CoPEC Custom IC Blocks for Enabling Digital Control in Switching Power Converters Dragan Maksimovic and Regan Zane July 11, 2003 Colorado Power Electronics Center University of Colorado, Boulder July 11, 2003 1 Outline CoPEC • Motivations & CoPEC directions • “Buffalo switcher” – Complete 1 MHz digital PWM controller IC – Hybrid digital PWM – Delay-line A/D • CoPEC research highlights • Education: – focus on power electronics & mixed-signal IC design July 11, 2003 2 Power Electronics Applications CoPEC Portable devices • On-chip power management /mW • Power supplies for LCD-s / hundreds of mW • Switching voltage regulators/ up to tens of Watts Computers and Consumers Electronics • Power supplies for components/ several watts • Micro-processor supplies: Voltage Regulator Modules (VRMs)/ up to hundreds of Watts • Off-line power supplies / up to kW Telecomm. equipment Industrial Automotive Lighting (HID, fluorescent) Aerospace July 11, 2003 3 PDA Example: Power Management USB Memory Expansion SDRAM SRAM FLASH ROM Power Power Switch Switch Logic Bus Drvr Wired I/F Bluetooth Audio Audio Codec Codec Wireless Access Wireless Ethernet 802.11b Wireless I/F Processing Core 1.5 / 1.8V / 2.5V Core Supply 3.3V / 5V System Supply Supply Buck SupplyVoltage Voltage Low-Dropout Low-Dropout Buck Supervisor Regulator Converter Supervisor Regulator Converter Power Management July 11, 2003 Touchscreen Touchscreen Control Control Buck-Boost Boost Buck-Boost Boost Converter Converter Converter Converter Battery Battery Monitor Monitor Battery Li+ Ni+ Alkaline Li-Ion Li-Ion Protector Protector Battery Battery Battery Charger Management Charger Microphone Microphone Amp Amp Microphone Audio AudioPwr Pwr Amp Amp Loudspeaker Headphones CoPEC Color or B/W LCD with Touchscreen Frontlight Backlight White LED CCFL Charge Charge Pump Pump CCFL CCFLCtrl Ctrl Wall Supply USB Power 4 CoPEC Buck Switching Converter Example Control L M + Vin + C vD _ vD(t) Vin Vout Load M -state ON Ts OFF pulse width modulator compensator Power Processing Vout = DVin July 11, 2003 switching converter Load d(t) t DTs • • • • • Vin Vout - Vref + + e(t) Controller Duty ratio Switching operation controls the average value of vD LC low-pass filter reduces the voltage ripple in the dc output Vout High switching frequency (hundreds of kHz to MHz), small size Ideally lossless, very high efficiency in practice Tightly regulated Vout through a feedback loop 5 Controller Implementation: Analog vs. Digital Analog Implementation + C D July 11, 2003 D C H H Hvout(t) vc(t) t saw-tooth waveform generator e(t) error amplifier and compensator Hvout(t) DPWM d[n] - + Vref Analog controller R - driver comparator Ts Vin + - driver VM vout + + R - + L M vout + + Vin Digital Implementation L M CoPEC Compensator d[n]=f{d[n-1], d[n-2],..,e[n],e[n-1]..} Digital Controller A/D e[n] + Hvout[n] Vref[n] 6 Research Motivation – Why Digital? CoPEC • Analog PWM controllers (30 year old technology) • Simple, low-cost • Well established design practices • What can be accomplished with digital control in power electronics applications? • Programmability (e.g. one controller can serve a much wider range of applications) • Elimination or reduction of the number of passive components • System integration (e.g. dynamic voltage scaling), diagnostics, etc. • Static and dynamic performance (e.g. through adaptive control techniques) • Reduced sensitivity to tolerances, process and temperature variations • Reduced cost July 11, 2003 7 Practical Limitations + Switching Converter V in Load v out - n dpwm Digital Controller could be simpler than a high-speed, • Processing unit -Available Digital Pulse W idth M odulator text • A/D –A complete analog controller high-resolution A/D d[n] Processing Unit CoPEC microcontroller/DSP systems are still n a/d A/D too slow, or too complex/costly • DPWM – High-speed/ High-resolution (ns) digital pulse width modulators are needed New design and implementation approaches for all functional blocks are needed July 11, 2003 8 CoPEC Research Program CoPEC Power Electronics and Mixed-Signal IC Design Pin New converter configurations tied to more sophisticated control techniques Switching power converter Gate-drive waveforms Programmable digital modulators Pout Voltage/current sensing Hardwareaccelerated computational unit Small, fast, scalable A/D converters Serial I/O Standard µC or DSP core and peripherals Digital signal transmission across isolation boundary New SMPS-specific controller building blocks New controller architectures for wide range of applications Digital SMPS controller Converter/controller co-design for significant gains in performance, size and/or cost: • reduced size of passive components • improved efficiency • improved dynamic responses, etc. July 11, 2003 System interface New control algorithms • parameter/state estimation • adaptive control • nonlinear control, etc. Modeling techniques 9 Examples of CoPEC Research Results CoPEC • Complete 1 MHz digital PWM controller IC – small size, programmable compensator, no discretes • Standard-cell based A/D converter ICs – small size, fast sampling, scalable with digital technology • Digitally controlled 3.3 V, 20 A DC power supply – chipset for isolated DC power supplies • Digital predictive current-mode control – very fast response – applications to PFC and DC-DC converters • Digitally-controlled power-factor correction rectifiers – order-of-magnitude improvement in dynamic response July 11, 2003 10 CoPEC Buffalo Switcher Complete High-Frequency Digital PWM Controller IC Delay-line A/D Vg L + – + C Vo _ DPWM, Compensator, Memory interface Switching power converter fs = 1MHz c(t) Vsense OUT SENSE e d Hybrid DPWM Compensator (look-up table) Vref Digital controller IC External memory July 11, 2003 Delay-line A/D • • • • • • 1 MHz switching frequency Programmable compensator 0.5µ CMOS technology Chip area: 0.96 mm2 All-digital, HDL-based design Standard digital design flow: • HDL (Verilog) based design • Synthesis to standard-cell gates • Automated place & route 11 CoPEC Chip architecture fs = 1/Ts dTs c(t) Vsense Ts SENSE OUT DPWM Digital pulse-width modulator d[n+1] + d[n] Table A Ts Table B Ts e[n-1] Ts Table C System clock e[n] +4 +3 +2 +1 0 -1 -2 -3 -4 e[n-2] Programmable compensator e Vq Vref Vo Vref (∆Vo)max A/D converter Look-up table programming interface External memory July 11, 2003 12 CoPEC A/D requirements Static voltage regulation e Only a few digital error outputs needed Vq ≤ ∆Vo Vq +4 +3 +2 +1 0 -1 -2 -3 -4 Vo Vref (∆Vo)max Dynamic voltage regulation July 11, 2003 small conversion range 13 CoPEC Delay-line A/D Delay td versus VDD Analog input is the supply voltage VDD for a chain of logic gates 1200 1000 Analog input Vsense SENSE test td (ps) 800 VDD VDD VDD VDD VDD R R R R R 600 400 delay cell 200 0 0 1 2 3 4 5 VDD t1 t2 D Q t3 D Q t8 D Q D Q sample q1 q2 q3 Encoder Digital output e July 11, 2003 q8 Digital output q (in “thermometer” code) Digital output e 14 Delay-line A/D Operation Start conversion CoPEC End conversion test t1 t2 td 1 1 t3 1 t4 1 1 t5 t6 t7 1 0 t8 0 q = {11111100} e = -2 sample 0 July 11, 2003 Ts 15 Delay-line A/D Experimental Results Vq = 53mV, σ = 3.6mV fs = 1 MHz sampling Error e +4 e Zero-error bin +3 Vq +2 +1 0 –1 –2 –3 –4 Vsense Vref – 0.2 V Vref – 0.1 V Vref Vref +0.1 V Vref +0.2 V Sampled output voltage Vsense July 11, 2003 CoPEC Advantages: • Small area/low power • Averaging over conversion time • All digital implementation Problem: • Basic configuration is highly susceptible to process/temperature • How to implement calibration to a reference voltage? 16 CoPEC Strobe-Calibrated Delay-Line A/D Vsense delay block 2 delay block 1 delay input delay block N/2 delay block N-1 delay block N reset D Vref D Q Strobe Delay D Q D Q D Q Q strobe therm<0> therm<1> therm<N/2> therm<N-1> therm<N> • Delay blocks constructed with standard cells • Matched “strobe delay” added to provide selfcalibrated reference point July 11, 2003 17 CoPEC Strobe-Calibrated Delay-Line A/D Exp Results July 11, 2003 9 8 7 Output Code • 1.8 V reference • 250ns typical conversion time (500ns worst case) • Standard-cell HDLbased design, 0.5µ CMOS process • Automated place-androute of primary and matched delay lines • Tested over the temperature range from -40ºC to 100ºC 6 5 4 3 2 1 0 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2 Vsense Experimental characteristics over temperature 18 CoPEC Strobe-Calibrated Delay-Line A/D Exp Results Histogram of the measured offset over 18 prototype chips July 11, 2003 • Average offset: 1.56mV (4% LSB) • 11 of 18 chips < 2 mV offset • Good performance holds over temperature • The worst offset prototype chip of 18 samples at the worst temperature corner: -7.3 mV offset • Total current consumption: – less than 100 µA 19 CoPEC Look-up Table Based Programmable Compensator Duty-cycle d[n+1] to DPWM 8-bit + d[n] e[n] Table A Ts Table B Ts Error from A/D e[n-1] Ts Table C e[n-2] Programmable compensator External memory PID compensator: d[n+1] = d[n] + a e[n] + b e[n-1] + c e[n-1] •“Zero” steady-state error •Programmable response •Very small area, very low power July 11, 2003 Table A Table B Table C 20 Conventional Counter-based DPWM Design N-bit Counter nDPWM A Comparator in=A Incr. Comparator in=0 Set Reset CoPEC clock f clk ≥ 2 N DPWM ⋅ f s fsw: switching frequency fclk: processor clock frequency nDPWM: number of bits of DPWM DPWM d[n] 10-bit @ 1 MHz => 1 GHz clock signal!? July 11, 2003 21 CoPEC High-Resolution Hybrid DPWM Combines a delay line (ring oscillator) with a counter to reduce the maximum clock speed Conventional DPWM: fclk = 2n ⋅ fs Hybrid DPWM: fs ≤ fclk ≤ 2n ⋅ fs Prototype: n = 8 bits fs = 1 MHz fclk = 8 MHz July 11, 2003 +VDD R D Q R D Q Q1 Q0 d[1:0] input d[3:0] 0 1 2 nd R D Q nd 2 :1 MUX R D Q Q2 +1 out[1:0] cnt[1:0] Q3 nc nc-bit comparator 1 (a ?= b) 3 a[1:0] n nc system clock 2-bit counter b[1:0] out (a=b) d[3:2] nc-bit comparator 2 (a ?= b) cnt[1:0] a[1:0] out nc (a=b) b[1:0] Reset Set R Q S c(t) OUT 22 CoPEC DPWM Experimental Results Output duty ratio [%] 100 90 80 70 60 50 40 30 20 10 0 July 11, 2003 0 32 64 96 128 160 DPWM input (decimal) 192 224 255 23 CoPEC High-Resolution Hybrid DPWM Hybrid DPWM combines a delay line (ring oscillator) with a counter to reduce the maximum clock speed Conventional DPWM: fclk = 2n ⋅ fs n = 8 bits fs = 1 MHz fclk = 256 MHz Hybrid DPWM: fs ≤ fclk ≤ 2n ⋅ fs Buffalo switcher hybrid DPWM prototype: n = 8 bits fs = 1 MHz fclk = 8 MHz July 11, 2003 +VDD R D Q R D Q Q1 Q0 d[1:0] input d[3:0] 0 1 2 nd R D Q nd 2 :1 MUX R D Q Q2 +1 out[1:0] cnt[1:0] Q3 nc nc-bit comparator 1 (a ?= b) 3 a[1:0] n nc system clock 2-bit counter b[1:0] out (a=b) d[3:2] nc-bit comparator 2 (a ?= b) cnt[1:0] a[1:0] out nc (a=b) b[1:0] Reset Set R Q S c(t) OUT 4-bit hybrid DPWM example 24 10-bit DPWM With Programmable Frequency CoPEC Delay line fsel[1:0] DQ clr Vdd Power On reset-start ndpw delay delay DQ clr DQ clr delay DQ clr delay reset start Input register [9:0] reset reset reset I0 in [4:0] 32:1 Multiplexer in[9:0] A reset I31 I1 B 10-bit NOR inc. 5-bit counter in[9:5] A B 5-bit comp. cnt[4:0] Vdd B A 5-bit OR delay block cnt[4] DQ clr in I0 S0 fsel[1] fsel[0] S I2 I3 4:1 Multiplexer S1 I7 I1 out Q DPWM R MR Delay- line/counter combination provides low power consumption, low on-chip area and high resolution at high frequencies July 11, 2003 25 10-Bit Hybrid DPWM Implementation CoPEC • 10-bit resolution • Programmable switching frequency: 750 kHz, 400 kHz, 200 kHz and 100 kHz/ 1.3 ns resolution • 32 times higher clock frequency • 0.5µ CMOS • Active chip area: 0.16 mm2 • Completely HDL coded July 11, 2003 26 Experimental Digitally Controlled Power Supply CoPEC Vg L + – + C Vo _ 4 V < Vg < 6 V Switching power converter fs = 1MHz c(t) OUT Hybrid DPWM Vsense e d Compensator (look-up table) L = 1 µH, C = 22 µF SENSE Delay-line A/D Vo = 2.7 V +/- 25 mV 0 < Io < 1.5 A fs = 1 MHz Vref Digital controller IC External memory July 11, 2003 27 CoPEC Experimental Results Vo – Vref [mV] Output voltage error +30 +20 Static line regulation Vo(t) [50 mV/div] +10 0 –10 Vq –20 Vg [V] –30 3.5 4.0 4.5 5.0 5.5 6.0 6.5 Input voltage Vo – Vref [mV] Output voltage error +30 Io(t) [1 A/div] 1A +20 +10 0A 0 –10 –20 –30 Static load regulation 0 0.2 0.4 0.6 0.8 1.0 1.2 Io [A] 1.4 1.6 1.8 Load Transient Response 2.0 Load current July 11, 2003 28 Conclusions CoPEC • Complete 1 MHz digital PWM controller IC • New architecture and HDL-based design of the key building blocks: – Calibrated delay-line A/D – Programmable look-up table compensator – Hybrid DPWM • Small area, low power, fast response • Design scales with digital technology • Open possibilities for a new generation of controller ICs (standard parts and ASICs) for power electronics July 11, 2003 29 Extension: Digital Chipset for Isolated Power Supply CoPEC Analog implementation Isolated DC-DC switching converter 1:n Vin vout Secondary C side Primary side c(t) e(t) Modulator Opto-coupler + + - load • Opto-coupler operates in linear mode H Hvout Vref Digital solution based on serial communication Isolated DC-DC switching converter 1:n Vin Primary side Secondary C side • Transfers just the error signal H DPWM e[n] Tx Rx Opto-coupler July 11, 2003 mode (as a logic gate) + c(t) regulator • Opto-coupler operates in digital vout e[n] Hvout A/D Vref[n] • Potential for less conservative design of the feedback loop 30 Isolated DC-DC: Test System CoPEC Tyco HW 100F • Isolated converter • 36 V ÷ 72 V to 3.3 V • up to 20 Amps load • 400 kHz switching frequency d[n] fsel[1:0] DPWM ndpw Regulator Primary side IC July 11, 2003 16 x fsw e[n] Serial receiver clk_out clk_in oc1 ser_in oc2 ser_out Vref + e[n] Serial transmitter • Replaced original analog current-mode controller on the board Secondary side IC 31 CoPEC Experimental Results output voltage output voltage load current 50% 25% 50% 25% Original analog controller July 11, 2003 load current Digital controller IC set 32 CoPEC Digital Controller for AC/DC PFC + Switching Power Converter Vin vo(t) Rectified AC line voltage input Load - vin(t) ig(t) A/D Analog/Digital Interface DPWM A/D vin[n] vo(t) d(t) ig[n] A/D d[n] vo[n] v L d [ n] = 2 − d [ n − 1] − (ig [n − 1] − iref ) − 2 in VTs V Deadbeat Control iref [n] 1 N x[ n ] N n=1 s[n] y[n] comparator u[n]=avu[n-1]+Kv(bvev[n]cvev[n-1]) Voltage loop regulator July 11, 2003 ev[n] (1 − rz −1 ) ⋅ (1 − z − ( M +1) ) H (z) = (1 − z −1 ) ⋅ (1 − r −( M +1) z −1 ) Comb Filter Sampling frequency selector vo[n] e[n] + - V [n] ref + Computational Unit 33 CoPEC PFC Experimental Results (current loop) Line frequency: 800Hz Switching frequency: 200KHz THD: 2.2% July 11, 2003 Switching frequency: 100KHz THD: 2.4% Dead-beat digital current mode control: near-perfect PFC even in demanding next-generation avionics applications (AC system with the line frequency up to 800 Hz) 34 CoPEC PFC Experimental Results (voltage loop) Output voltage Conventional voltage loop High-bandwidth loop with and without a notch filter Load current Line current Without comb THD > 20% With comb THD = 4.3% Output voltage With STCF Load current Line current July 11, 2003 35 CoPEC Other CoPEC Research Projects (2003) • Advanced digital control of DC-DC converters High-performance predictive digital current-mode control for DC-DC converters (TI) • Power management for low-power electronics Digital DC-DC switcher for battery-powered systems (NSC) Adaptive DC-DC converters for RF power amplifiers (DARPA) Adaptive DC-DC converters and power management architecture for base-band µP/DSP (NSF, NSC) Energy harvesting for wireless sensors and Implantable sensors for neuronal recording (Coleman Institute) • Microprocessor power supplies Multi-phase digital controller for microprocessor power supplies (Artesyn) • Off-line switching power supplies Modular mixed-signal control for electronic ballasts (GE) Digital controllers for solar/utility power system (Philips) Digitally controlled matrix converters for wind power system (NREL) July 11, 2003 36 CoPEC Educational Program Objectives CoPEC • Strong undergraduate and graduate programs in power electronics and mixed-signal IC design • Internship and job opportunities for students • Continuing education – Courses available through CATECS – Certificate program in power electronics • Technology transfer to CoPEC sponsors – Jointly defined and directed projects – Access to CoPEC IP July 11, 2003 37 CoPEC Growth of Program: Enrollment Enrollment for Analog IC Design, Spring 2002: 31, Spring 2003: 66 Enrollment for Mixed-Signal IC Design, Fall 2002: 15 Our visibility is increasing, and we are attracting more students to the power electronics and micro-electronics areas July 11, 2003 38 CoPEC Growth of Program: Graduate Students Power Electronics Program 16 Number of graduate students 14 12 other 10 TA 8 other RA 6 CoPEC RA 4 2 0 2000 2001 2002 2003 Year With increased visibility and availability of projects, we are able to attract better students into our program July 11, 2003 39 CoPEC Mixed-Signal IC Design Flow 4228/5008: Analog IC • Spring 2003 • Analog portion only System/Application Specification IC Specification IC Functional Description Analog/Digital Distribution Functional Analog Analog Sim Circuit & Verilog-A Mixed-Signal Simulation Functional Digital Verilog/VHDL Synthesis Complete Analog Digital Sim Complete Design 5007: Mixed-Signal IC • Fall 2003 • Full System • Emphasis on mixed blocks July 11, 2003 Verification Layout LVS, Extraction Custom, Place & Route, DRC Tape-Out 40 Analog IC Course Outline CoPEC • Week 1: Review circuits I-II • Text Ch. 1, Appendix A & C; Supplementary notes • Week 2: Review CMOS technology and device models • Text Ch. 2-3 • Weeks 3-4: Analog CMOS sub-circuits • Text Ch. 4 • Weeks 5-7: CMOS amplifiers • Text Ch. 5 • Weeks 8-10: CMOS operational amplifiers • Text Ch. 6 • Weeks 11-13: High-performance CMOS op-amps • Text Ch. 7 • Weeks 14-15: Comparators and select advanced topics • Text Ch. 8, Supplementary notes Text used: Allen/Holberg, Gray/Meyer, Johns/Martin July 11, 2003 41 Mixed-Signal IC Lecture Topics Comparators • 2-stage amp, hysteresis, latched, high-speed Sample & Hold Circuits Discrete-Time Signals (Fundamentals) Sampled-Data Circuit Techniques • SC & SI Circuits: Filter Design, Amplifiers, Applications • Non-idealities: clock-feedthrough, matching Data Converters • Fundamentals • Nyquist Rate D/A, A/D • Oversampling Converters System Level IC Design • System Description & Specification • IC Functional Specification • Top Down & Bottom Up Methodologies • System Planning: fabrication options, foundry selection, silicon area estimation, packaging options, prototype and production cost & time estimation • Design for Testability • Reviews: data sheet preparation, design reviews, risk analysis July 11, 2003 CoPEC System Simulation • Software Preparation: technology files, model files, standard cell libraries, software setup • Functional Simulation: Verilog-A and Verilog HDL languages, hierarchical designs with multiple cell-views • Mixed-Signal Simulation: co-simulation of analog & digital, functional and circuit level blocks in the Cadence tools • Ballast Controller & PLL Case Studies Physical Layer (time & setup permitting) • Floorplanning & Layout: custom and semi-custom layout in Cadence • Practical Considerations: matching, digital/analog isolation, latch-up, ESD and pad design, power distribution, noise coupling • Verification: LVS, DRC, extracted simulation • Fabrication: GDSII extraction to foundry 42 Mixed-Signal IC Final Project CoPEC • Select a mixed-signal project that targets a specific application • Work in teams of 1 to 4 • Deliverables include: • Proposal: Create a final project website with an overview of the target application, preliminary IC specifications, and a functional description Industry Involvement (?) of the digital & Local analog IC blocks – Due Oct 17 • Suggest project/research • Functional Design Review:relevant In-class presentation on your topics results to date, which must include systemwith level simulations verifying • Be involved design and/or finalyour functional blocksreviews in the application environment. Simulations must include at least one blockfabrication of each: Verilog-A, holdand a • Fund of best Verilog designsor VHDL, circuit level block. Include your presentation and simulation files on competition? your project website. Reviews Scheduled Nov 5-14 • Final Design Review: Final in-class presentation on your project. The complete “front-end” design of the projects must be complete, ready for transition to a layout engineer. Time permitting, various phases of layout and verification may be required as well. July 11, 2003 43