Discrete or combined controllers are better for AC/DC power supplies

If you have heard about employee corridor conversations at power design companies, they are likely to be arguing that the design of the 75W power supply should use the architecture shown in Figure 1 or Figure 2. In fact, the power components of the two architectures are identical, the only difference being the controller.

Figure 1: AC/DC design based on discrete controller IC

Figure 2: AC/DC design based on a combined controller IC

TI has support for both architectures and has products based on both architectures.

Although TI has a long-standing portfolio of modular controllers and is able to implement more functions in the same solution, I still believe that in the long run, independent power factor correction (PFC) controllers and independent DCs The /DC converter offers engineers an unparalleled advantage in designing a wide range of applications. This advantage is even more pronounced, especially in today's consumer-focused environment.

layout

Most power supply designers will tell you that printed circuit board (PCB) layout is the power supply design technology that is the biggest headache for them. A bad layout often leads the design process into a dead end. Power supplies come in a variety of shapes and sizes, and require very different layouts depending on the shape requirements.

Figure 3 shows the 150W reduced LED TV power supply reference design that meets the form factor. Note that there is a considerable gap between the components. In addition, the "small" requirements in television make the layout extremely low, making large components on the board look awkward. The PFC stage and inductor-inductor-capacitor (LLC) stages are far apart, making it difficult to achieve optimal layout for a combined controller. Discrete solutions do not have this problem because the controllers are in close proximity to their respective power stage components.

Figure 4 shows a 350W high-efficiency AC/DC power supply reference design for industrial power supplies. This is a space-constrained design that looks more like the dense and compact Dallas city centre, rather than a low-cost two-layer PCB layout. Controlling the signal line with a single combined controller is like parking a vehicle in Manhattan with a large parking lot, and there is only one one-way street, which is very inconvenient to enter and exit.

Figure 3: TV Power Figure 4: Industrial Power

The uniqueness of the power requirements and the fact that all of the combined controllers use the same shape are fundamentally contradictory. Some power supplies are constant current, some are constant voltage, some require high total harmonic distortion (THD), some require low standby, and some are fixed loads - but almost no power supply requires all of this.

As long as the diversity of power supplies persists, you can logically find out why 2-IC solutions are more suitable for your application.

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