High-efficiency and ultra-wide input voltage range DC-DC converter design method - News - Global IC Trade Starts Here.
One of the parameters of an isolated DC/DC converter is the range of input voltages at which the converter can operate normally. For industrial standard brick products used in the 48V input telecom market, the input voltage range is typically 36V to 75V, or the ratio of the highest to the lowest value of the input voltage is 2:1. But there are many applications that expect converters to handle a wider range of input voltages. For example, in some system applications, distributed input voltages have large transients and surges that last a long time and require filters to filter out.
As an example, Table 1 shows the steady state and transient ranges of distributed voltages in different railway system standards. Military vehicle design specifications also require a similar wide input voltage range to accommodate variations in their distributed voltage. Another reason for using a wide input voltage range DC/DC converter is to create a "universal" product that can be used in different DC systems. For battery systems with nominal 12V, 24V and 48V, three different systems are generally required. The input voltage version, as an alternative, provides a single solution for a converter capable of operating from 9V to 75V. This single solution saves production costs and reduces inventory.
Table 1: Specification requirements for input voltage ranges in several railway standards.
Although one expects a wide input converter, there is a major problem: in conventional products, the wider the input voltage range at which the module operates, the worse the performance of the converter. In general, at a given size, such as 1/4 brick, the efficiency of the converter and the power that can be processed will decrease as the input voltage range becomes wider. This is a natural consequence because the maximum input voltage must be designed while handling the very large input current at the lowest input voltage. For a 2:1 input range variator, the product of the maximum input voltage and the maximum input current is twice the processing power required, and this result is acceptable as a reasonable compromise. However, when a converter is designed to handle an 8:1 input range, the product of its maximum input voltage and maximum input current is eight times the processing power required. This result is extremely extreme. It is very serious for the power circuit associated with the converter isolation transformer.
Due to the above limitations, there are not many commercially available DC/DC converters capable of handling a wide range of input voltages, but a few "ultra-wide" 4:1 input converters typically do less than 1/min in a given physical size. The power of 2, which is compared to the power processed by the converter with only a 2:1 input voltage input range at the same size. In addition, the conversion efficiency of a wide input converter is typically 10%-25% lower than a 2:1 input converter.
One way to reduce this loss in wide input range converters is to separate the converter's adjustment function from its isolation function, as shown in Figure 1. In this figure, the first stage of the converter is a non-isolated buck converter, while the voltage adjustment function is performed by changing the duty cycle. The second stage of the converter provides electrical isolation without any voltage regulation, and can generally be further stepped down based on the transformer's ratio. That's how SynQor is the leader in high-efficiency DC/DC converters to design all of its products.
Figure 1: SynQor two-stage DC/DC converter topology with non-isolated adjustment stages before the unregulated isolation stage.
The advantage of this two-stage design is that only the first stage sees a wide range of input voltages. When the loss caused by the wide input voltage must be assumed by this first stage, the loss is not serious because the first stage does not require an isolation transformer. For isolation stages with transformers, there is no need to face a wide input voltage range. In this two-stage design, the input voltage is always constant as the intermediate bus voltage in the two-stage scheme. This allows the isolation stage to be optimized for a single operating condition, and makes the isolation stage very easy to implement based on synchronous rectification, which can greatly reduce power consumption. Efficiently improving at the isolation level makes up for any additional losses that occur at the adjustment level.
Figure 2: SynQor's new semi-brick series IQ64 is rugged and has an input voltage range of up to 8:1.
Figure 2 shows the new SynQor series of IQ64 series 8:1 ultra-wide input half-brick DC/DC converters. Table 2 shows the different input voltage ranges for the new SynQor family of products. As can be seen from the table, in addition to the normal 2:1 input range, there is a 4:1 input range for the product, or even an 8:1 input range for the product. The maximum power level and typical efficiency for the 3.3V output voltage are also shown in this table. Although there is some reduction in power level and efficiency as the input voltage range is widened, it is not very noticeable. This is the result of a two-stage topology scheme for power circuit design.
In addition to meeting the different input voltage ranges, the SynQor industrial grade DC/DC converter InQor series is fully sealed and rugged enough to be used in demanding environments, often accompanied by systems with such challenging technical requirements. .
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