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Abstract: The approach of this article is to develop a sequential approach of practically designing the SMPS design Which
are examined by me for years practically. The aim is to look on ground levels to clear fundamentals intelligence regarding
SMPS. I had never seen Easy & step- by-step calculations to ideally decide the nature of SMPS. The Step-by-step
calculations illustrated in this article will help you to actually see the practical result on paper before performing it practically.
This also include the expertise tips wherever it is desired for either caution or for intelligence.
Moreover, when you will make the actual schematic using these calculations, you will just need a perfect guidance for
implementing correct component data book. I was also looking to include the probable components that could be referred
but finally I am not including it in this.
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Introduction:
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SMPS Power Supplies
Designing the system step-by step could be realized below. Moreover the block diagram above is a self-explanatory
Universal block diagram of SMPS.
I had enlisted the Sequential formulas below which will clear the insight towards SMPS.
15-minute Charger
Duracell.ca
If No information is available , just assume Eff=0.75 for low output applications & 0.85 for high voltage applications.
1. Maximum input power:
Pin = Po / E ff
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KLn=Po(n)/Po
Here, Po(n) is the maximum output power for nth output.
Usually, if single output from smps is desired, key rule is to consider KL = 1
Where ,
Dch- dc link capacitor charging duty ratio.
Dch is 0.2 to 0.25
Dch = t1 /t2
4. maximum dc link voltage:
Vdc max = sqrt (2 )* V line max
5. maximum DC link ripple voltage:
Change in Vdc max = sqrt (2) * Vlin min V dc min
While calculating this factor, care should be taken as accuracy of this factor affects the system a lot.
6. output reflected voltage:
Vro = Dmax* Vdc min / (1- Dmax)
7. Maximum MOSFET voltage :
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LV and MV Switchgear
w w w .grimard.ca/products
Key rule:
For discontinuous mode , set krf =1
For continuous mode, set kef < 1
If you are making flyback converter to be operated in CCM mode, just prefer to set krf between 0.25 0.5
for universal input range & krf = 0.4 0.8 for European input range.
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Key rule: if no information is available regarding Bsat,for generalized smps, set Bsat between 0.3 to 0.35
tesla
Key suggestion:
Now, determine the proper integer number for NS1 so that resulting Np is larger than Np min Obtained from step
14.
16. The number of turns for the other output , nth output, is determined as:
Ns (n) = [ V0 (n) + Vf(n)* Ns1] / [ V01 +Vf1 ] turns
18. with determing turns of the primary side, the gap length of the core is obtained as :
G = 40* 3.14 * Ae [ {Np^(2)/ 1000Lm}-1/Al ] units in mm
Key information:
The current density is 5A / mm2 when the wire is long (> 1m). when the wire is short with a small number of
turns , a current density of 6-10 A/mm is also acceptable.
Avoid using wire with a diameter larger than 1mm to avoid severe eddy current losses as well as to make winding
easier.
For high current output, it is better to use parallel winding with multiple strands of thinner wire to minimize skin
effect.
Key tip:
Usually, fill factor is in between 0.2 to 0.25 for single output application.
For, multiple output, it is in between 0.15 to 0.2.
20. The maximum voltage & the rms current of the rectifier diode of the nth output are obtained as :
21: Idn rms = Ids rms sqrt ( 1- Dmax /Dmax ) * Vro * Kln/ ( Von + Vfn )
22.
The typical voltage & current margins for rectifier diode are as follows:
23.
where ,
for equation 23 & 23,
Vrrm maximum reverse voltage
I f average forward current of diode.
Trr- maximum reverse recovery time.
24. The ripple current of the nth output capacitor C0n is obtained as :
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Where
Io (n) load current of the nth output
Idc n rms equation 21.
25.
where:
Con- capacitance
Ron- effective series resistance ESR, of the nth output capacitor.
Ion load current
Von- output voltage
Vfn diode forward voltage
If we use single output capacitor, with high ESR, it is possible to meet ripple specification . If further required, use
additional lc filter stages (post filter). When using post filter, be careful not to place the corner frequency too low.
Too low corner frequency make the system unstable or limit the control bandwidth. It is typical to set the corner
frequency of the post filter around 1/10 to 1/ 5 of the switching frequency.
designing a snubber circuit is a vast field for calculations & implementations. But, the key formula is as below:
Where
Ids peak refer equation 9
Fs switching frequency
Lik leakage inductance
Vsn- snubber capacitance voltage At min i/p v & full load.
Vro- reflected output voltage
Rsn- snubber resistor
Key tip:
Vsn should be greater than Vro & It is typical to set Vsn To be 2 to 2.5 times of Vro. Too small Vsn results in a severe
loss in the snubber network as shown in equation 26.
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The leakage inductance is measured at the switching frequency with all other windings shorted.
Key information:
In general, 5 to 10 % ripple is reasonable. Use better quality capacitor, I would recommend it because high voltage
spike affects the performance of Capacitor, so poor quality capacitor would be a worst option to use in such case.
28.
Snubber capacitor Voltage under maximum input voltage & full load condition is obtained as :
29:
If the converter is operated in CCM mode, at the maximum input voltage & full load condition , for equation 28,
I ds2 = [Pin (Vdc max + Vro)/ ( Vdc max * Vro)] + Vdc max * Vro/ [ 2Lm * Fs * ( Vdc max + Vro ) ]
30:
If converter is operated in DCM at maximum input voltage & full load condition :
Key tip:
Check if Vds max is below 90% of the rated voltage of MOSFET Bvdss . The voltage rating of snubber diode should
be higher than BVdss.
Usually ultra fast diodes with 1A current rating is used for snubber circuit.
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The voltage divider network of R1 & R2 should be designed to provide 2.5 to the reference pin of LM431/ Tl 431/ Ka431
32-B:
The Rbias & Rd used together with the opto coupler & the shunt regular LM431 should be designed to provide proper
operating current for the LM431 & to guarantee the full swing of the feedback voltage for switching device used.
In general , the minimum cathode voltage & current for the LM431 are 2.5 & 1mA. Respectively.
32-C
32-D
34: For CCM operation, the control to output transfer function of the flyback converter using current mode control is given
by :
Gvc = [ V01/ V fb ]
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W2 = 1/ RC1* Co1 ;
Wr2 = (1-D)^(2)/[D * Lm * (NS1 /Np)^(2)
Wp = {1+D/ Rl * Co1}
Wp = 2/ [ Rc1* Co1 ]
Where ;
Wi= Rb/ [ R1*Rd* Cf ]
W2c = 1/ [ (Rf+R1)*Cf]
Prasun Kulshrestha, Sr. Design Engineer Hardware, Intellect Systems (i) Pvt Ltd., Nagpur, INDIA
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