第十一部分電路及線路方案70w adapter design

1、張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的Features···············Very compact design: (4.1” ´ 2.25” ´ 1.06”) High power density - 7 W / inch³Full output power (70 W) in sealed enclosure at 40°C ambient High

2、 efficiency: 84% (85 VAC), 89% (230 VAC)Low no-load consumption: 350 mW (115 VAC), 500 mW (230 VAC)Low value input capacitor: 74% DCMAX and line feed forward allows 2 mF/W Power limited during overload: overload output current less than 5 A at 19 V Primary side soft-start: minimizes component stress

3、es during start-upLow EMI due to frequency jittering: meets CISPR22B with output cap. earthed Line under voltage sense: no output glitches on power up or power downLine over voltage shutdown: extended line surge protectionHysteretic thermal shutdown: supply automatically recovers when fault is remov

4、ed Low component count: simple circuit and designSingle sided PC board: no plated through holes No surface mount components requiredPower Integrations Inc5245 Hellyer Avenue, San Jose, CA 95138 USA.Tel:Fax:www:張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開TitleEngineering Prototype Report - 70 W (19 V 3.66A) Universal Input Adapter

5、(EP11)Target ApplicationsLaptop Adapters, LCD Monitors, Audio, High Power AdaptersAuthorPower Integrations Applications Dept.Doc NumEPR-00011Date22-January-2001Revision1.4張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的EPR-00011 - 70 W Adapter22-Jan-01Table of Contents123Introduction4Power Supply Specifica

6、tion6Schematic73.1 Description7PCB Layout.10Bill of Materials11Transformer Documentation126.1 Transformer Sources14Transformer Spreadsheet15Performance Data174567Efficiency17No-load input power18Regulation / Power Limiting189Thermal Performance2010Waveform Scope Plots2410.410.5

7、10.6Drain Voltage and Current During Normal Operation24Output Voltage During Power-up.25Output Voltage During Power-down26Drain Voltage and Current during Power-Up (265 VAC)26DRAIN Current During Power-Up and Power-Down.27Load Transient response (15 to 100% load change)2810.6.1 15 to 100% load chang

8、e, 85 VAC2810.7Load Transient response (0 to 50% load change)2910.7.1 0 to 50% load change, 85 VAC2910.7.2 0 to 50% load change, 130 VAC2910.7.3 0 to 50% load change, 130 VAC3010.8Ripple Measurements3010.8.1 DC Ripple Measurement Technique3010.8.2 Ripple Measurement Results3111Control Loop Character

9、istics3211.1Gain Phase Results3312Conducted EMI Scans36Power Integrations IncTel: www:Fax:Page 2 of 46張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開Important Note:Although the EP11 is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore all testing should be performed u

10、sing an isolation transformer to provide the AC input to the prototype board張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的22-Jan-01EPR-00011 - 70 W Adapter13Appendix A - Thermal considerations:3713.413.5Efficiency:38Heat Sinking:38Heat Spreading and Enclosure Surface Temperature:39Component T

11、emperature:39: . 4014Appendix B - Custom Component Documentation:414.4Toroid Filter Inductor (L2):41Output Inductor (L1)42Heat sink #1 (TOPSwitch-GX and Input Bridge)43Heat sink #2 (Output Diodes)4315Revision History44Power Integrations IncFax:Tel:Page 3 of 46www:張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打

12、開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的EPR-00011 - 70 W Adapter22-Jan-011IntroductionThis document is an engineering report that describes a universal input power supplythat utilises a TOP249Y. This supply is an off-line flyback converter that operates continuous mode. Below is a list of notable features:in&

13、#183;········Very compact design: (4.1”´2.25”´1.06” internal box dimensions) High power density - 7 W / inch³Full output power in sealed enclosure at 40°C ambient High efficiency: 84% (85 VAC), 89% (230 VAC)Low no-load consumption: 350mW (1

14、15 VAC), 500 mW (230 VAC)um duty cycle allows 2mF/WLow value input capacitor: extendedPower limited during overload: overload output current < 5 A at 19 V Primary side soft-start: minimizes component stresses during start-up Low EMI due to frequency jittering: meets CISPR22 B / EN55022 B with out

15、put earthedLine under voltage sense: no output glitches on power up or power down Line over voltage shutdown: extended line surge protectionHysteretic thermal shutdown: supply automatically recovers when fault is removedLow component count: simple circuit and design Single sided PC board: no plated

16、through holes No surface mount components required······Thisboard demonstrates the basic performance features and the increasedpowercapability of the new TOPSwitch-GX family. It was designed to allow testing within the enclosure of a commercial laptop power adapter. Thi

17、s enclosure was used for the thermal testing in section 9.This document contains the power supply specification, schematic, bill of materials and transformer documentation. Typical operating characteristics are presented at the rear of the report and consist of performance curves and scope waveforms

18、Power Integrations IncTel: www:Fax:Page 4 of 46張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的22-Jan-01EPR-00011 - 70 W AdapterFigure 1 - EP11 Inside Commercial Laptop Enclosure(4.25 x 2.5 x 1.2" / 108 x 64 x 30mm external diemonsions)Height=1.06” / 26.9 mm2.25” / 57mm4.1” / 104.1mmFigure

19、 2 - EP11 Populated Circuit Board (dimensions include heat spreader not shown)Power Integrations IncFax:Tel:Page 5 of 46www:張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的EPR-00011 - 70 W Adapter22-Jan-012Power Supply Specification Output voltage tolerance may be improved through choice of fee

20、dback components. Nominal output voltage for purposes of determining regulation limits is measured at 115 Vinput and 3.66 A output current.ACTable 1 - Power supply specificationPower Integrations IncTel: www:Fax:Page 6 of 46張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開DescriptionSymbolMinTypMaxUnitsCommentInputInput Voltage Input F

21、requencyNo-load Input Power (115 VAC) No-load Input Power (230 VAC)VINf8547115/23050/6037052026564VACHz mW mWSee fig 7See fig 7OutputOutput Voltage Output Ripple Voltage Output CurrentContinuous Output Power Total Regulation Efficiency (85 VAC)Efficiency (230 VAC)VOUT VRIPPLE IOUT POUTh18.700-284891

22、9.219.71203.6670+2VDCmVp-p ADC W%At output terminals 20 MHz BW0 100% load,85 265 VACAt full loadEnvironmental Conducted EMI SafetyExternal Ambient TemperatureTAMB02540oCMeets CISPR22 B Designed to meet IEC950 In enclosure with naturalconvection (see section 9)張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)

23、的EPR-00011 - 70 W Adapter22-Jan-013SchematicFigure 3 - 70W TOP249Y Power Supply Schematic3.1DescriptionThe EP11 is a low-cost flyback switching power supplyusing the TOP249Y integratedcircuit from the TOPSwitch-GX family.The circuit shown in Figure 3 details a 19 V,70 W supply that operates from an

24、input range of 85 to 265 VAC, suitable for applicationsrequiring either an open frame supply or an enclosed adapter.AC power is rectified and filtered by BR1 and C7 to create the high voltage DC bus applied to the primary winding of transformer (T1). Only a 150mF capacitor is required(2.1 mF/W) due

25、to the widerDCMAXof TOPSwitch-GX and the line feed forward functionprovided by the LINE SENSE Pin.The other side of the primary is driven by theintegrated high-voltage MOSFET within the TOP249Y.Diodes, D4 and D2 clamp theDRAIN voltage spike caused by transformer leakage inductance to a safe value be

26、lowthe 700 V dissipation.um. Capacitor C6 is added in parallel with D2 to reduce zener clampThe TOPSwitch-GX family provides new operating features and extended specifications. The EP11 power supply is designed using several of these features. Resistors R14 and R15 connected to the LINE SENSE pin (L

27、) of TOPSwitch-GX (U1) are used to implementPower Integrations IncTel: www:Fax:Page 7 of 46張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的EPR-00011 - 70 W Adapter22-Jan-01an under-voltage detect (100V), over-voltage shutdown (450V) and line feed forward withDCMAXreduction features.Two resistor

28、s are used in series to allow low cost ¼ Wresistors which have a lower voltage rating.The under-voltage detect ensures that the output is glitch free at start-up and shutdown. With the combined value of R14 and R15 as shown, the power supply does not start operating until the DC rail voltage re

29、aches 100 VDC. On removal of the AC input the UV sense prevents the output glitching as C7 discharges turning off the TOPSwitch-GX when output regulation is lost or when the input voltage falls to 40 V, whichever occurs first.The over-voltage feature shuts down the supply if the rectified input volt

30、age exceeds approximately 450V. If exceeded this protects the TOPSwitch-GX from excessive drainvoltages providing an extended AC surge withstand to 700 countries with poor power quality.VDC(BVDSS rating), ideal forFinally the line feed forward feature reduces output line frequency ripple by modulati

31、ng the control loop with the line frequency ripple on the DC rail, ideal when using a relatively small input capacitor.Resistors R5, R6, and R12 connect to the EXTERNAL CURRENT LIMIT pin (X) and are used to externally program the current limit level of the device to just above the operating peak cur

32、rent at full load and low line. This allows use of a smaller transformer core and / or higher transformer primary inductance for a given output power. Reducing transformer size and TOPSwitch-GX power dissipation, while at the same time avoiding transformercore saturation during start-up or output lo

33、ad transient.This resistor network alsoreduces the current limit with increasing line voltage. This limits theum availablepower during overload conditions at high line (see Figure 10) removing the need for anyprotection circuitry on the secondary.The secondary windings are rectified and filtered by

34、D1, D5, C1, and create the 19 V output voltage. Two windings are used, with separate dual rectifiers (for equal currentsharing), to lower winding losses andise efficiency.Inductor L1 providedadditional filtering in conjunction with C4 and C14.The 19 V output is directly sensed by the series combinat

35、ion of R4 and R13 that form a divider with R10. These resistors together with the reference node voltage of U3 set the output voltage. Other output voltages are also possible by adjusting the transformer turns ratios and value of R4 and R13. Resistor R2 sets the overall DC gain of the control loop a

36、nd R7 provides bias for voltage reference U3. Capacitor C11 is the main compensation capacitor and together with R11, C9, R8 and C10 ensure stability of the control loop.The TOPSwitch-GX control circuit allows the switching frequency to reduce at light orzero load conditions, eliminating theneedfor

37、apre-loadresistor to control the outputPower Integrations IncTel: www:Fax:Page 8 of 46張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的EPR-00011 - 70 W adapter22-Jan-01voltage at zero load. By lowering the switching frequency, no-load power consumption is also greatly reduced.The bias winding is

38、 rectified and filtered by D3, R3 and C8 to create a bias voltage to power the TOP249Y. A 1mF capacitor is required for C8 to maintain sufficient voltage during zero to full load transients. Resistor R8 provides leakage inductance filtering to prevent peak charging. A ceramic capacitor is shown for

39、C8 however for lower cost an electrolytic type can be used.Common mode choke L3 and capacitor C12 attenuate common-mode emission currents caused by high-voltage switching waveforms on the drain side of the primary winding and the primary to secondary capacitance. Inductor L2 in conjunction with C5,

40、C15 and C16 attenuate differential-mode emission currents caused by the fundamental and harmonics of the primary current waveform.Capacitor C16 provides a high frequency bypass of C7 which shortens the loop formed by these high frequencies passing through the transformer primary and thus reduces bot

41、h the differential and common mode conducted noise.Frequency jitter is employed by the TOPSwitch-GX family to reduce the conducted noise as measured for both the CISPR and EN standards (see section 12)Capacitor C17 filters internal MOSFET gate-drive charge current spikes on the CONTROL pin and toget

42、her with R11 and C11 determines the auto-restart frequency.Power Integrations IncTel: www:Fax:Page 9 of 46張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的EPR-00011 - 70 W Adapter22-Jan-014PCB LayoutFigure 4 - PCB layout (not to scale)Power Integrations IncTel: www:Fax:Page 10 of 46張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開張

43、飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的EPR-00011 - 70 W adapter22-Jan-015Bill of MaterialsEP11 - 19.2V, 3.66A Universal Input FlybackItemQty.ReferencePartComment123456789101112131415161718192021222324252627282930313233343536373839404113111113111121111111111111111111112111111BR1C1, C2, C4 C5C6 C7 C8

44、 C9C10, C14, C17 C11C12 C15 C16 D5, D1 D2D3 D4 F1 J1 J2 L1 L2 L3 RT1 R2 R3 R4 R5 R6 R7 R8 R10 R11 R12 R13R14, R15 T1U1 U2 U3 HS1 HS2RS805 820uF 25V0.1uF0.01uF 400V150uF 400V1.0uF 50V0.0047uF 50V0.1uF 50V47uF 16V.0022uF 0.33uF 400V0.02uF 500V MBR20100 P6KE200A 1N4148 UF4006 3.15A, 250VMolex Header Mo

45、lex Header 200uH75uHCM Choke10 Ohm 1.7A270 1/8W4.7 1/8W31.6K 1/8W 1%7.5M 1/4W5.6M 1/4W1.0K 1/8W56K 1/8W4.75K 1/8W 1%6.8 1/8W20.5K 1/8W562 1/8W 1%1M 1/4WX2 Safety 250VACY1 Safety 250VAC(custom see appendix) (custom see appendix) 820uH 2.0AIn-rush limiter (Keystone CL 120)PQ26/20 Core Transformer - re

46、vision F (custom see appendix) TOP249YPC817A TL431CLPCopper Heat Sink EP11-HS1D Copper Heat Sink EP11-HS2DPower Integrations IncTel: www:Fax:Page 11 of 46張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的EPR-00011 - 70 W Adapter22-Jan-016Transformer DocumentationTransformer, T1 (rev. F)CORE CONTA

47、CT12SHIELD1 TURN OF FOIL3T# 26AWG x 3 T.I.WDG #219WDG #3WDG #19T # 26AWG x 2113T# 26AWG x 3 T.I.2WDG #589T # 26AWG x 235WDG #42 TURNS OF FOIL6ELECTRICAL SPECIFICATIONS:MATERIALS:Power Integrations IncTel: www:Fax:Page 12 of 46張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開ItemDescription1Core: FPQ26/20-A, TDK PC40 (or equivalent); ga

48、pped for ALG=843nH/T2 Lower loss ferrite can be substituted to obtain lower core temperatures.2Bobbin: TDK BPQ26/20-1112CP (or equivalent)3Magnet Wire: # 26 AWG Solderable Double Coated4Triple Insulated Wire: # 26AWG5Copper foil; 8mm wide Thickness=0.051mm (.002”)6Copper foil tape; 3M 1181 (or equiv

49、alent)11mm wide7Tape: 3M 74 Polyester Film (or equivalent)12mm wide8Tape: 3M 74 Polyester Film (or equivalent)9.2mm wide9Varnish10Tape: 3M 1298 Polyester Film (or equivalent) 19.5mm wideElectrical strength60 Hz 1 minute, from Pins 2-6to Pins 8-123000 VACPrimary InductancePins 1-3; all windings open.

50、 Measure at 130kHz273mH +/-10%Resonant FrequencyPins 1-3; all windings open.1.3 MHz (Min.)Primary leakage inductancePins 1-3; Pins 8,9,11, 12shorted. Measure at 130kHz.3mH (Max)張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的EPR-00011 - 70 W adapter22-Jan-01TRANSFORMER DIAGRAM:Tape 6Pin Side21/2 Primary 33

51、Tape 656Bias 58119Secondary 412Tape 31Shield 511/2 Primary 32SHIELD and BIAS Winding PREPARATION:#26 copper wire(only one required for shield)ABCopper FoilTape20.012.08.04.02.065 for Shield and 120 for Bias WindingFigure 1-A(Top View before folding tape)Figure 1-B(Top View after folding tape)CopperT

52、apeFigure 1-C(Cross Section)Power Integrations IncTel: www:Fax:Page 13 of 46張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開，有問必答）（勿擾100%拒絕水貼，10名瘋狂工程師運(yùn)營(yíng)的EPR-00011 - 70 W Adapter22-Jan-01TRANSFORMER CONSTRUCTION:6.1Transformer SourcesFor information on the vendors used to source the transformer, please visit our website att

53、he address below and select Engineering PrototypsPower Integrations IncTel: www:Fax:Page 14 of 46張飛實(shí)戰(zhàn)電子： 點(diǎn)擊打開1/2 Primary WindingStart at pin 2. Wind 9 turns of 2 parallel strands of item 3 from left to right. Wind a single layer and finish at pin 1.Shield Band (*see diagram)Prepare cuffed foil 5. Start at unterminated e