Synchronous Rectifier DC/DC Converters: 1956 - C12.fm Page 575 Monday, August 18, 2003 3:17 PM
Synchronous Rectifier DC/DC Converters: 1956 - C12.fm Page 575 Monday, August 18, 2003 3:17 PM
Synchronous Rectifier DC/DC Converters: 1956 - C12.fm Page 575 Monday, August 18, 2003 3:17 PM
12
Synchronous Rectifier DC/DC Converters
D1 Lf RL
T
R1 C1 L m v3 D2 Cf R v2
V1
1 : N
Q0
PWM Q0
FIGURE 12.1
Forward converter with dynamic clamp circuit.
1.00
0.80
Efficiency
Synchronous
0.60
Rectifier
Schottky Diode
0.40
Normal Diode
0.20
0.00
0.2 0.3 0.4 0.5 0.6 0.7 0.8
Duty Cycle
FIGURE 12.2
Efficiencies of different types of forward converter.
12.1 Introduction
A synchronous rectifier is an electronic switch that improves power-conver-
sion efficiency by placing a low-resistance conduction path across the diode
rectifier in a switch-mode regulator. At 3.3 V, the traditional diode-rectifier
loss is significant with very low efficiency (say less than 70%). For step-down
regulators with a 3.3 V output and 12 V battery input voltage, a 0.4 V forward
voltage of a Schottky diode represents a typical efficiency penalty of about
12%, aside from other loss mechanisms. The losses are not as bad at lower
L
T
S2
v3 D2 C R v2
S1
V1
1:N
D1
PWM
S
FIGURE 12.3
Synchronous rectifier converter with low-resistance MOSFET.
input voltages because the rectifier has a lower duty cycle and, thus, a shorter
conduction time. However, the Schottky rectifier’s forward drop is usually
the dominant loss mechanism.
For an input voltage of 7.2 V and output of 3.3 V, a synchronous rectifier
improves on the Schottky diode rectifier ’s efficiency by around 4%.
Figure 12.1 also shows that, as output voltage decreases, the synchronous
rectifier provides even larger gains in efficiency.
A practical circuit arrangement of a synchronous rectifier (SR) DC/DC
converter with purely resistive load is shown in Figure 12.3. It has one
MOSFET switch S on the primary side of the transformer. Two MOSFETs S1
and S2 on the secondary side of the transformer are functioning as the
synchronous rectifier. T is the isolating transformer with a turn ratio of 1:N.
an L-C circuit is the low-pass filter and R is the load. V1 is the input voltage
and V2 is the output voltage. The main switch S is driven by a PWM pulse-
train signal. Repeating frequency f and turn-on duty cycle K of the PWM
signal can be adjusted.
When the PWM signal is in the positive state, the main switch S conducts.
The primary voltage of the transformer is V1, and subsequently the second-
ary voltage of the transformer is v3 = NV1. In the mean time the MOSFET S1
is forward biased, so it turns ON and inversely conducts.
When the PWM signal is in the negative state, the main switch S is switched
off. The voltage of the transformer, v3, at this moment in time is approxi-
mately –NvC1. At the mean time the MOSFET S2 is forward biased, so it turns
ON and inversely conducts. It functions as free-wheeling diode and lets the
load current remain continuous through the filter L–C and load R.
A lot of papers in literature with practical hardware circuit achievements
on synchronous rectifier have been presented about the recent IEEE Trans-
actions and IEE Proceedings. The paper “Evaluation of Synchronous-Rectifi-
cation Efficiency Improvement Limits in Forward Converters” supported by
Virginia Power Electronics Center is one of the few outstanding research
publications on synchronous rectifiers (Jovanovic et al., 1995). This chapter
provides a practical design of a 3.3V/20A FSR (forward synchronous recti-
fier) with an efficiency of 85.5%. Similarly, another paper in 1993 also showed
the principle of a RCD clamp forward converter with an efficiency of 87.3%
at low output current (Cobos et al., 1993). Two Japanese researchers from
Kumamoto Institute of Technology designed an FSR with an additional
winding and switching element that is able to hold the gate charge for the
freewheeling MOSFET (Sakai and Harada, 1995). Their experimental results
for a 5 V/10 A SR gives a maximum efficiency of approximately 91% at a
load of 7 A and an efficiency of 89% at 10 A. Another comparable FSR project
was made by James Blanc from Siliconix Incorporated (Blanc, 1991). In his
paper, he has included a lot of practical and useful simulation and experi-
mental waveform data from his 3.3 V/10 A FSR. As the output voltage
decreased, the operating efficiency decreased. Until now, no recent paper
has been published on any practical hardware FSR that is able to provide
1.8 V/20 A output current at high efficiency.
Analysis and design of DC/DC converters has been the subject of many
papers in the past. From the moment averaging techniques were used to
model these converters, interest has been focused on finding the best
approach to analyze and predict the behavior of the averaged small signal
or large signal models. The main difficulty encountered is that the converter
models are multiple-input multiple-output nonlinear systems and thus,
using the well-known transfer function control design approach is not
straightforward. The most common approach has been that of considering
the linearized small signal model of these converters as a multi-loop system,
with an outer voltage loop and an inner current loop. Since the current loop
has a much faster response than that of the outer loop, the analysis is greatly
simplified and the transfer functions obtained allow the designer to predict
the closed loop behavior of the system. Another approach in analysis and
design has been that of state-space techniques where the linearized state-
space equations are used together with design technique such as pole place-
ment or optimal control.
Synchronous rectifier DC/DC converters are called the fifth generation
converters. The developments in microelectronics and computer science
require power supplies with low output voltage and strong current. Tradi-
tional diode bridge rectifiers are not available for this requirement. Soft-
switching technique can be applied in synchronous rectifier DC/DC con-
verters. We have created converters with very low voltage (5 V, 3.3 V, and
1.8 ~ 1.5 V) and strong current (30 A, 60 A, 200 A) and high power transfer
efficiency (86%, 90%, 93%). In this section new circuits different from the
ordinary synchronous rectifier DC/DC converters are introduced:
L RL
T
S3
Lm v3 D3 CO R v2
S2
V1
1:N
PWM D2
Cj
S1
FIGURE 12.4
Flat transformer synchronous rectifier Luo-converter.
• Transformer Is in magnetizing
• Forward on
• Transformer Is in demagnetizing
• Switched off
1
ω= (12.1)
LmC j
where the Lm is the leakage inductance of the primary winding, the Cj is the
drain-source junction capacitance of the main switch MOSFET S.
If Cj is very small in nF, its charging process is very quickly completed.
The primary current increases with slope V1/Lm, then the time interval of
this period can be estimated
Lm
t1 = NI O (12.2)
V1
This is the process used to establish the primary current from 0 to rated
value NIO.
12.2.2 Switching-On
Switching-on period is controlled by the PWM signal, therefore,
t2 ≈ kT (12.3)
π V1
t3 = LmC j [ + ] (12.4)
2 Lm
V1 +
2
( NI O ) 2
Cj
When the main switch is switching-off there is a voltage stress, which can
be very high. The voltage stress is dependent on the energy stored in the
inductor and the capacitor:
Lm
Vpeak = NI O (12.5)
Cj
The voltage stress peak value can be tens to hundreds of volts since Cj is
small.
12.2.4 Switching-Off
The switch-off period is controlled by the PWM signal, therefore,
t4 ≈ (1 − k )T (12.6)
© 2003 by CRC Press LLC
1956_C12.fm Page 581 Monday, August 18, 2003 3:17 PM
L RL
T
S4
Lm CO R v2
C v3 D4
S2 S3
V1
1:N
D2 D3
S1
PWM
FIGURE 12.5
Active clamped flat transformer synchronous rectifier Luo-converter.
12.2.5 Summary
Average output voltage V2 and input current I1 are
Lm 2
V2 = kNV1 − ( RL + RS + N )I O (12.7)
T
and
I 1 = kNI O (12.8)
L
V2 I O RL + RS + m N 2
η= = 1− T IO (12.9)
V1 I 1 kNV1
When we set the frequency f = 150 to 200 kHz, we obtained the V2 = 1.8 V,
N = 1/12, IO = 0 to 30 A, Volume = 2.5 (in.3). The average power transfer
efficiency is 92.3% and the maximum PD is 21.6 W/in.3.
stored in the leakage inductor Lm. Since the clamp capacitor C is much larger
than the drain-source capacitor Cj by usually hundreds of times, the stress
voltage peak value remains at only a few volts.
There are four working modes:
• Transformer Is in magnetizing
• Forward on
• Transformer Is in demagnetizing
• Switched off
1
ω= (12.10)
LmC j
where the Lm is the leakage inductance of the primary winding, the Cj is the
drain-source junction capacitance of the main switch MOSFET S.
If Cj is very small in nF, its charging process is very quickly completed.
The primary current increases with slope V1/Lm, then the time interval of
this period can be estimated
Lm
t1 = NI O (12.11)
V1
This is the process to establish the primary current from 0 to rated value NIO.
12.3.2 Switching-On
Switching-on period is controlled by the PWM signal, therefore,
t2 ≈ kT (12.12)
π V1
t3 = LmC [ + ] (12.13)
2 L
V12 + m ( NI O )2
C
© 2003 by CRC Press LLC
1956_C12.fm Page 583 Monday, August 18, 2003 3:17 PM
where C is the active clamp capacitor in µF. The voltage stress depends on
the energy stored in the inductor and the capacitor:
Lm
Vpeak = NI O (12.14)
C
The voltage stress peak value is very small since capacitor C is large, mea-
sured in µF.
12.3.4 Switching-Off
Switching-off period is controlled by the PWM signal, therefore,
t4 ≈ (1 − k )T (12.15)
12.3.5 Summary
Average output voltage is V2 and input current is I1:
Lm 2
V2 = kNV1 − ( RL + RS + N )I O (12.16)
T
and
I 1 = kNI O (12.17)
L
V2 I O RL + RS + m N 2
η= = 1− T IO (12.18)
V1 I 1 kNV1
When we set the frequency f = 150 to 200 kHz, we obtained the V2 = 1.8 V,
N = 1/12, IO = 0 to 30 A, volume = 2.5 (in.3). The average power transfer
efficiency is 92.3% and the maximum power density (PD) is 21.6 W/in.3.
FT L2
Lm S4 D4 CO
C
D2
+ 1:N
S3 D3 _ R +
V1 V2
–
S2 L1
PWM S1 D1
FIGURE 12.6
Double-current synchronous rectifier Luo-converter.
• Transformer Is in magnetizing
• Forward on
• Transformer Is in demagnetizing
• Switched off
1
ω= (12.19)
LmC j
where the Lm is the leakage inductance of the primary winding, the Cj is the
drain-source junction capacitance of the main switch MOSFET S.
If Cj is very small in nF, its charging process is very quickly completed.
The primary current increases with slope V1/Lm, and the time interval of this
period can be estimated
Lm
t1 = NI O (12.20)
V1
This is the process used to establish the primary current from 0 to rated
value NIO.
12.4.2 Switching-On
Switching-on period is controlled by the PWM signal, therefore,
t2 ≈ kT (12.21)
π V1
t3 = LmC [ + ] (12.22)
2 L
V12 + m ( NI O )2
C
When the main switch is switching-off there is a very low voltage stress
since the active clamp circuit is applied.
12.4.4 Switching-Off
Switching-off period is controlled by the PWM signal, therefore,
t4 ≈ (1 − k )T (12.23)
12.4.5 Summary
Average output voltage V2 and input current I1 are
Lm 2
V2 = kNV1 − ( RL + RS + N )I O (12.24)
T
and
I 1 = kNI O (12.25)
L
V2 I O RL + RS + m N 2
η= = 1− T IO (12.26)
V1 I 1 kNV1
© 2003 by CRC Press LLC
1956_C12.fm Page 586 Monday, August 18, 2003 3:17 PM
FT L2
+
CO I2
S4 D1 R
_V2
1:N S3
D3
Lm
L1
C
+ Cr
V1 L4
–
S6 D4
D2
1:N
S5 D5
L3
S2
Lr
PWM
S1 D1
FIGURE 12.7
ZCS synchronous rectifier Luo-converter.
When we set the frequency f = 200 to 250 kHz, we obtained the V2 = 1.8 V,
N = 12, IO = 0 to 35 A, volume = 2.5 (in.3). The average power transfer
efficiency is 94% and the maximum PD is 25 W/in.3.
• Transformer Is in magnetizing
• Resonant period
• Transformer Is in demagnetizing
• Switched off
© 2003 by CRC Press LLC
1956_C12.fm Page 587 Monday, August 18, 2003 3:17 PM
1
ωr = (12.27)
Lr Cr
Lr
Zr = (12.28)
Cr
I 1Zr
α = sin −1 ( ) (12.29)
V1
where the Lr is the resonant inductor and the Cr is the resonant capacitor.
The primary current increases with slope V1/Lr , then the time interval of
this period can be estimated
I 1Lr
t1 = (12.30)
V1
1
t2 = (π + α) (12.31)
ωr
V1 (1 + cos α )Cr
t3 = (12.32)
I1
When the main switch is switching-off there is a very low voltage stress
since active clamp circuit is applied.
12.5.4 Switching-Off
Switching-off period is controlled by the PWM signal, therefore,
V1 (t1 + t2 ) V cos α
t4 = (IL + 1 ) − (t1 + t2 + t3 ) (12.33)
V2 I 1 Zr π / 2 + α
12.5.5 Summary
Average output voltage V2 and input current I1 are
Lr + Lm 2
V2 = kNV1 − ( RL + RS + N )I O (12.34)
T
and
I 1 = kNI O (12.35)
L + Lm 2
V2 I O RL + RS + r N
η= = 1− T IO (12.36)
V1 I 1 kNV1
Since Lr is larger than Lm, therefore Lm can be ignored in the above formulae.
When we set the V1 = 60 V and frequency f = 200 to 250 kHz, we obtained
the V2 = 1.8 V, N = 1/12, IO = 0 to 60 A, volume = 4 (in.3). The average power
transfer efficiency is 94.5% and the maximum PD is 27 W/in.3.
• Transformer Is in magnetizing
• Resonant period
• Transformer Is in demagnetizing
• Switched off
© 2003 by CRC Press LLC
1956_C12.fm Page 589 Monday, August 18, 2003 3:17 PM
FT L2
CO +
S4 D4 I2 R
_V2
1:N
S3 D3
Lm
L1
C1
Lr
+
V1 L4
–
S6 D6
D2
1:N
S5 D5
S2 L3
D1
PWM S1 Cr
FIGURE 12.8
ZVS synchronous rectifier Luo-converter.
1
ωr = (12.37)
Lr Cr
Lr
Zr = (12.38)
Cr
V1
α = sin −1 ( ) (12.39)
Zr I 1
where the Lr is the resonant inductor and the Cr is the resonant capacitor.
The switch voltage increases with slope I1/Cr , then the time interval of
this period can be estimated
V1Cr
t1 = (12.40)
I1
1
t2 = (π + α) (12.41)
ωr
I 1 (1 + cos α )Lr
t3 = (12.42)
V1
While the main switch is switching-off there is a very low voltage stress
since active clamp circuit is applied.
12.6.4 Switching-Off
Switching-off period is controlled by the PWM signal, therefore,
t1 + t2 + t3
t4 = (12.43)
V1
−1
V2
12.6.5 Summary
Average output voltage V2 and input current I1 are
Lr //Lm 2
V2 = kNV1 − ( RL + RS + N )I O (12.44)
T
and
I 1 = kNI O (12.45)
L //Lm 2
V2 I O RL + RS + r N
η= = 1− T IO (12.46)
V1 I 1 kNV1
Since Lr is larger than Lm, therefore Lr can be ignored in the above formulae.
When we set the V1 = 60 V and frequency f = 200 to 250 kHz, we obtained
the V2 = 1.8 V, N = 12, IO = 0 to 60 A, volume = 4 (in.3). The average power
transfer efficiency is 94.5% and the maximum PD is 27 W/in.3.
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