design or analysis parameters for simulation models, then user can simulate very easily. Thermal 3D simulation is very slow, we give a total solution. [See Fig. 21]

Fig. 22 Rapid thermal evaluation *Limited by this papers space, algorithm and much more detail information are omitted. *The core driver engine and database maintenance tools realization focus on software architecture theory. Base on operation events and messages driver. The two parts are omitted in this paper. IV. PEES AUXILIARY SYSTEMS Somebody will ask that PEES only give a total AI solution for technical aspect design and analysis. How to resolve non technical problems before the power supply unit prototype is finished? PEES auxiliary systems meet the requirements. The subsystems are developed in Chinese. PEES builds subsystem Technical marketing to cover marketing information for PEES users browsing what are collected by technical sales dept. [Fig. 23]

Fig. 23 Technical marketing subsystem PEES builds child subsystem Patent system to integrate the key project patents and monitoring patents for PEES users what are collected by patent team.[Fig. 24]

Fig. 21 PEES thermal solution [Undergoing] Now, PEES expert knowledge BASE had finished the research in rapid thermal evaluation and simplified thermal simulation. All of the function blocks will improve the simulation speed much more quickly. Take rapid thermal simulation knowledge base as an example. [See Fig. 22]

Fig. 24 Patent subsystem

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Of course, Engineers will cooperate to finish a project. How to give more support in this process? PEES builds subsystem Projects management system to help PEES users improve the cooperating efficiency. [Fig. 25]

Flyback, single switch Forward or dual switches Forward, LLC HB and FB are integrated into PEES. Diode rectifier and SR are both supported. The system is stable, flexible and extensible based on software development techniques, such as Components reuse technique, OOP, ActiveX controls, DLL etc. So more topologies, more components, more experience rules, more function blocks will be integrated into PEES very quickly. ACKNOWLEDGMENT PEES had been developed for more than 3 years in Delta Electronics. I am appreciated for all the teammates: Bin Wu, Ke Wang, Jian Jiang, Peng Wei, Lei Xu, Qingyou Zhang, Yuling Huang, Bo Wan, Xinchun Liang, Zhijie Zhu, Wenxin Chen, Yueqing Wang, Xinmin Bai, Yanxiong Bian, Qinghua Su,. Thanks for coaching from Miss Chee Pan and Dr. Jianping Ying. References
[1] http://en.wikipedia.org/wiki/Business_intelligence [2] http://en.wikipedia.org/wiki/Artificial_intelligence [3] Wei Li, Chee Pan, JianPing Ying, "Power Electronics Expert System (PEES) user manual version 2.0". [4] Wei Li, QingHua Su, Chee Pan, JianPing Ying, "Power Electronics Expert System (PEES) online help version 2.5". [5] YanXiong Bian, Jian Jiang, Wei Li, HaoYi Ye, JianPing Ying, "Prediction of MOS switching-off loss based on datasheet", DPEC seminar 2007. [6] Yuling Huang, "MOSFET switching process and loss analysis derived from experimental method," DPEC seminar 2004. [7] Yueing Wang, Qingou Zhang, Jianping Ying, "Prediction of PIN Diode Reverse Recovery,"DPEC seminar 2003. [8] Xinchun Liang,Yunxiu Li, Wei Chen, "Loss Analysis and Selection Guidline of Litz Wire,"DPEC seminar 2003. [9] Xinchun Liang,Yunxiu Li, Wei Chen, "Winding Loss Calculation fot Toroidal Inductors under Sinusoidal Excitation,"DPEC seminar 2003. [10] Xinchun Liang, Yuequan Hu, Wei Chen, "Winding Loss Calculation fot Toroidal Inductors under Sinusoidal Excitation,"DPEC seminar 2002. [11] E.X.Yang, F.C.Lee and M.M.Jovanovic, "small signal modeling of power electronic circuits by extended describing function concept", VPEC Seminar 1991 [12] R.D.Middlebrook and S.Cuk, "A general unified approach to modeling switching converter power stages", in PESC 1976. [13] Jim Groves, "small signal analysis using harmonic balance methods", PESC1991. [14] R.B.Ridley, "A new Small-signal model for current-mode control", Ph.D.Dissertation, Virginia Polytechnic Institute and State University, Blacksburg, Nov.1990. [15] W.Tang, F.C.Lee, R.B.Ridley and I.Cohen, "Charge Control:Modeling, Analysis and Design", PESC1992.

Fig. 25 Projects management subsystem PEES builds subsystem Technical BBS to note down PEES users feedback, sharing, questions. PEES specialists will answer the questions and share some experience. It is a technical discussion brainstorm platform. [Fig. 26]

Fig. 26 Technical BBS subsystem PEES will develop more subsystems with AI thinking and experience knowledge to resolve what bothers us. If you have good ideas or troubles, you can feel free to contact with me. V. SUMMARY AND CONCLUSION The paper describes how to realize design AI and analysis AI for power supply engineering. The paper demonstrates expert system as a solution with completed architecture. It reviews PEES purpose, main function blocks, runtime results performance comparison. PEES algorithm models plus specialists experience rules are accurate enough for pre-evaluation and power supply loss analysis. After all, there are some errors in light load, algorithm models will be updated with latest research result. PEES can give much more help to engineers with AI expert system concept. Till now, Buck, Boost, PFC, Bridgeless PFC, PSFB,

2015