Taufik Tutorial PDF

Practical Design of Buck Converter
Dr. Taufik
Associate Professor
Electrical Engineering Department
California Polytechnic State University, USA
taufik@calpoly.edu
http://www.ee.calpoly.edu/faculty/taufik
Tutorial Outline
• Brief Review of DC-DC Converter
• Design Equations
• Loss Considerations
• Layout Considerations
• Efficiency Improvement
• Synchronous Buck
• Resonant Buck
• PWM Controller
• Multiphase
PECON 2008, Johor Bahru, Malaysia Practical Design of Buck Converter Taufik | Page 2
Review: DC-DC Converter Basics
• A circuit employing switching network that
converts a DC voltage at one level to
another DC voltage
• Two basic topologies:
– Non-Isolated
• Buck, Boost, Buck-Boost, Cuk, SEPIC
– Isolated
• Push-pull, Forward, Flyback, Half-Bridge,
Full-Bridge
• When ON: The output voltage is the same as the input

voltage and the voltage across the switch is 0.
• When OFF: The output voltage is zero and there is no current
through the switch.
• Ideally, the Power Loss is zero since output power = input
power
• Periodic opening and closing of the switch results in pulse
output
T DT
1 1 ton
V 0 = ∫ vo ( t ) dt = i
∫ V dt = V Di Dutycycle = D = ton f s =
T 0 T 0 T
• Duty Cycle range: 0 < D < 1
• Two ways to vary the average output voltage:
– Pulse Width Modulation (PWM), where ton is varied while the
overall switching period T is kept constant
– Pulse Frequency Modulation (PFM), where ton is kept constant
while the switching period T is varied
Source Side Load/User Side
DC-DC
Converter
Wants: Wants:
to switch
DC Voltage and DC DC Voltage and DC
Current Current
Wants:
No AC Component
No Harmonics
Source Side Load/User Side

DC-DC
Converter
Gets: Wants:
Current with some Voltage with some

ripple ripple
Needs Filtering
What is Buck Converter?
• A dc-dc converter circuit that steps down a dc voltage at
its input
• Non-isolated hence ideal for board-level circuitry where
local conversion is needed
– Cell-phones, PDAs, fax machines, copiers, scanners,
computers, anywhere when there is the need to convert
DC from one level (battery) to other levels
• Widely used in low voltage low power applications
• Synchronous version and resonant derivatives provide
improved converter’s efficiency
• Multiphase version supports low voltage high current
applications
The Basic Topology
Controller
• Two types of Conduction Modes

– Continuous Conduction Mode (CCM)
where Inductor current remains positive
throughout the switching period
– Discontinuous Conduction Mode (DCM)
where Inductor current remains zero for
some time in the switching period
The Basic Topology
Steady State Analysis of CCM Buck: Transfer Function
• Inductor is the main storage element

• Transfer function may be derived from Volt Second
Balance:
– Average Voltage across Inductor is Zero in steady state
– Inductor looks like a short to a DC
VL = vLonton + vLoff toff = 0

CCM Buck: Transfer Function
• When the switch is closed or ON

– Diode is reverse biased since
• Cathode (at Positive of Input) more
positive than Anode (at 0 volt)
– Voltage across inductor: vLon =VS −VO
– Recall that: D = ton/T
– Then, duration of on time, ton: ton = DT
• When the switch is OPEN or OFF

– Inductor discharges causing its voltage to reverse polarity
– Diode conducts since
• Anode (0 volt) is more positive than the Cathode (at
some negative voltage)
– Voltage across inductor: vLoff = −VO
– Recall that: toff = T – ton = T – DT Î t = 1− D T ( )
off
vLonton + vLoff toff = 0
(VS − VO ) DT + ( −VO )(1 − D ) T = 0

VS D − VO D − VO + VO D = 0
VO = DVS
• Average output voltage is LESS than Input Voltage
CCM Buck: Sizing Components
For MOSFETs: Vds and Id L and Ipk
Vrrm, and If C, V and Irms
CCM Buck: Inductor Current
• When switch is ON, Inductor is charging:
di L diL VS − VO
v L = V S − VO = L = =⊕
dt dt L
VS − VO
ΔiLon = Δton
L
VS − VO
ΔiLon = DT
L
• When switch is OFF, Inductor is
discharging:
diL diL −VO
vL = −VO = L = = −
dt dt L
−V
ΔiLoff = O Δtoff
L
−VO
ΔiLoff = (1 − D ) T
L
Average Inductor
Current = Average
Output Current = Vo/R
ΔiL
• We can then determine ILmin and ILmax

ΔiL V0 1 ⎡V0 ⎤ ⎡ 1 (1 − D) ⎤
I L min =IL− = − ⎢ (1 − D)T ⎥ = V0 ⎢ − ⎥
2 R 2⎣ L ⎦ ⎣ R 2 Lf ⎦
Δ iL V0 1 ⎡ V0 ⎤ ⎡ 1 (1 − D ) ⎤
I L max = I L + = + ⎢ (1 − D )T ⎥ = V0 ⎢ + ⎥
2 R 2⎣L ⎦ ⎣ R 2 Lf ⎦
Sizing Inductor: Critical Inductance
Minimum Load
(output current)
• ILmin is used to determine the Critical Inductance (Minimum

Inductance value at which the inductor current reaches Boundary
Conduction Mode)
• Any inductance lower than critical inductance will cause the buck to
operate in Discontinuous Conduction Mode
• Requirement is set either by means of maximum ∆iL or by
specifying the minimum percentage load where converter still
maintains CCM
• Set ILmin = 0, then solve for L = LC, then choose L > 1.05*LC
ΔiL ⎡ 1 (1 − D) ⎤ (1 − Dmax ) Rmax

I L min = 0 = I L − = V0 ⎢ − ⎥ LC =
2 ⎣ Rmax 2 LC f ⎦ 2f
Sizing Inductor: Critical Inductance
(1 − Dmax ) Rmax
LC =
2f
Calculated at Minimum • Calculated at Minimum Output

Input Voltage Current = Rmax = Vo/Iomin
• Iomin is either given as
percentage of load to maintain
CCM, e.g. 10% load with CCM
• Switching frequency normally
chosen by the designer • Or, Iomin is calculated as
specified by maximum ∆iL,
• The higher the switching
such that Iomin = ∆iL/2
frequency, the smaller the required
critical inductance, i.e. beneficial
for reducing size of Buck
Sizing Inductor: Peak Current
Maximum Load
(output current)
• ILmax is used to determine peak current rating of Inductor

• Worst case maximum inductor current occurs at maximum
load Î Maximum output power rating per specified required
output voltage
Calculated from
ΔiL ⎡ 1 (1 − Dmin ) ⎤
I L max =IL+ = V0 ⎢ + Highest Input
⎥
2 R
⎣ min 2 Lf ⎦ Voltage
Chosen inductance value as

discussed previously
Sizing Switch: Voltage Rating
• With ideal diode, the Vswitch-max = Vinmax

• For non-ideal diode, Vswitch-max = Vinmax + VF where VF is the
maximum forward drop across the diode (calculated at
maximum load current)
• Use safety factor of at least 20%
• For MOSFET, the rating would be VDSmax
Sizing Switch: Current Rating
• Switch current rating is calculated based on average

value
• Draw switch current waveform and then compute the
average value
• By KCL, Inductor Current = Switch Current + Diode Current
• During tON, Inductor current equals switch current
• During tOFF, Inductor current equals diode current
Switch Current Waveform
iL
ON OFF ON OFF ON OFF

t
T 2T 3T
iSwitch
iDiode
Switch Current Waveform for Current Rating
iLmax
iSwitch
iLmin
Average Value
ON ON ON
t
0 T 2T
I Switch =
( iL min + iL max ) ⋅ ton
2 ⋅T
( [i L max − ΔiL ] + iL max ) ⋅ DT ( 2iL max − ΔiL ) ⋅ D
I Switch = =
2 ⋅T 2
⎛ ΔiL ⎞
I Switch = ⎜ iL max − ⎟ D = I L ⋅ D = Io ⋅ D
⎝ 2 ⎠
I Switch − max > I o max ⋅ Dmax

MOSFET Rating Example
Sizing Diode (Schottky): Voltage Rating
• Known as PIV (Peak Inverse Voltage) or VRRM is the

maximum voltage across the diode
• With ideal switch, the VRRM = Vinmax
• For non-ideal diode, VRRM = Vinmax + VSW where VSW is the
maximum forward drop across the switch (calculated at
maximum load current)
• Allow at least > 20% safety factor
Sizing Diode (Schottky): Current Rating
• Same approach as that for the switch current
iDiode Average Value
OFF OFF OFF

t
T 2T 3T
( iL min + iL max ) ⋅ toff

IF =
2 ⋅T
IF =
([iL max − ΔiL ] + iL max ) ⋅ (1 − D ) T =
( 2iL max − ΔiL ) ⋅ (1 − D )
2 ⋅T 2
I F = I L ⋅ (1 − D ) = I o ⋅ (1 − D )
I F > I o max ⋅ (1 − Dmin )
Schottky Diode Rating Example
Sizing Output Capacitor: Voltage Rating
• Capacitor Voltage should withstand the maximum output

voltage
– Ideally: Vcmax = Vo + ∆Vo/2
– More realistic: Capacitor has ESR (Equivalent Series
Resistance) which worsens ∆Vo
– Output voltage ripple contributed by ESR is (ESR * ∆IL)
– Suppressing ripple contribution from ESR
• Reduce ESR (Paralleling Caps, Low ESR Caps)
• Reduce ∆IL by increasing L or increasing switching frequency
Sizing Output Capacitor: Minimum Capacitance
• The AC component (ripple) of inductor current flows

through the capacitor, leaving the average flowing
through the load
• Capacitor current waveform will look like:
iC
t
T 2T 3T
Sizing Output Capacitor: Minimum Capacitance
+Q
iC
-Q t
T/2
VO
1 ⎛ T ⎞ ⎛ ΔiL ⎞ ΔiL (1 − D ) T (1 − D )VO
q = Area ⋅ Δ = ⎜ ⎟ ⎜ ⎟= = L =
2 ⎝ 2 ⎠⎝ 2 ⎠ 8 f 8f 8 Lf 2
q (1 − D ) VO (1− D)
q = C ⋅ ΔVo ⇒ C = = 2
=
ΔVo 8 Lf ΔVo 8 Lf 2 ( ΔVo VO )
C=
(1 − Dmin )
8 Lf 2 ( ΔVo VO ) Percent Vopp
Sizing Output Capacitor: RMS Current Rating
iLmax – Io = ∆iL/2
iC
t
T 2T 3T
iCpk ΔiL 2 (1 − D ) VO
iCrms = = =
3 3 2 3Lf
iCrms =
(1 − Dmin ) VO
2 3Lf
Sizing Input Capacitor: Voltage Rating
• Capacitor Voltage should withstand the maximum input

voltage
– Ideally: Vcmax = Vinmax
– More realistic: Capacitor has ESR (Equivalent Series
Resistance) contributes to capacitor loss
– Minimizing loss contribution from ESR
• Reduce ESR (Paralleling Caps, Low ESR Caps)
Sizing Input Capacitor: Minimum Capacitance
iLmax – D*IO
iC
– D*IO t
T 2T 3T
q = Area ⋅ = toff ⋅ D ⋅ I O = (1 − D ) T ⋅ D ⋅ I O =
(1 − D ) ⋅ D ⋅ IO
f
(1 − D ) ⋅ D ⋅ IO
q f (1 − D ) ⋅ D ⋅ IO
q = C ⋅ ΔVin ⇒ C = = =
ΔVin ΔVin f ΔVin
C=
(1 − D ) ⋅ D ⋅ I O max
f ΔVin
Sizing Input Capacitor: RMS Current Rating
iLmax – D*IO
iC
– D*IO t
T 2T 3T
2 2
I Crms = ( I Switch−rms ) − ( I switch−avg )
2
⎛ ⎛ ⎡ ΔiL ⎤ ⎞ ⎞ 2
I Crms ⎜
= I o D ⎜⎜1 + ⎢ ⎟
⎥ ⎟⎟ − ( D ⋅ I o )
⎜ ⎝ ⎣ 2 ⋅ Io ⎦ ⎠ ⎟
⎝ ⎠
To Summarize
⎡ 1 (1 − Dmin ) ⎤
I L max = V0 ⎢ + ⎥
I Switch − max > I o max ⋅ Dmax R
⎣ min 2 Lf ⎦
Vswitch-max = Vinmax (1 − Dmax ) Rmax
LC =
2f
C=
(1 − Dmin )
8 Lf 2 ( ΔVo VO )
I F > I o max ⋅ (1 − Dmin )
Vcmax = Vo + ∆Vo/2
VRRM = Vinmax (1 − Dmin )VO
iCrms =
2 3L
Simple Buck Design: 12V to 2.5V 1A
Given: Vs := 12V Vo := 2.5V Iomax := 1A
Ioccm := 0.1A %Vo := 1% f := 50kHz
Solution:
Vo
D := D = 0.208
Vs
Inductor:
( 1 − D) Vo −4
Lcrit := ⋅ Lcrit = 1.979 × 10 H
2 ⋅f Ioccm
−6
Choose: L := 200 ⋅10 H
( 1 − D) ⋅Vo
ILmax := Iomax + ILmax = 1.099 A
2 ⋅L ⋅f
( 1 − D) ⋅Vo
ΔIL := ΔIL = 0.198 A
L ⋅f
MOSFET:
Vds := Vs Vds = 12 V
Id := D⋅Iomax Id = 0.208 A
Diode:
Vrrm := Vs Vrrm = 12 V
If := ( 1 − D) ⋅Iomax If = 0.792 A
Capacitor:
%Vo⋅Vo
Vcmax := Vo + Vcmax = 2.513 V
2
( 1 − D) 1 −5
C := ⋅ C = 1.979 × 10 F
2 %Vo
8 ⋅L⋅f
−6
Choose Co := 50 ⋅10 F
( 1 − D)
%Vo := %Vo = 0.396 %
2
8 ⋅L⋅f ⋅Co
Simple Buck Design: 12V to 2.5V 1A L1
1 2
200u
-
+
S1
-
+
V1 Sbreak D1 R1
12 Dbreak C1
2.5
50u
V1 = 0 V2
V2 = 1
TD = 0
TR = 10n
TF = 10n
PW = {(3.185/12)*(1/50k)}
PER = {1/50k}
1.25A Inductor Current
1.00A
SEL>>
0.59A
I(L1)
2.0A
Input Current
1.0A
0A
3.6800ms 3.7000ms 3.7200ms 3.7400ms 3.7600ms 3.7800ms 3.8000ms 3.8182ms
-I(V1)
Time
Non-ideal Buck: Loss Considerations
• When efficiency estimation is required in the
design, losses in Buck circuit should be
considered
• Several major losses to consider:
– Static loss of MOSFET
– Switching loss of MOSFET
– MOSFET Gate Drive Losses
– Static loss of diode
– Switching loss of diode
– Inductor’s copper loss
– Capacitor’s ESR loss
Static Loss of MOSFET
• With MOSFET, its on resistance RDSon directly impacts
the static loss
• RDSon depends on applied gate voltage and MOSFET’s
junction temperature
Static Loss of MOSFET
• Recall, switch current:
iLmax
iSwitch
iLmin
Average Value
ON ON ON
t
0 T 2T
• Static loss for MOSFET with RDSon:

2
Pstatic = I switch − rms ⋅ RDSon
2
⎛ ⎛ ⎡ ΔiL ⎤ ⎞ ⎞
Pstatic = ⎜ I o D ⎜⎜1 + ⎢ ⎥ ⎟⎟ ⎟ ⋅ RDSon
⎜ ⎝ ⎣ 2 ⋅ Io ⎦ ⎠ ⎟
⎝ ⎠
Switching Loss of MOSFET
• The switching loss depends on how the voltage and current
overlaps
• May be approximated with a scenario where voltage and
current start moving simultaneously and reach their
endpoints
• The overlap causes power loss (V x I)
• Will assume to occur both at turn-on and turn-off transitions
turn on Io Io turn off

VIN VIN
0
ton toff
Switching Loss of MOSFET
turn on Io Io turn off
VIN VIN
ton toff
I oVinton I oVin toff

P(ton ) = P (toff ) =
6T 6T
I oVinton I oVintoff
Pswitching = P(ton ) + P(toff ) = +
6T 6T
I oVin
Pswitching = ( ton + toff )
6T
Switching Loss of MOSFET & Gate Drive Loss
• When MOSFET is off, its output capacitance Coss is
being charged Î translates to loss
1
PC os s = COSSVin2 f
2
• Gate drive loss comes from the total gate charge Qgate
and the gate drive voltage Vgate used
1
Pgate = QgateVgate f
2
Static Loss of Diode: Forward Loss
• Losses that occur during diode’s fully on (forward
loss) and fully off (reverse loss) conditions
• Forward loss come from the product of diode’s
forward voltage (VF) and forward current (IF), in
addition to the rms loss due to diode dynamic
resistance, rd
j 2
Pforward = V f ⋅ I f + I f ⋅ rd
Static Loss of Diode: Forward Loss
From datasheet
Pforward = V f ⋅ I f + Ij2f ⋅ rd
I f = (1 − D ) ⋅ I o (1 − D ) ⎡ I 2 2
Ijf = + I
⎣ max min + I max ⋅ I min ⎤⎦
3
Static Loss of Diode: Reverse Loss
• Loss occurs when the diode is in the fully off or non-
conducting condition
Preverse = Vr ⋅ I r ⋅ (1 − D )
Switching Loss of Diode: Turn On Loss
• The switching behavior at turn-on is characterized by a
low value of peak forward voltage (VFP) and forward
recovery time (tfr)
PON = 0.4 ⋅ (VFP − V f )⋅ t fr ⋅ I f ⋅ f
Switching Loss of Diode: Turn On Loss
• Both VFP and tfr are normally plotted against dId(t)/dt in the
datasheet, whereas dId(t)/dt itself is also available in the datasheet
for a given set of conditions
Switching Loss of Diode: Turn Off Loss
• Turn-off loss constitutes appreciable switching losses
due to the overlapping of diode voltage and current at
turn-off with its associated reverse-recovery time
Id0
t rra = I rrm dI d
( dt t1( rr )
)
t rrb = 1.11 ⋅ (t rr − t rra )
[t 2rr , t3rr ] = k rr ⋅ t rrb
Id0
Poff = 0.5Vds I d 0 dI d
(
+ 0.033Vd 0 I rrm t rra + Vd 0 I rrm 0.467 − 0.433k rr + 0.15k rr2 t rrb )
dt
( t1( rr ) )
Inductor’s Copper Loss
• Inductor’s winding is made of copper and hence
inherently it will have resistive loss
Average
Inductor
Current, I
• With inductor’s dc resistance of RL and inductor’s rms

current, the copper loss of inductor is:
2
i
PL = I L RL
2
i 1 ⎛ ΔiL ⎞
IL = I 1+ ⎜ ⎟
3 ⎝ 2I ⎠
Inductor’s Core Loss
• Factors affecting core loss: switching frequency F,
temperature, flux swing B
• General form:
Core Loss = Core Loss/Unit Volume x Volume

Where,
Core Loss/Unit = k1 x Bk2 x Fk3
• Constants k1, k2, and k3 are normally provided by the

core manufacturers
Capacitor’s ESR Loss
• Real world capacitors posses ESR (Equivalent Series
Resistance)
• ESR can measured with, for example, Capacitor Wizard
iC
t
T 2T 3T
2
• Loss due to Capacitor’s ESR is: PESR j
= I C ESR
j ΔiL
IC =
2 3
Buck Design With Losses
Buck Design with Losses Taufik
Maximum Output Power: −6

Pomax := 120W μ ≡ 1⋅ 10
Nominal Output Voltage: −3
Vonom := 12V m ≡ 1⋅ 10
Nominal Input Voltage: Vinom := 24V
Switching Frequency: Fs := 250kHz
Minimum Percent CCM: Iccm := 10%
Maximum Ripple Percentage: Vopp := 2%
Design Calculations and Sizing Components:
Vonom
Nominal Duty Cycle: D := = 0.5
Vinom
⎛ Vonom2 ⎞
( 1 − D) ⋅ ⎜ ⎟
Critical Inductance: Lc :=
⎝ Iccm⋅ Pomax ⎠ = 12.000H⋅ μ
2⋅ Fs
Choose L > Lc Lo := 200μH with assumed DC resistance of: RLo := 100mΩ
1 ( 1 − D) ⎤
Peak Inductor Current: ILopk := Vonom⋅ ⎡ + = 10.06A
⎢ 2 2⋅ Lo⋅ Fs ⎥
Vonom
⎢ ⎥
⎣ Pomax ⎦
Switch Voltage: Vswmax:= Vinom = 24V
Pomax
Switch Current: Id := D⋅ = 5A
Vonom
Choose MOSFET IRF7471 40V 10A Rdson 13mO
Diode Vrrm: Vrrm:= Vinom = 24V
Pomax
Diode Forward Current: If := ( 1 − D) ⋅ = 5A
Vonom
Choose MBR3040
Capacitor Voltage Rating: Vcap := Vonom + ⎛ Vopp⋅ Vonom ⎞ = 12.12V

⎜ ⎟
⎝ 2 ⎠
( 1 − D) −3
Capacitance: Co := = 250 × 10 F⋅ μ
2
8⋅ Lo⋅ Fs ⋅ Vopp
( 1 − D) ⋅ Vonom
RMS Current Rating: Icaprms := = 0.035A
2 3⋅ Lo⋅ Fs
Choose a 25V 50uF capacitor
Power Loss Calculations
MOSFET Loss Calculations: Rdson := 13m⋅ Ω n := 0 .. 11

Load :=
n
0.01
5
10
⎛ Loadn ⎞ 20
⎜ ⋅ Pomax ⎟
30
100
Output Current Array: Io := ⎜ ⎟
n 40
⎝ Vonom ⎠
50
Static Loss: 60
70
Idrms := Io ⋅ D⋅ 1 + Iccm 80
n n
90
Pmos1 := Io ⋅ D⋅ 1 + Iccm Rdson
( )2 100
n n
Switching Loss: ton1 := 12ns toff1 := 15ns Coss := 700pF Qg := 21nC
Io ⋅ Vinom⋅ ( ton1 + toff1) ⋅ Fs Vg := 12V

n
Pmos2 :=
n 6
1 2 1
Pcoss := ⋅ Coss ⋅ Vinom ⋅ Fs = 0.05W Pgate := ⋅ Qg⋅ Vg⋅ Fs = 0.032W
2 2
Pmostot := Pmos1 + Pmos2 + Pcoss + Pgate

n n n
Diode Loss Calculations

Vf :=
Ifavg := Io ⋅ ( 1 − D) From Diode Datasheet: n
n n
0.02V
0.62V − 0.4V
Dynamic Resistance: Rd := = 0.063Ω 0.46V
4A − 0.5A 0.5V
Vonom⋅ ( 1 − D) 0.58V
Peak to peak ΔIL := = 0.12A
Lo⋅ Fs 0.61V
Inductor Current
0.64V
2 2
0.66V
( 1 − D) ⎡⎛ ΔIL ⎞ ⎛ ΔIL ⎞ 0.68V
Ifrms := ⋅ ⎢⎜ Io + + Io − + ⎛ Io − ΔIL ⎞ ⋅ ⎛ Io + ΔIL ⎞⎤⎥
⎟⎜ ⎟
n 3
⎟ ⎜ n ⎟ ⎜ n
⎣⎝ n 2 ⎠ ⎝ 2 ⎠ ⎝ 2 ⎠⎝ n 2 ⎠⎦ 0.7V
0.71V
Pd1 := Vf ⋅ Ifavg + Ifrms ( 0.73V
n n n )n 2Rd
From Datasheet: Vr := Vinom − Vonom Ir := 0.00015A
Pd2 := Vr⋅ Ir⋅ ( 1 − D) = 0.001W
Efficiency of 12V 120W
0.95
Assume: tfr := 500ns Vfp := 10V 0.905
0.86
0.815
Pd3 := 0.4⋅ Vfp − Vf ⋅ tfr⋅ Ifavg ⋅ Fs
( ) 0.77
n n n
ηn 0.725
Efficiency
Pdtot := Pd1 + Pd2 + Pd3 0.68
n n n 0.635
0.59
0.545
Inductor Loss Calculation 0.5
0 10 20 30 40 50 60 70 80 90 100
Loadn
Percent Load
2
1 ⎞ ΔIL
ILrms := Io ⋅ 1 + ⋅ ⎛⎜ ⎟ PLo := ILrms
(
n n 3 2⋅ Io n )n 2⋅ RLo
⎝ n⎠
Capacitor Loss Calculation Assume: ESR := 150m⋅ Ω
ΔIL 2
Icrms := = 0.035A Pc := Icrms ⋅ ESR
2 3
Total Loss Calculation
Ptotal := Pmostot + Pdtot + PLo + Pc Po := Vonom⋅ Io

n n n n n n
Po
n
Efficiency ==> η :=
n Po + Ptotal
n n
Another Example
PARAMETERS:
Vref = 2.5
Vo = 12
ratio = {Vref/Vo}
Rtop = 10k
Vg mult = 0.992
percentload = 10
-
+
S1 I
+
-
0 L1 Vout
Sbreak 1 2
V1 50u
V
R1a Vfb
48 C1 {Rtop}
D1 R1
Dbreak 50u
R1b
{mult*((ratio*Rtop)/(1-ratio))}
0 {(100/percentload)*(Vo/10)}
4
COMPARATOR Vg
{Vref} 100 IN+ OUT+
0 IN- OUT-
Vfb EVALUE
LIMIT(1MEG*V(%IN+, %IN-),5,0)
V1 = 5 Vtri
V2 = 0
TD = 0
TR = {5u-10n} 0
TF = {5u-10n}
PW = 20n 0
PER = {1/100k}
20V
Output Voltage at Maximum Load
(12.008 V)
10V
SEL>>
0V
V(Vout)
30A
Inductor Current at Maximum Load
20A
(10.000 Amps)
10A
0A
0s 0.5ms 1.0ms 1.5ms 2.0ms 2.5ms 3.0ms 3.5ms 4.0ms 4.5ms 5.0ms
I(L1)
Time
Output Voltage Ripple at Maximum Load

12.0200V
(12.023 V)
12.0000V
11.9800V
(11.977 V)
SEL>>
11.9695V
V(Vout)
11A
Inductor Current Ripple at Maximum Load
(9.1136 Amps)
10A
(10.883 Amps)
9A
4.68517ms 4.69000ms 4.69500ms 4.70000ms 4.70500ms 4.71000ms 4.71500ms
I(L1)
Time
Efficiency Improvement
• Ways to improve converter’s efficiency:
– MOSFET
• Low Rdson for High Duty Cycle
• Low Gate Charge for Low Duty Cycle
• Paralleling for High Current
– Schottky Diode
• Low forward drop
• Short recovery time
– Inductor
• Multiple parallel winding such as Bifiliar (two
windings), Trifiliar (three windings)
Efficiency Improvement
– Capacitors
• Low ESR
• Paralleling caps (increasing capacitance while
reducing ESRs)
– Lower inductor current ripple
• Reduce rms loss (inductor and output capacitor)
• Increase switching frequency or inductance
– Switching loss and real-estate trade off
– Lower gate drive voltage
– Use of Synchronous MOSFET in place of
diode, especially for low voltage and high
current output
Synchronous Rectification
• Replaces freewheeling schottky with MOSFET
• Especially beneficial on low duty cycle and high current applications
• Due to required dead time and slow MOSFET’s body diode, a
Schottky is connected across the Synchronous MOSFET
• MOSFET + Schottky = FETKY combo such as IRF7326D2
Soft-Switching
• Prevents hard-switching or the overlapping of switch’s voltage and
current during turn-on and turn-off transitions
– switching losses which is proportional to switching frequency
• Use of resonant circuit to shape switch voltage and/or current
waveforms to inherently go to zero at which switching transition is
initiated Î zero switching loss
pswitching(t)
Ion Ion
Voff Voff
turn on turn off

Soft-Switching
• Quasi-resonant buck topologies such as Zero-Voltage
and Zero Current Resonant Switch Buck converter
• Needs constant-on or constant-off controllers such as
UC1865 - UC1868, UC1861 – UC1864, MC34067 and
MC33067, TDA4605-3, TDA4605-2
Voff Ion Ion

Voff
0
turn on turn off
Soft-Switching
• Zero-Current Resonant Switch Buck
– Turns switch OFF at zero current
• Zero-Voltage Resonant Switch Buck

– Turns switch ON at zero voltage
PWM Controller
• Current Mode Controller will be used due to many of its advantages
– Easy Compensation
• With voltage-mode, the sharp phase drop after the filter resonant frequency
requires a type III compensator to stabilize the system
• Current-mode control looks like a single-pole system, since the inductor has
been controlled by the current loop
• Improves the phase margin, makes the converter much easier to control
• A type 2 compensator is adequate, greatly simplifies the design process
• With voltage-mode control, crossover has to be well above the resonant
frequency, or the filter will ring.
– CCM and DCM Operation
• It is not possible to design a compensator with voltage-mode that can
provide good performance in both CCM and DCM
• With current-mode, crossing the boundary between the two types of
operation is not a problem
• Having optimal response in both modes is a major advantage, allowing the
power stage to operate much more efficiently
– Line Rejection
• Closing the current loop gives a lot of attenuation of input noise
• Even with only a moderate gain in the voltage feedback loop, the attenuation
of input ripple is usually adequate with current-mode control
• With voltage-mode control, far more gain (or feed forward) is needed in the
main feedback loop to achieve the same performance
PWM Controller
• For the sake of example, we’ll use UC184x or MIC38HC4x family
PWM Controller
PWM Controller
• Selecting Timing Resistor and Timing Capacitor
– Maximum Duty Cycle and Switching Frequency have to be determined
first
– Percent Dead time would then be computed from Dmax
– Using % Dead time along with Switching Frequency, we can then use
plots provided in the data sheet to determine the required timing capacitor
and timing resistor
• Example: Let’s say that Dmax was calculated to be 70% or 0.7. Add safety
factor to Dmax. Say 10% such that Dmax’ = 0.8
• The dead time is therefore = 100% - 80% = 20%

• If switching frequency used is 80 kHz, then the value for % dead time along
with switching frequency can be used to determine the required Timing
Capacitor
• This is done by using the plot provided in the data sheet.
PWM Controller
• From plot, 80 kHz intersects the 20% dead time at
approximately Timing Capacitor value of 10 nF.
• Next, the timing resistor is found from the plot which is
also provided in the data sheet
PWM Controller
• Plot shows that 80kHz intersects the timing capacitor plot for 10 nF
at timing resistance approximately equals to 2kΩ
• So, in order to provide the 20% dead time at 80 kHz switching
frequency, the timing components are: CT = 10 nF and RT = 2 kΩ
= 2kΩ
= 10nF
PWM Controller
• Feedback Compensation
– As a start, typically a small capacitor is placed on ZF (such
as 2200 pF) for feedback compensation
– Once a prototype is built, the feedback compensation will
be investigated to give the desired gain and phase margin
and stability (over wide range of load)
– Involves decision of whether to use type I, II, or III error
amplifier
PWM Controller
PWM Controller
• Steps for selecting components in Type 2
– Choose cross-over frequency Fcross to be around 1/3 of
switching frequency Fswitch
– The required pole frequency Fp0 that yields the desired Fcross
crossover frequency of the open loop gain (where H0 is dc gain Fp 0 =
of the plant) Ho
1
– Calculate capacitor C1 where R1 should have been selected when C1 =
setting the voltage divider 2π R1 Fp 0
1
– Calculate R2 using the previously calculated C1 and the output R2 =
pole of the plant Fp 2π C1 Fp
– Calculate capacitor C3 where Fesr is the location of the ESR zero 1
C3 =
2π ESR ⋅ Fesr
PWM Controller
• Current Sensing Resistor
– Need to calculate power rating of the sensing resistor. This
involves calculating worst case Irms through the sensing resistor,
and then compute P = (Irms)2*Rsense
– A low pass RC filter circuit is also needed to eliminate leading
spike on the pulse voltage resulted from current being sensed
– Ensure that voltage out of the filter is less than 1V (for this
controller). If not, then reduce the value of Rsense
Layout Considerations
• Keep trace inductance low (preferably by reducing length, not
increasing width) for the critical path (switch and diode paths)
– Noise spikes may appear in input and output, and to the controller chip
– Avoid using a current probe (a loop of wire) for diode and switch due to
additional inductance it will produce
• Provision of good Input decoupling since input capacitor is in the
critical path
– Besides the usual bulk capacitor, also put a small ceramic capacitor at
the supply end to ground, and another one close to the switch to ground
• Provision of good decoupling with a small ceramic capacitor
between input and ground pins
• Try using shielded inductor, and position the inductor away from the
controller and feedback trace
• In multi-layer boards, dedicate one layer for ground
• Keep the feedback trace as short as possible to minimize noise
pickup and place it away from noise sources
Multiphase
• The technique used mainly in very low voltage and high
power applications such as processors
– Next-generation networking ASICs and processors require
multiple lower voltages, higher currents, faster dynamic
response, greater efficiency and power management solutions
that reside close to the load
– To meet the need of increasing power density through higher
efficiencies and higher operating frequencies
• A novel power architecture, multiphasing topologies, is
emerging to contend with tomorrow's power
requirements
• High-density applications with lower power levels are
usually managed with 2-phase solutions, whereas higher
power levels can require up to 4-phase solutions
Multiphase
• Multiphasing address 5 key parameters in power conversion
– Efficiency: The best power efficiency is achieved by converting a
voltage in a single stage, rather than double conversion.
• For example, assume you want to convert 48V to 1.2V at
100W using a 2-phase forward converter
• In a 2-phase conversion, current is split equally in the two
phases. The FET on-losses are I2 × R, which equates to a
50% reduction in on-losses
• Lower peak currents provide lower turn-on and turn-off
losses, resulting in lower switching losses
• Lower turn-on and switching losses provide overall greater
efficiency
– Input/output ripple reduction: Multiphasing PWM controllers
increases switching frequency. The resulting frequency is
equivalent to the PWM clock frequency times the number of
phases. Higher operating frequency equates to less input/output
capacitance and smaller input/output inductors
Multiphase
– Fast dynamic response. Improved dynamic response is
the result of smaller output inductors allowing for fast
response to current changes combined with higher
operating frequency, equal to clock frequency times the
number of phases, which allows for higher crossover.
– Ease of manufacturability: Next-generation designs
demand smaller form factors and automated assembly,
eschewing hand soldering of large transformers, inductors
and capacitors.
– Better thermal management: Thermal management is
critical at these new power densities. The challenge is
even higher with the emergence of modules operating in
extended temperature range. With multiphasing
techniques, you spread the heat evenly over the whole
converter, avoiding hot spots and improving converter
reliability
Multiphase
Multiphase
Two-Phase vs. 1 Buck
L1 L2
1 2 1 2
200u 200u
-
-
+
+
S1 V
S2 V
-
-
+
+
V1 Sbreak D1 R1 V3 Sbreak D2 R2
12 Dbreak C1 12 Dbreak C2
2.5 2.5
50u 50u
0 0
V1 = 0 V2 V1 = 0 V4
V2 = 1 V2 = 1
TD = 0 TD = 0
TR = 10n TR = 10n
TF = 10n TF = 10n
PW = {(3.185/12)*(1/50k)} PW = {Duty *(1/50k)}
PER = {1/50k} PER = {1/50k}
L3
1 2
200u
-
+
S3
-
+
Sbreak D3
Dbreak
V1 = 0 V5 PARAM ET ERS:
V2 = 1 Duty = {3.135/12}
TD = {0.5/50k}
TR = 10n
TF = 10n
PW = {Duty *(1/50k)}
PER = {1/50k}
4.0V
Two-Phase Buck Output Voltage
3.0V Just a Buck
2.5 Volts
2.0V
1.0V
0V
0s 0.5ms 1.0ms 1.5ms 2.0ms 2.5ms 3.0ms 3.5ms 4.0ms 4.5ms 5.0ms
V(R1:2) V(L2:2)
Time
2. 520 0V
Ou tpu t V olt age Ri ppl e
2. 510 0V
Ju st a B uck
2. 500 0V
T wo- Pha se Buc k

2. 490 0V
2. 480 3V
3. 620 3ms 3 .64 00m s 3 .66 00m s 3. 680 0ms 3. 700 0ms 3.7 200 ms
V (R1 :2) V(L 2:2 )
Ti me
200mA
Capacitor Current
Two-phase Buck
0A
Just a Buck
-200mA
4.6705ms 4.6800ms 4.6900ms 4.7000ms 4.7100ms 4.7200ms 4.7300ms 4.7400ms 4.7500ms
-I(C2) -I(C1)
Time
1.5A
Input Currents
Just a Buck
1.0A
Two-Phase
0.5A
0A
3.9886ms 4.0000ms 4.0200ms 4.0400ms 4.0600ms 4.0800ms 4.1000ms

-I(V1) -I(V3)
Time
Power Electronics Lab at Cal Poly State University
• 6 Instructional Lab Benches, 2 Project/Thesis Benches
• For further information, contact Power Electronics Lab Coordinator, Dr. Taufik at taufik@calpoly.edu

Taufik Tutorial PDF

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Practical Design of Buck Converter

• When ON: The output voltage is the same as the input

Source Side Load/User Side

Current with some Voltage with some

• Two types of Conduction Modes

• Inductor is the main storage element

VL = vLonton + vLoff toff = 0

• When the switch is closed or ON

• When the switch is OPEN or OFF

(VS − VO ) DT + ( −VO )(1 − D ) T = 0

• Average output voltage is LESS than Input Voltage

For MOSFETs: Vds and Id L and Ipk

Vrrm, and If C, V and Irms

• We can then determine ILmin and ILmax

• ILmin is used to determine the Critical Inductance (Minimum

ΔiL ⎡ 1 (1 − D) ⎤ (1 − Dmax ) Rmax

Calculated at Minimum • Calculated at Minimum Output

• ILmax is used to determine peak current rating of Inductor

Chosen inductance value as

• With ideal diode, the Vswitch-max = Vinmax

• Switch current rating is calculated based on average

ON OFF ON OFF ON OFF

I Switch − max > I o max ⋅ Dmax

• Known as PIV (Peak Inverse Voltage) or VRRM is the

iDiode Average Value

OFF OFF OFF

( iL min + iL max ) ⋅ toff

• Capacitor Voltage should withstand the maximum output

• The AC component (ripple) of inductor current flows

• Capacitor Voltage should withstand the maximum input

Ioccm := 0.1A %Vo := 1% f := 50kHz

1.25A Inductor Current

• Static loss for MOSFET with RDSon:

turn on Io Io turn off

I oVinton I oVin toff

PON = 0.4 ⋅ (VFP − V f )⋅ t fr ⋅ I f ⋅ f

• With inductor’s dc resistance of RL and inductor’s rms

Core Loss = Core Loss/Unit Volume x Volume

• Constants k1, k2, and k3 are normally provided by the

Maximum Output Power: −6

Design Calculations and Sizing Components:

Choose L > Lc Lo := 200μH with assumed DC resistance of: RLo := 100mΩ

Capacitor Voltage Rating: Vcap := Vonom + ⎛ Vopp⋅ Vonom ⎞ = 12.12V

Power Loss Calculations

MOSFET Loss Calculations: Rdson := 13m⋅ Ω n := 0 .. 11

Io ⋅ Vinom⋅ ( ton1 + toff1) ⋅ Fs Vg := 12V

Pmostot := Pmos1 + Pmos2 + Pcoss + Pgate

Diode Loss Calculations

Assume: tfr := 500ns Vfp := 10V 0.905

Capacitor Loss Calculation Assume: ESR := 150m⋅ Ω

Total Loss Calculation

Ptotal := Pmostot + Pdtot + PLo + Pc Po := Vonom⋅ Io

Inductor Current at Maximum Load

Output Voltage Ripple at Maximum Load

turn on turn off

Voff Ion Ion

• Zero-Voltage Resonant Switch Buck

• The dead time is therefore = 100% - 80% = 20%

Two-Phase Buck Output Voltage

3.0V Just a Buck

Ou tpu t V olt age Ri ppl e

T wo- Pha se Buc k

3.9886ms 4.0000ms 4.0200ms 4.0400ms 4.0600ms 4.0800ms 4.1000ms