Delta Electronics (Shanghai) Design Center Alpha J. Zhang 章进法章进法 Shanghai, March 2010 LLC Series Resonant ConverterLLC Series Resonant Converter 再谈LLC串联谐振变换器再谈LLC串联谐振变换器 Delta Confidential Delta Electronics (Shanghai) Design Center PFC Rectifier DC/DC Converter 1. PFC rectifier for satisfying input harmonic current limit 2. 400v Bus voltage design for small bus capacitor selection 3. DC/DC Converter operates at 400v input at normal operation 4. DC/DC operates at lower input voltage when AC line fails Typical Architecture of Switching Power Supply Delta Electronics (Shanghai) Design Center Efficiency Characteristic of Conventional Converters Single-end Forward Converter Dual-Switch Forward Converter Half-Bridge DC/DC Converter Full-Bridge DC/DC Converter Asymmetric H/B DC/DC Converter Phase-Shift F/B DC/DC Converter SPRC Bridge DC/DC Converters Conversion Efficiency Input Voltage Low Efficiency at High Input High Efficiency at Low Input High Effi. Low-In Low Effi. High-In Wanted Efficiency Characteristics Delta Electronics (Shanghai) Design Center Ls Cs Cin S1 S2 Co TrD1 D2 1. Whole range ZVS for switches and ZCS for rectifiers 2. Wide range operation and higher efficiency for higher input 3. 96% efficiency under variable frequency control 4. Magnetic integration and smaller size LLC-Series Resonant Converter - LLC-SRC Delta Electronics (Shanghai) Design Center S1 S2 iLb iLs iC1 vc vp iLm Ls Cs S1 S2 Tr iC1 iLs D1 D2 Co iLb Lm vc vp Cin Mode I Operation Analysis of LLC-SRC Converter Delta Electronics (Shanghai) Design Center S1 S2 iLb iLs iC1 vc vp iLm Ls Cs S1 S2 Tr iC1 iLs D1 D2 Co iLb Lm vc vp Cin Mode II Operation Analysis of LLC-SRC Converter Delta Electronics (Shanghai) Design Center S1 S2 iLb iLs iC1 vc vp iLm Ls Cs S1 S2 Tr iC1 iLs D1 D2 Co iLb Lm vc vp Cin Mode III Operation Analysis of LLC-SRC Converter Delta Electronics (Shanghai) Design Center S1 S2 iLs iLb iC1 Ls Cs Cin S1 S2 Tr iC1 iLs D1 D2 Co iLb Typical Operation Current Waveforms: Delta Electronics (Shanghai) Design Center 0 0.5 1 1.5 2 2.5 3 3.5 4 00.511.5 M DC Gain r=2 r=4 r=6 r=8 8=r 6=r 4=r 2=r R = sR o L Rn r 2 = () R s min o TT nC I n V V+= 42 RR TTT20mS Hold-up Time Design 47u Bus Capacitor EFD25 Core for Transformer Ls Cs S1 S2 Tr D1 D2 Co Lm IM 400v Input LLC-SRC with Diode Rectifier 100Khz Switching Synchronous Rectifiers 380v-400v Input Range Operation 1mS Hold-up Time Design 68u Bus Capacitor PT30/19 Core for Transformer 400v Input Ls Cs S1 S2 Tr D1 D2 Co Lm IM Ld AHB with Synchronous Rectifier Early Stage Demonstration Design 86.00 87.00 88.00 89.00 90.00 91.00 92.00 Input Voltage (V) Efficiency(%) AHB88.85 90.20 90.50 90.80 91.00 91.60 LLC-SRC88.60 89.90 90.60 90.90 91.20 91.60 90v120v150v180v220v260v 60 65 70 75 80 85 90 95 Load Current (A) Efficiency(%) effi. (%) 64.2 72.5 79.9 87.7 90.1 90.8 91.2 91.1 0.26 0.45 0.75 1.75 2.75 3.75 4.75 5.75 - High Efficiency & Low Cost Adapter Delta Electronics (Shanghai) Design Center - Symmetrical Half-Bridge LLC-SRC DC/DC Converter Early Stage Demonstration Design 1kw AC/DC converter Size: 330*120*70 mm Frequency: 150kHz Efficiency: 81%87% Power density: 6W/inch3 Size: 220*120*40 mm Frequency.: 340kHz Efficiency: 85%91% Power density: 15W/inch3 Ls Cs1 Cin S1 S2 Co2 TrD1 D2 Co Ld Cs2 Delta Electronics (Shanghai) Design Center LLC-SRC Topology Extensions Ls Cs Cin S1 S2 Co Tr D1 D2 Ls Cin S1 S2 Tr D1 D2 Co Cs1 Cs2 Ls Cin S1 S2 Tr Cs1 Cs2SR1 Co SR2 Ls Cs Cin S1 S2 Tr Co SR2SR1 Delta Electronics (Shanghai) Design Center Ls Cs Cin S1 S2 TrD1 D2 Co S3 S4 Ls Cs Cin S1 S2 Co Tr S3 S4 D1 D2 D3 D4 Ls Cs Cin S1 S2 Co1 Tr S3 S4 D1 D2 D3 D4 Co2 Ls Cs Co Tr D1 D2 Cin1 S1 S2 S3 S4 Cin2 LLC-SRC Topology Extensions Delta Electronics (Shanghai) Design Center Application for High Density Modular Converter 32.0 x 21.5 x 6.0 778W/in3 & 12.3g 58.4 x 22.8 x 11.2 218W/in3 & 31.8g Delta Electronics (Shanghai) Design Center Application for High Efficiency LED Power Input Filter LLC-SRC With SR Interleaved Boost PFC Buck Cap. Output Filter Ls 400 Vdc S1 S2 12/24 Vdc Tr SR1 SR2 Cs1 Cs2 Delta Electronics (Shanghai) Design Center Application for Golden/Platinum Sever Power Input Filter LLC-SRC With SR Interleaved Boost PFC Buck Cap. Output Filter Ls S1 S2 12 Vdc Tr 400 Vdc SR1 SR2 S1 S2 Cs 72.0 74.0 76.0 78.0 80.0 82.0 84.0 86.0 88.0 90.0 92.0 94.0 96.0 Output Current (A) Efficiency (%) 230Vac-I74.0 85.0 90.0 89.5 110Vac-I72.0 82.0 86.0 85.5 230Vac-II88.4 92.5 94.3 93.3 110Vac-II84.2 89.5 91.9 90.7 10%20%50%100% 80 Plus Delta Electronics (Shanghai) Design Center 230Vac/50Hz 87 88 89 90 91 92 93 94 95 96 97 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Ouput Current (A) Eff. (%) Application for High Efficiency Rectifier Ls Cs 400 Vdc S1 S2 48 Vdc Tr S3 S4 SR3SR1 SR4SR2 Input Filter LLC-SRC With SR Interleaved Boost PFC Buck Cap. Output Filter Delta Electronics (Shanghai) Design Center Application for PHEV/EV AC/DC Charger Input Filter LLC-SRC Convert