Goals of the Seminar

You Will Learn

The value of designing your own DC/DC power
conversion circuits
Basics of power conversion design
Simulation of key thermal and electrical
parameters
Tradeoffs and pitfalls in DC/DC design
Passive component selection for optimum
results
LED driver design considerations
Layout optimization
Agenda
DC-DC Buck Design
Lab 1: Design a Buck converter
Lab 2: Optimize a Buck converter
Break
Lab 3: Investigate Thermals
Vishay : Capacitors and Inductors for DC-DC Designs
High Power Buck Design
Lab 4: Higher Power Designs
Lunch
Vishay : Discrete Semiconductors
Boost/Buck Boost
Lab 5: Buck Boost, LM3668
Break:
Powering LED's
Lab 6: LED WeBench
Lab 7: Driving a string of LEDs
Review, Questions and Feedback
Lab 1
Design a Buck Converter with
WeBench Power Designer
Myths and Legends
DC-DC Power conversion is black magic
No, but RF design is
DC-DC Design requires a special skill set
Most everything is learned in a first year engineering
course on circuit theory.
DC-DC Design requires special tools
Special tools like MathCad and PSpice exist, but are not
necessary, WeBench Power Designer and Excel are
more than enough
DC-DC Designs takes weeks to develop implement
and test
Today we will design modify and test a complete design
Basic DC-DC Operation
2 or more Switches
1 or more Inductors
1 Capacitor
How the Buck Converter Works
2 SW I
OUT V
1 SW I
2 SW I
1 SW I
Duty Cycle
% 35
12
2 . 4
= = =
IN
OUT
V
V
D
Not so scary math
Selecting the Inductor
t
i
L V
A
A
=
i
t
V L
A
A
=
IN
OUT
OUT IN OUT IN
V
V
V V D V V V ) ( ) ( = =
MIN MAX I I i = A
Ripple Current
S F
t
1
= A
S IN
OUT
OUT IN
F i V
V
V V L
- A
- =
1
) (
S IN
OUT
OUT IN
F i V
V
V V L
- A -
- = ) (
IN
OUT
V
V
D =
Not so scary math
Pick the Inductor
Inductance
Input Voltage
Output Voltage
6 . ) 5 . 1 4 (. 12
2 . 4
) 2 . 4 12 (
- - -
- = L
32 . 4
2 . 4
8 . 7 - = L
uH L 10 =
IN V
OUT V
L
i A
S F
Inductor Ripple Current
Switching
S IN
OUT
OUT IN
F i V
V
V V L
- A -
- = ) (
Tradeoffs in Speed and Size
You cant have it all
Inductance
Input Voltage
Output Voltage
IN V
OUT V
L
i A
S F
Inductor Ripple Current
Switching
S IN
OUT
OUT IN
F L V
V
V V i
- -
- = A ) (
i L V
V
V V F
IN
OUT
OUT IN
A - -
- = ) ( S
S IN
OUT
OUT IN
F i V
V
V V L
- A -
- = ) (
Output Capacitor Selection
Inductance
Input Voltage
Output Voltage
C ESL ESR OUT OUT OUT V V V VOUT A + A + A = A
S
L
OUT
IN
OUT
L OUT
F C
I
V
ESL
L
V
V
ESR I V
C
ESL
ESR
- -
A
= A
- = A
- A = A
0 8
IN V
OUT V
L
i A
S F
Inductor Ripple Current
Switching
Hz F
A
ESL
H
V
m A
000 , 600 8 - -
-
O -

Efficiency
Losses
Switching Losses
In the IC Fixed
In the Diode Depends on the Diode
Conduction Losses
Inductor Losses DCR
Diode Losses
IN
OUT
P
P
AVG L I DCR -
) D I V AVG DFWD - - 1
Efficiency
Losses
Switching Losses
In the IC
IN
OUT
P
P
Future PDB LM22676
LM22676
Screen clipping taken: 10/12/2008, 11:29 PM
LM22676 circuit
Basic circuit
SW1: Internal to the LM22676
SW2: D7
Ind: L3
Cap: C32
LM22676 circuit
Whats all this other stuff?
C27, C31: Input Capacitors
Enable Pin
C28: Boost Capacitor
R42, R41: Feedback Voltage Resistors
Future Electronics Power Training Board
National LM22676: Standard Async Buck
National LM3668: Sync Buck Boost
Background
Future Electronics Power Training
Board
Power Input
Output adjust for LM22676
Background
Future Electronics Power Training
Board
National LM3410: Boost
Dimming capabilities
Background
Future Electronics Power Training
Board
3 Lumiled Rebels
Background
Future Electronics Power Training
Board
National LM3150: Sync Buck
Background
Future Electronics Power Training Board
We will focus on this circuit.
Background
Future Electronics Power Training Board
Background
Each section of the
board has its own
Ground
Each section of the
board has test points
to measure input
current
Each section of the
board has test points
to measure across
the Inductor
Each section of the
board has a scope
probe jack on the
output
Lab 2
Optimize a Buck converter using
WeBench Power Designer
LM22676 Layout
LM22676 circuit
Where does the current go?
LM22676 Layout
LM22676 Layout
Lab 3
Using WeBtherm
Power Passives
Types of Converters
PWM
Hysteretic
Constant On Time
Constant Off Time
PFM
How the Synchronous Buck
Converter Works
2 SW I
OUT V
1 SW I
Duty Cycle
% 10
12
2 . 1
= = =
IN
OUT
V
V
D
1 SW I
2 SW I
Why Synchronous?
Diode Losses
If the Diode is on 90% of the time, a better switch
yields a better efficiency
) D I V AVG DFWD - - 1
Pick the Inductor
Inductance
Input Voltage
Output Voltage
S IN
OUT
OUT IN
F i V
V
V V L
- A -
- = ) (
5
10 3 ) 10 4 (. 12
2 . 1
) 2 . 1 12 (
x
L
- - -
- =
7
10 4 . 1
2 . 1
8 . 10
x
L - =
uH L 1 =
IN V
OUT V
L
i A
S F
Inductor Ripple Current
Switching Frequency
Output Ripple
Output Ripple
Output Voltage OUT V
i A
Inductor Ripple Current
ESR I V L OUTESR - A = A
ESR V ESR OUT - = A 10 * 4 .
ESR V ESR OUT - = A 4
Output Capacitor Selection
Inductance
Input Voltage
Output Voltage
C ESL ESR OUT OUT OUT V V V VOUT A + A + A = A
S
L
OUT
F C
I
V C
- -
A
= A
0 8
IN V
OUT V
L
i A
S F
Inductor Ripple Current
Switching
Hz F 000 , 600 8
4
- -
LM3150 Design
Future PDB Minimum Circuit
Future Demonstration Board
Future PDB Minimum Circuit
Future Demonstration Board
SW1: Q4
SW2: Q3/D4
Ind: L1
Cap: C1, C2
LM3150 Current Flow
Feedback
Enable
Boost Diode and Cap
Input Caps
LM3150 Current Flow
SW1: Q4
SW2: Q3/D4
Ind: L1
Cap: C1, C2
LM3150 Layout
LM3150 Layout
Lab 4
Lab 3: Design and Optimize a
Synchronous Buck Controller
Lunch
Power Discretes
How the a Boost Converter
Works
% 53
4 . 6
4 . 3 6
=
+
+
= =
+
+
D OUT
D IN OUT
V V
V V V
D
% 34
4 . 6
2 . 2
4 . 6
4 . 2 . 4 6
= =
+
+
= =
+
+
D OUT
D IN OUT
V V
V V V
D
OUT V
2 SW I
1 SW I
1 SW I
2 SW I
Its Back
Selecting the Inductor
t
i
L V
A
A
=
i
t
V L
A
A
=
D V V IN) ( =
260 . 4 . 652 . 40 . = - = - = A L I i
Ripple Current
S F
t
1
= A
65 . 1
6 . 1 26 .
53 . 3
=
-
-
=
- A
-
=
S
IN
F i
D V
L
53 . = =
+
+
D OUT
D IN OUT
V V
V V V
D
652 .
46 .
3 .
) 54 . 1 (
3 .
) 1 (
= =

=
D
I
I
OUT
L
How the Synchronous Buck
Boost Converter Works
As a Buck
2 SW I
OUT V
1 SW I
1 SW I
2 SW I
How the Synchronous Buck
Boost Converter Works
As a Boost
OUT V
% 35
12
2 . 4
= = =
+
+
D IN
D IN OUT
V V
V V V
D
3 SW I
4 SW I
3 SW I
4 SW I
LM3668 PDB Circuit
LM3668 PDB Circuit
SW1: Internal to the LM3668
SW2: Internal to the LM3668
Ind: L2
Cap: C26
LM3668 PDB Circuit
C23: Input Capacitor
Pin 6: Enable
Pin 11: Vselect
Pin 12: Feedback
LM3668 PDB Circuit
LM3668 Layout
LM3668 Layout
Lab 5
Lab 5: Buck Boost, LM3668
How the Boost Converter
Works
OUT V
2 SW I
1 SW I
1 SW I
2 SW I
LM3410 PDB
LM3410
SW1: Internal to the LM3410
SW2: D12
Ind: L4
Cap: C40
LM3410
LM3410
LM3410
Lab 6
Lab 6: WeBench LED Designer
LM3410 Boost LED Driver
THANK YOU!!
Layout
Parasitic Inductance of bypass caps