Circuits, Devices, Networks, and Microelectronics CHAPTER 14. DC-DC SWITCHING CONVERTERS 14.1 INTRODUCTION TO POWER CONVERTERS Converters are the most common form of power electronics. They take one form of electrical power and convert it into another. The desired context is that a converter will convert with no loss of energy, which is a probably something of a ‘faith’ assumption but is also a reasonable starting point. I 1V1 I 2V2 (14.1-1) AC-AC conversion is a case-in-point. It is achieved by inductive coupling, which is simple and direct and well suited to the time-varying context of an AC current. The ideal transformer makes use of equation (14.1-1) via the assumption that the transformer constant k = 1. AC-AC converters are the principal means by which power is tapped from the power grid at frequency of either 50Hz or 60Hz, depending on what part of the world is being considered. AC-DC conversion from AC (= bipolar) waveform to DC (= unipolar) is also relatively simple. It is accomplished by transformer-coupled diode topologies that rectify (convert) the AC waveform to halfwave, full-wave, or three-phase outcomes. These waveforms are then improved by backend circuits that yield a fairly respectable fixed level DC with relatively little ripple. DC-DC conversion is accomplished by high-speed switches, usually in the form of power transistors. These are categorized as ‘switching power supplies’. A variant of these topologies is the DC-AC converter, also identified as an ‘inverter’. Given the technology advances in semiconductor devices the DC-DC switching technique has taken the lead over the older linear technologies since it offers many advantages in adaptability, size, weight, and efficiency. 14.2 THE DC-DC DOWNCONVERTER There is no power dissipation in an ideal switch since either Vswitch = 0 (when the switch is closed) or Iswitch = 0 (when the switch is open). So, for a converter based on ideal switches, equation (14.1-1) is an exact relationship. DC-DC converters are designed as either a ‘down converter’ or an ‘up converter’. The down converter is one where the voltage V2 at the output (load) is lower than the voltage V1 at the source end of the converter. The basic down converter topology is represented by figure 14.2-1 and consists of a series switch and a shunt switch, with drop-down topology not unlike that of a voltage divider except with 387 Circuits, Devices, Networks, and Microelectronics switches. However as a caveat, the two switches must be complementary in order to satisfy equation (14.1-1). The 12V - 9V example of Figure 14.2-1(a),(b),(c) conveys the context and concept. Figure 14.2-1(a) and (b). Basic down converter topology. 12V - 9V example Figure 14.2-1(c). (I,V) waveforms for the 12V - 9V down converter and their time-averaged levels. As represented by the figure, source voltage V1 and load current I2 are assumed to be fixed. Current I1 and voltage V2 are then time-averaged quantities, as represented by V2 V2 (t ) DS V1 (14.2-1a) I 1 I SW1 (t ) DS I 2 (14.2-1b) 388 Circuits, Devices, Networks, and Microelectronics where x(t ) indicates time averaging and DS represents the duty cycle of the series (connecting) switch.. Equations (14.2-1a) and (14.2-1b) are exactly consistent with equation (14.1-1). It should also be self evident as well as affirmed by equation (14.2-1a) that voltage V2 is defined by the duty cycle DS of series switch. And it should also be evident that current I2 will remain constant only if shunt switch SW2 toggles on when SW1 toggles off. For the 12V - 9V converter of figure 14.2-1 the duty cycle for the series switch (SW1) must then be DS = 9.0/12.0 = 0.75. And the duty cycle of the shunt switch SW2 is then = (1 – DS) = 0.25. As is also represented by figure 14.2-1(c), that the V2(t) and I1(t) associated with the naked switches would suffer from an unacceptable degree of ripple. It is therefore in order to temper them by means of capacitance and inductance components. Since L and C components are also (ideally) lossless then the assumption of equation (14.1-1) is still completely intact. The advantage of the switching converters is that the switches are transistors, which can be toggled at frequencies sufficiently high so that capacitances and inductances of relatively modest size will suffice to keep the ripple low. These elements also are energy storage elements. Capacitances store voltage, for which VC = V1 is kept relatively constant. Inductances store current, which keeps the current IL = I2 relatively constant. Which is exactly the premise that defines equations (14.2-1a) and (14.2-1b). The effect of the L and C components are realized by dV I dt C (14.2-2a) dI V dt L (14.2-2b) So it should be no great revelation that the larger the values of C and L, the smaller the ripple. Take note that there are also time constants at each end of the converter: 1 R1C (14.2-3a) 2 L R2 (14.2-3b) where R1 is the resistance of the source and R2 is the resistance of the load. Neither is represented by figure 14.2-1 but do play a role in the ripple considerations. Equation (14.2-2b) also emphasizes that an emf (voltage) is induced across the inductance for any change in current. This effect is represented by figure 14.2-2, which indicates how an interruption of current flow by a switch induces an emf of magnitude that can easily cause an arc break-over of the switch gap. In the 389 Circuits, Devices, Networks, and Microelectronics early part of the century, when unwary experimenters would hook up a DC induction motor to a simple knife switch, a panicky yank on the switch to shut off the motor would create a dangerous arc, usually sufficient to melt parts of the switch. In modern circuits, this effect merely annihilates the switching transistor. For this reason many circuits containing an inductance include a ”snubber” to shunt destructive overvoltage spikes and arcs. Figure 14.2-2. Induced voltages in an inductance due to current interruption. When a switch opens it is equivalent to a transition of RSWITCH = very small to RSWITCH = very large. In this respect the end of the switch connected to the inductor will be driven low by the flow of current. This response is of operational advantage to converter circuits because the action of opening the controlled switch will act to forward-bias a reactive (diode switch) element as is illustrated by figure 14.2-3 Figure 14.2-3. Inductive complementary switching by means of a diode ‘switch’ being toggled by the back emf of the inductance. The diode switch element is toggled by the emf induced across the inductance in a complementary response to the action of the controlled switch. The controlled switch is usually a transistor. The down converter (a.k.a. direct downconverter) topology is therefore of the form represented by figure 14.2-4 Figure 14.2-4. The direct down-converter topology. As represented by the figure of the down converter the input voltage V1 is also that which is stored on capacitance C. The capacitance is partially discharged by a current of magnitude I2 during the interval in which SW1 is on. 390 Circuits, Devices, Networks, and Microelectronics Figure 14.2-5. Charge and discharge current. and so the drop in voltage on the capacitance over the interval from 0 to DST is then 1 VC V1 C DS T I 2 I 1 dt 0 1 I 2 I1 DS T I1 1 I1 T C C I2 since DS I2 = I1. The ripple in source voltage is then VC V1 I1 1 DS T C I1 R1 1 DS T 1 Figure 14.2-6 illustrates the ripple on voltage V1 due to the charge flux. Figure 14.2-6. Ripple on VC = V1 due to charge/discharge of capacitance. 391 (14.2-4) Circuits, Devices, Networks, and Microelectronics The amplitude of this ripple can also be evaluated by evaluating VC when SW1 is open, for which the capacitance is charged up by a flow of current I1 onto the capacitance. This current causes an increment of voltage across C of value VC V1 1 C T I 1 dt DS T I1 1 DS T C (14.2-5) and is the same as that of equation (14.2-4), as expected. Similarly, a ripple in the current I2 will occur as the inductance discharges through the load while SW2 is closed, i.e. I 2 T V 1 V2 dt 2 1 DS T L DS T L V2 1 DS T R2 2 (14.2-6) This ripple will induce a corresponding ripple in V2, i.e. V2 I 2 R2 (14.2-7) EXAMPLE 14.2-1: A VB = 13V source with internal resistance RB = 1.2 is used to supply 5V to an RL = 2.5 load. It is switched by a clock at fs =50 kHz. (a) What are the converter values I2, V1, and I1 and what duty cycle DS is required? (b) What minimum values of L and C are needed to keep the ripple at the output and input to less than 5%? Figure 14.2-7: 13V-to-5V direct converter operating at fs = 50 kHz. SOLUTION: I2 = V2/R2 = 5/2.5 = 2A PL = IL x VL = 2 x 5 = 10W Assuming V1 x I1 = V2 x I2 = 10 W, and I1 = (13 – V1 )/RB, we get the quadratic: V1 x (13 - V1) = 10 x 1.2 392 Circuits, Devices, Networks, and Microelectronics which has solutions V1 = 12.0 and V1 = 1.0. Only the solution V1 = 12.0V makes sense since the other solution is less than V2 (= 5V). For this value, we then get: I1 = (13 – V1 )/RB = 0.833A The duty cycle DS is then: DS = V2 / V1 = 0.417 The ripple current at the output is, from equation (14.2-6), I 2 .05 2 1.0 5.0 (1 0.417) 20 s L where T = 1/50kHz = 20 s. The inductance needs to be (at least) L 5.0 0.583 20u = 583H 0.05 2 Similarly, from equation (14.2-4) V1 .05 12 1 0.833 (1 0.417) 20s C from which the capacitance will need to be (at least) C 0.833 0.583 20u 0.05 12 = 16.2F If the topology of figure 14.2-4 is framed in terms of a source consisting of VB and RB and a power level PL to the load, the lossless condition I1V1 I 2V2 PL translates to V1 V B V1 PL R B which has solution V1 VB 2 1 1 4 PL R B V B2 (14.2-8) where only the positive root is valid, required in order that V1 > V2. 14.3 THE DC-DC UPCONVERTER The topology represented by figure 14.2-4 is also called the down converter or buck converter since it ‘bucks’ the voltage down to a lower output level V2 < V1 . It has a sister topology that uses the same principles, called the boost converter or up converter for which V2 > V1, represented by figure 14.3-1. 393 Circuits, Devices, Networks, and Microelectronics Figure 14.3-1. The direct converter ‘boost’ topology. Much of the action identified for the down converter applies to the up converter. The inductance will store energy in the form of current, and when SW1 is toggled off, then SW2 will be toggled on because the current I1 through the inductance will not be denied without a fight and has to go somewhere. The current stored in the inductance during the first part of the duty cycle will toggle SW2 in the same way as it did for the down converter by induced emf and flowing into the right-hand side of the circuit at a higher voltage V2 > V1. The controlled switch, SW1, which is a shunt switch, has duty cycle DP . Current through the diode (series switch) results only when the controlled switch is toggled off. It has duty cycle DS = 1 – DP. The current through the diode is therefore I D I 2 DS I1 (14.3-1) And since we assume that the circuit is ideal and lossless, for which I2V2 = I1V1, then equation (14.3-1) identifies voltage V2 as V2 V1 DS (14.3-2) Since DS is always less than 1, then V2 > V1, and the converter therefore ‘boosts’ the voltage. The voltage across capacitance C is VC = V2. Compare this condition to the down converter for which V1 was that that was across capacitance C. Equation (14.3-2) is the same as equation (14.2-1a) with the subscripts flipped. This is no coincidence, of course. The topologies are the same, except that figure 14.3-1 is a right-to-left flip of figure 14.3-4. Otherwise the only difference is that the shunt switch is now the controlled switch and the series switch is now a reactive switch. Analysis is therefore entirely the same as for the down converter except that subscripts are interchanged. And the ripple for the voltage across the capacitance and the current through the inductance are the same as (14.2-4) and (14.2-6), except that the subscripts will be interchanged if we retain the orientation 394 Circuits, Devices, Networks, and Microelectronics nomenclature of subscript 1 at the input and subscript 2 at the output. A comparison is represented by example 14.3-1. EXAMPLE 14.3-1: Warrior-brand combat underwear uses a muscle electrostimulation (ESM) unit which requires 72V at 1A to operate in the superman mode. If it is supplied by a 9V battery belt capable of supplying 50A of short-circuit current, determine (a) converter values V1, and I1 and duty cycle DP of the controlled switch, (b) values of L and C needed to keep voltage ripple at the output and current ripple of the input to less than 2%, assuming that the circuit is toggled at switching frequency fs = 50 kHz. SOLUTION: (a) The output requirement is P2 = PL = I2 V2 = 1.0A × 72V = 72W. Assuming that the converter is approximately lossless, I1V1 = I2V2. In this case we have V1 = VB – I1R1, where VB = battery voltage = 9V and R1 = RB = 9V/50A = 0.18. Therefore (V B I 1 R B ) I 1 P2 72 which, with values is of the form (9 0.18 I 1 ) I 1 72 which has solutions I1 = 10A and 40A. Although both solutions will work, I1 = 10A is the more reasonable one, and will correspond to V1 = 7.2V and DP = 1 – I2/I1 = 0.9 (b) For ripple of less than 2%, V2 = VC = .02 × 72 = 1.44 V According to equation (14.2-4) C I1 1 DS T VC 395 Circuits, Devices, Networks, and Microelectronics Take note that DP and (1 - DS) are the same, since both are the fraction of the cycle for which the two sides are not conjoined. For the boost converter I1 must be replaced by I2 since I2 is the current flowing from the capacitance to the load = 1.0A, so that C 1.0 (0.9 20 s) 1.44 = 12.5F where we have used T = 1/fs = 20s. Similarly for a 2% ripple in input current and evaluating for the condition that SW1 = ON (and for which the two sides are disconnected) equation (14.2-6a), with the orientation subscripts flipped, then gives 1 I 1 I L .02 10 (7.2 (0.9 20 s)) L and which gives L = 648H The topology of figure 14.3-8 suggest the usage of I1V1 = I2V2 = PL as a quadratic equation of the form I1 (VB I1 RB ) PL for which the required solution (negative root) is I1 VB 2 RB 1 1 4 PL R B V B2 (14.3-3) Synopsis: For the direct converter (whether up or down), equations (14.2-8) and (14.3-3) identify the electrical characteristics at the input port as defined by the load and the source. If a little fun algebra is applied to the product of equations (14.2-8) and (14.3-3) I 1 V1 VB 2RB 1 1 4 PL R B V B2 V B2 4RB VB 2 1 1 4 PL R B V B2 4 PL R B 1 1 V B2 = PL (14.3-4) Which is exactly the same as equation (14.1-1). The converter use the switching action to pass energy between energy storage components L and C, for which for downconverter: V1 = VCX (14.3-5a) for upconverter): I1 = ILX (14.3-5b) 396 Circuits, Devices, Networks, and Microelectronics where VCX is the voltage across the capacitance and ILX is the current through the inductance. The inductance also induces the emf (voltage) necessary to toggle the reactive (diode) switch. In order to avoid the nomenclature question about orientation subscripts, it is also a better option to restate ripple denoted by equations (14.2-4) and (14.2-6a) as VCX I CX 1 DS T C (14.3-6a) I LX VLX 1 DS T L (14.3-6b) where current ICX is that which flows from the capacitance and voltage VLX is that induced across the inductance. The part of the duty cycle for which the two sides of the converter are momentarily disconnected relates only to the series switch, for which the It is a also practical to express equations (14.3-6a) and (14.3-6b) in terms of the time constants associated with the reactive elements. Regardless of the orientation of the direct converter, whether up converter or down converter, time constant CX = RCXC and LX= L/RLX may be defined, for which RCX is the resistance in the side of the circuit having the capacitance and RLX is the resistance in the side having the inductance . Using these identifications the ripple equations take the form VCX 1 t (off ) I CX RCX CX (14.3-7a) I LX 1 t (off ) VLX RLX LX (14.3-7b) Where t(off) is the part of the duty cycle for which the series switch (with duty cycle DS) has toggled off. In the case of the direct-down converter topology, the resistance in the capacitance path corresponded to RB and the resistance in the inductance path corresponded to RL. Consistent with equations (14.3-5) the current I1 corresponds to ICX and current I2 corresponds to ILX. Take note that VCX I CX RCX for the down converter since VCX is a node voltage at the input port and ICXRCX is the voltage drop across RCX = RB. 397 Circuits, Devices, Networks, and Microelectronics 14.4 THE DC-DC INDIRECT (UP/DOWN) CONVERTER Another topology is the indirect converter represented by figure 14.4-1. This topology can be either an ‘up’ converter or a ‘down’ converter. Figure 14.4-1. The indirect (buck-boost) converter topology. If we acknowledge that the time average of voltage over the inductance must be zero, then V1 DT V2 (1 D)T 0 so that V2 D V1 1 D (14.4-1) where D is the duty cycle of the controlled switch and T is the period of the cycle. Depending on the value of D, V2 can be either greater or less than V1. We also note that the average capacitance current must be zero, in which case, I 2 DT I 1 (1 D)T which is the same as I2 1 D I1 D (14.4-2) This result just confirms that the (ideal) net power going into the converter should be zero, assuming that the converter is approximately lossless. 14.5 LOSS ANALYSIS FOR DC-DC CONVERTERS The reality of the DC-DC converter is that it is not lossless since some power is dissipated in the switching components themselves. The context is represented by figure 14.5-1. The switches are semiconductor devices. Although considerably faster than electromechanical switches these components 398 Circuits, Devices, Networks, and Microelectronics will have finite turn-on and turn-off times. They will also have a finite voltage drop VON across the switch when it is conducting. Significant power dissipation occurs. The principle is represented by figure 14.5-1. Figure 14.5-1: Power dissipation in the switches. In a quasi-ideal context the switching transition can be represented as an approximately linear transition over the interval (0 < t < tON) as represented by Figure 14.5-8. Consequently I (t ) I ON t t ON and t V (t ) VOFF VON 1 t ON VON The power dissipated in the switch during transition is the time-average P(t ) over the switching interval 0 < t < tON for which 1 P(t ) T tON 0 I (t )V (t )dt t 1 1 VON I ON VOFF T 6 3 VOFF (14.5-1) where t is the transition time (= either tON or tOFF) and T = 1/fS, with fS = switching frequency. Equation (14.5-1) is the same for either the ON-OFF or the OFF-ON transition. 399 Circuits, Devices, Networks, and Microelectronics If you examine the down converter and up converter topologies and their operation, the current ION that is passed by the switches when they are ON is always the current through the inductance. Likewise the voltage VOFF across a switch when it is OFF is always the voltage across the capacitance. In the context of energy being transferred from one type energy storage element to another it should be no surprise that they also directly define the electrical quantities for the two switches. Furthermore, the power dissipated when a switch is ON is DT t ON PD (ON ) I ON VON T (14.5-2) where D is the duty cycle for the switch, whether it be DS or DP. Turn-on and turn-off times tON and tOFF for a semiconductor switch involve more overhead than represented by figure 14.5-1. They are functionally related to the levels of current and voltage, since these switches must usually be ”charged up” for minority-carrier injection or if they have a drift region it must be depleted before ceasing to conduct. For power transistors and power diodes the transition times tON and tOFF are therefore assumed to be on the order of s and these response times are the fundamental limit to the switching speed fs. Semiconductor devices will also suffer a finite voltage drop across the conduction path, particularly for devices that are designed to accommodate higher level voltages. These may on the order of 1 to 6V for a power BJT in the ‘ON’ state. A power diode will have a voltage drop on the order of 0.6V to 2.0V. For lower voltage converters as represented by examples 14.2-1, and 14.3-1 common off-the-shelf power BJTs and diodes may be employed, for which the ‘ON voltage’ voltage drop across the devices should be less severe. EXAMPLE 14.5-1: Assume that the controlled switch (= BJT) of example #14.2-1 has VCE (on) = 1.0V, and that the diode has VD(on) = 0.6 V. Assume that tON = 1.0s = tOFF for both devices. Determine the power dissipated in the switches. SOLUTION: The switching frequency fS = 50kHz, for which T = 1/fS = 20s. From the example it was determined that I2 = IL = ION = 2A and V1= VC = VOFF = 12V. From equation (14.5-1) the power dissipated during switch transitions is then PD1 (transition ) 2.0 12 1.0s 1.0s 1 1 1.0 20s 6 3 12.0 PD 2 (transition ) 2.0 12 1.0s 1.0s 1 1 0.6 20s 6 3 12.0 400 = 0.467W = 0.44W Circuits, Devices, Networks, and Microelectronics The power dissipated during the time when the switches are ON is PD1 (ON ) 2.0 A 1.0V (0.417 20s) 1.0s 20s = 0.733W PD 2 (ON ) 2.0 A 0.6V (0.583 20s) 1.0s 20s = 0.64W Therefore the power dissipated budget due loss in the switches is PD1 (SW1) PD1 (trans) PD1 (ON ) = 1.2W PD2 (SW 2) PD2 (trans) PD2 (ON ) = 1.08W Take note that each switch has two transitions during a toggle cycle. This loss represents a total PD of 2.28 W. Since the power load requirement was 10W, then for a more accurate assessment it would be appropriate to include this power loss into the analysis. And then it would be necessary that duty cycle DS be increased in order to compensate for the loss in the switches. The process then becomes iterative. If an iteration is carried back and forth between examples 14.2-1 and 14.5-1 using the modification I 1V1 I 2V2 PD with PD = PD1 + PD2 and a repeat of the analysis, we find that the duty cycle must be increased to DS = 0.426. And with this change we also find that V1 decreases to 11.75 V. The change in the duty cycle D due to the power loss in the switches is usually minor. But the analysis does acknowledge that we need to have a BJT and a diode capable of dissipating approximately 1.2W and 1.08W, respectively, each of which should then be assessed for thermal de-ratings, safety margins, and the use of heat sinks. As a rough assessment, and allowing for safety margins and de-rating via the heat sinks, this converter can probably be constructed using a 5W power transistor and a 5W diode to support the 10W load with circuit efficiency 81%. 401 Circuits, Devices, Networks, and Microelectronics PORTFOLIO and SUMMARY Direct converter Ideal: I 1V1 I 2V2 V1 VB 2 1 1 4 PL RB VB2 I1 VB 4P R 1 1 L2 B 2 RB VB Down converter Ripple VC I L I Cx 1 DS T C VLx 1 DS T L Up converter Non-ideal DC-DC converter: PD (transition ) t 1 1 VON t 1 1 VON I ONVOFF I LxVCx T 6 3 VC T 6 3 VC DT t ON PD (ON ) I ON VON T Indirect Converter V2 D V1 1 D I2 1 D I1 D Thermal: TJ T A JA PD JA JC CS SA JC TJ (max) 25 PD (rated ) 402 Circuits, Devices, Networks, and Microelectronics Simulation exercises results 1. 12V- 9V down converter 2. 9V - 45V up converter 403 Circuits, Devices, Networks, and Microelectronics 404