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scheduledtoenterproduction.
Thistypeofsituationcanleadtothe“millstoneeffect”whichinsimpletermsmeans“Youdesignedit,youfixit(forever).”Nowondernoonewantstotouchitand,whenasked,disavowsanyknowledgeofhavingeverdesignedapowersupply.
1.1GettingStarted.ThisJourneyStartswiththeFirstQuestion
Inordertoproduceagooddesign,manyquestionsmustbeaskedpriortothebeginningofthedesignprocess.Theearliertheyareaskedthebetteroffyouare.Thesequestionsalsoavoidmanyproblemslaterinthedesignprogramduetolackofcommunicationandforethought.Thebasicquestionstobeaskedincludethefollowing.
Fromthemarketingdepartment
1.Fromwhatpowersourcemustthesystemdrawitspower?
Therearedifferentdesignapproachesforeachpowersystemandonecanalsogetinformationastowhatadverseoperatingconditionsareexperiencedforeach.
2.Whatsafetyandradiofrequencyinterferenceandelectromagneticinterference(RFI/EMI)regulationsmustthesystemmeettobeabletobesoldintothetargetmarket?
Thiswouldaffectnotonlytheelectricaldesignbutalsothephysicaldesign.
3.Whatisthemaintenancephilosophyofthesystem?
Thisdictateswhatsortofprotectionschemesandphysicaldesignwouldmatchtheapplication.
4.Whataretheenvironmentalconditionsinwhichtheproductmustoperate?
Thesearetemperaturerange,ambientRFlevels,dust,dirt,shock,vibration,andanyotherphysicalconsiderations.
5.Whattypeofgracefuldegradationofproductperformanceisdesiredwhenportionsoftheproductfail?
Thiswoulddeterminethetypeofpowerbusingschemeandpowersequencingthatmaybenecessarywithinthesystem.
Fromthedesignersoftheotherareasoftheproduct
1.Whatarethetechnologiesoftheintegratedcircuitsthatarebeingusedwithinthedesignofthesystem?
Onecannotprotectsomething,ifonedoesn’tknowhowitbreaks.
2.Whatarethe“bestguess”maximumandminimumlimitsoftheloadcurrentandarethereanyintermittentcharacteristicsinitscurrentdemandsuchasthosepresentedbymotors,videomonitors,pulsedloads,andsoforth?
Alwaysadd50percentmoretowhatistoldtoyousincetheseestimatesalwaysturnouttobelow.Alsowhatarethemaximumexcursionsinsupplyvoltagethatthedesignerfeelsthatthecircuitcanwithstand.Thisdictatesthedesignapproachesofthecross-regulationoftheoutputs,andfeedbackcompensationinordertoprovidetheneedsoftheloads.
3.Arethereanycircuitsthatareparticularlynoise-sensitive?
Theseincludeanalog-to-digitalanddigital-to-analogconverters,videomonitors,etc.Thismaydictatethatthesupplyhasadditionalfilteringormayneedtobesynchronizedtothesensitivecircuit.
4.Arethereanyspecialrequirementsofpowersequencingthatarenecessaryforeachrespectivecircuittooperatereliably?
5.Howmuchphysicalspaceandwhatshapeisallocatedforthepowersupplywithintheenclosure?
Itisalwaystoosmall,sostartnegotiatingforyourfairshare.
6.Arethereanyspecialinterfacesrequiredofthepowersupply?
Thiswouldbeanypower-downinterrupts,etc.,thatmayberequiredbyanyoftheproduct’scircuits.
Thisinquisitivenessalsosetsthestageforthebeginningofthedesignbydefiningtheenvironmentinwhichthepowersupplymustoperate.Thisthenformsthebasisofthedesignspecificationofthepowersupply.
1.2PowerSystemOrganization
Theorganizationofthepowersystemwithinthefinalproductshouldcomplementtheproductphilosophy.Thegoalofthepowersystemistodistributepowereffectivelytoeachsectionoftheentireproductandtodoitinafashionthatmeetstheneedsofeachsubsectionwithintheproduct.Toaccomplishthis,oneormorepowersystemorganizationcanbeusedwithintheproduct.
Forproductsthatarecomposedofonefunctional“module”thatisinseparableduringtheproduct’slife,suchasacellulartelephone,CRTmonitor,RFreceiver,etc.,anintegratedpowersystemisthetraditionalsystemorganization.Here,theproducthasonemainpowersupplywhichiscompletelyself-containedandoutputsdirectlytotheproduct’scircuits.Anintegratedpowersystemmayactuallyhavemorethanonepowersupplywithinitifoneoftheloadcircuitshaspowerdemandorsequencingrequirementswhichcannotbeaccommodatedbythemainpowersupplywithoutcompromisingitsoperation.
Forthoseproductsthathavemanydiversemodulesthatcanbereconfiguredoverthelifeoftheproduct,suchasPCBcardcagesystemsandcellulartelephonegroundstations,etc.,thenthedistributedpowersystemismoreappropriate.Thistypeofsystemtypicallyhasonemain“bulk”powersupplythatprovidespowertoabuswhichisdistributedthroughouttheentireproduct.Thepowerneedsofanyonemodulewithinthesystemareprovidedbysmaller,board-levelregulators.Here,voltagedropsexperiencedacrossconnectorsandwiringwithinthesystemdonotbotherthecircuits.
Theintegratedpowersystemisinherentlymoreefficient(lesslosses).Thedistributedsystemhastwoormorepowersuppliesinseries,wheretheoverallpowersystemefficiencyistheproductoftheefficienciesofthetwopowersupplies.So,forexample,two80percentefficientpowersuppliesinseriesproducesanoverallsystemefficiencyof64percent.
Thetypicalpowersystemcanusuallyendupbeingacombinationofthetwosystemsandcanuseswitchingandlinearpowersupplies.
Theengineer’smottotolifeis“Lifeisatradeoff”anditcomesintoplayhere.Itisimpossibletodesignapowersupplysystemthatmeetsalltherequirementsthatareinitiallysetoutbytheotherengineersandmanagementandkeepitwithincost,space,andweightlimits.Thetypicalinitialrequirementofapowersupplyistoprovideinfinitelyadaptablefunctions,deliverkilowattswithinzerospace,andcostnomoney.Obviously,somecompromiseisinorder.
1.3SelectingtheAppropriatePowerSupplyTechnology
Oncethepowersupplysystemorganizationhasbeenestablished,thedesignerthenneedstoselectthetechnologyofeachofthepowersupplieswithinthesystem.Attheearlystageofthedesignprogram,thisprocessmaybeiterativebetweenreorganizingthesystemandthechoiceofpowersupplytechnologies.Theimportantissuesthatinfluencethisstageofthedesignare:
1.Cost.
2.Weightandspace.
3.Howmuchheatcanbegeneratedwithintheproduct.
4.Theinputpowersource(s).
5.Thenoisetoleranceoftheloadcircuits.
6.Batterylife(iftheproductistobeportable).
7.Thenumberofoutputvoltagesrequiredandtheirparticularcharacteristics.
8.Thetimetomarkettheproduct.
Thethreemajorpowersupplytechnologiesthatcanbeconsideredwithinapowersupplysystemare:
1.Linearregulators.
2.Pulsewidthmodulated(PWM)switchingpowersupplies.
3.Highefficiencyresonanttechnologyswitchingpowersupplies.
Eachofthesetechnologiesexcelsinoneormoreofthesystemconsiderationsmentionedaboveandmustbeweighedagainsttheotherconsiderationstodeterminetheoptimummixtureoftechnologiesthatmeettheneedsofthefinalproduct.Thepowersupplyindustryhaschosentoutilizeeachofthetechnologieswithincertainareasofproductapplicationsasdetailedinthefollowing.
Linear
Linearregulatorsareusedpredominantlyinground-basedequipmentswherethegenerationofheatandlowefficiencyarenotofmajorconcernandalsowherelowcostandashortdesignperiodaredesired.Theyareverypopularasboardlevelregulatorsindistributedpowersystemswherethedistributedvoltageislessthan40VDC.Foroff-line(plugintothewall)products,apowersupplystageaheadofthelinearregulatormustbeprovidedforsafetyinordertoproducedielectricisolationfromtheacpowerline.Linearregulatorscanonlyproduceoutputvoltageslowerthantheirinputvoltagesandeachlinearregulatorcanproduceonlyoneoutputvoltage.Eachlinearregulatorhasanaverageefficiency
ofbetween35and50percent.Thelossesaredissipatedasheat.
PWMswitchingpowersupplies
PWMswitchingpowersuppliesaremuchmoreefficientandflexibleintheirusethanlinearregulators.Onecommonlyfindsthemusedwithinportableproducts,aircraftandautomotiveproducts,smallinstruments,off-lineapplications,andgenerallythoseapplicationswherehighefficiencyandmultipleoutputvoltagesarerequired.Theirweightismuchlessthanthatoflinearregulatorssincetheyrequirelessheatsinkingforthesameoutputratin