ECE Department

ECE497 – Power Electronics: DC-DC Converters

Winter 2001

Instructor Information
Instructor: Marc E. Herniter
Office Hours : See Schedule.
Office Phone Number : 877-8512
Office Number : C204
WEB Address: http://www.rose-hulman.edu/~herniter
E-mail: [email protected]
MS Instant Messenger: [email protected]

PREREQUISITE: ECE 351

REQUIRED MATERIALS:
TEXTBOOK: Schematic Capture With Cadence PSpice,2nd Edition, M.E. Herniter, Prentice Hall, 2003.
ISBN: 0-13-048400-8. (The first edition is O.K. if you already have it.)

TEXTBOOK: Switching Power Supply Design, Second Edition, A.I. Pressman, McGraw-Hill.

LECTURE NOTES: Lecture notes will be available on my webpage. You will need the Adobe Acrobat
Reader version 4 or higher to view these notes.

REQUIRED SOFTWARE:
PSpice: OrCAD PSpice and Capture version 9.2 with RHIT Libraries. OrCAD PSpice is available in the
textbook Schematic Capture With Cadence PSpice. The libraries are available for download from my website at
http://www.rose-hulman.edu/~herniter/Software/Cadence/Orcad_Lib_92A.exe. install the OrCAD software first,
then install the libraries.

EVALUATION METHODS: Your final grade will be based on the schedule below:
Homework 30%
Lab 30%
Exam1 20%
Final Exam 20%

• Your grade will be based on a curve generated at the end of the semester or the standard 90%, 80%,
70%,60% scale, whichever represents the performance of the class. Note that a curve can both raise or
lower the standard scale.
• Approximate class standings and grade distributions will be distributed after each exam. This distribution
is a work of fiction and should only be used as a gross approximation of your performance in the class.
• A grade of incomplete will only be given for circumstances beyond a student’s control. Class load, extra
curricular activities, and jobs are all circumstances that are under the control of a student and will not
justify a grade of incomplete.
COURSE POLICIES:

HOMEWORK: There will be 10 homework assignments (order of magnitude estimate). These assignments
should be done independently but it never hurts to consult your colleagues. Homework is due at the
beginning of class on the due date. Late homework will not be accepted. Solutions are available on my web
site. The files are downloadable and can be viewed with the Adobe Acrobat Reader. You are required to
use the standard RHIT format for homework.

ATTENDANCE: Attendance is required.

LATE HOMEWORK: Homework is due at the beginning of class on the specified due date. Late
homework will not be accepted.

IN CLASS EXAMS: These exams are open book, open notes, and open brain (your brain only). Expect a
difficult exam with an average near 50%. Personal computers may only be used during exams to view the
class notes. You may not use Maple or PSpice during the exam.

HONOR CODE: The honor code will be enforced in this class.

MAKEUP EXAMS: Makeup exams will not be given.

LABORATORY: You will construct two DC-DC power supplies. The first is a 50 W boost regulator that
boosts 12 V DC to 25 V DC. This lab is graded as two labs: construction of the power electronics and then
the operation of the complete supply. The second lab is a 50 W buck-boost regulator that converts 12 V to -
25 V DC. This lab is graded as three labs: the construction of the power electronics, the gate drive circuit, a
local -15 Volt DC power supply, and the complete operation of the entire supply.

INSTRUCTIONAL PHILOSOPHY: Topics will be covered in three levels: Theoretical analysis, simulation,
and laboratory verification. The following synthesis procedure is used to gain an understanding of circuits
covered in the class: The theoretical analysis of the circuit is covered to understand the operation of the circuit or
to design a circuit. Circuit simulation using industry standard analysis tools to verify the theoretical analysis or
circuit design. If the simulations agree with theoretical analysis, the circuit is constructed in the lab.
Measurements of the circuit performance are made and compared to the theoretical calculations and
simulation results.

INSTRUCTIONAL OBJECTIVES
1. Linear DC Supplies
Half-Wave, Full-Wave, And 3-Phase Rectifier Circuits
Zener Regulator Circuits
Pass Transistor Regulators
OPAMP-Pass Transistor Regulators

2. Buck DC-DC Converter Topology

Circuit Analysis
Energy Analysis
Circuit Simulation
Continuous and Discontinuous Modes of Operation
Capacitor Selection
3. Boost DC-DC Converter Topology
Circuit Analysis
Energy Analysis
Circuit Simulation
Continuous and Discontinuous Modes of Operation
Capacitor Selection

4. Cuk Converter Topology

Circuit Analysis
Energy Analysis
Circuit Simulation
Continuous Mode of Operation

5. Components and Devices

MOSFETS
IGBT's
PWM Control Integrated Circuits
Diodes
Inductors
Capacitors
Gate Drivers

6. Charge Pumps
Inverting Topology
Voltage Doubling Topology
Circuit Analysis
Circuit Simulation

7. Flyback Converter Topology

Circuit Analysis
Energy Analysis
Circuit Simulation

8. Transformer Topologies
Forward
Half-Bridge
Full-Bridge
Push-Pull
Current-Mode
Current Fed
 ECE 456 HW # 1
Due 12/13/02
Problem 1:
Visit Pulse Engineering’s web site at http://www.pulseeng.com and find and download the data sheet for the power inductor
PE-51518.

Problem 2
Design a continuous mode boost DC-DC converter with the following specifications:
• Input voltage between 12 VDC and 14 VDC.
• Output Voltage is 25 V DC.
• Maximum output current = 2 Amps.
• Available Inductor: Pulse Engineering PE-51518: 335µH at 6 A DC.
• Ripple voltage at the output: Less than 100 mV.
• Switching frequency is 20 kHz.

In your design you must specify:

• The inductor peak current and the inductor average (DC) current. Note that this current is not 2 Amps.
• The output capacitor value and capacitor RMS ripple current.

Turn in the following documents:

• A MathCAD or Maple file that documents every calculation and the choice of each part. This file should be designed so
that you can easily change the design parameters so that you can use it to design other boost DC-DC converters. You
should be able to change the switching frequency, input voltage, output voltage, and output power (or current).
• The following PSpice simulations. All simulations should start with an initial output capacitor voltage of zero.
1. Output voltage at no load.
2. Output voltage at full load.
3. Inductor current at no load.
4. Inductor current at full load.
5. Verification that your design works for all input voltages.
 ECE 456 Power Electronisc: DC-Dc Converters
Lab 1 Procedure
For the first two labs we will build and test the power supply shown in Figure 1. The design of
the circuit is covered in the homework. For this first lab, we will build the high-current portion of the
circuit. Layout of this part is very important. Even if you wire the entire circuit correctly, the circuit may
not function if you have a poor layout.
We will construct the portion of the circuit shown in Figure 2. This portion contains two high-
current loops:
J1

D12
Positive Input Output Output
12V PE-51518 Voltage
L1
J2 1 2
335U
+ C1 C2
+ C3 Q2 4700U 0.1u
C4 IRF540 Q3 Poly
0.1u G2
IRF540
G1
Poly

Input 12 - 14 Volts
U6

+
CS1050
-

Loop1 Loop2 Ground

B

J4
Out
J3

Ground Input

You must construct your board so that these loops have as little cross-sectional area as possible.

When you layout and construct your board, you must remember the following:
1. MOSFET’s are static sensitive. Ask me how to handle them without destroying them.
2. Use banana plug connectors to for the input and output power connections.
3. Remember that the gate connections should be as short as possible. We will not connect the gates
in this lab, but you need to keep this in mind.
4. Use bus-bar wire for as many connections as possible.
5. See my example layout before starting yours.
 5 4 3 2 1

J1
D D
D12
Output
Positive Input Output
12V Voltage
L1
J2 1 2

+ C1 C2 R3
+ C3 Q2 0.1u
C4 IRF540 Q3 Poly
0.1u G2
Input 12 - 14 Volts IRF540
G1
Poly

J4
J3 R5

UF1006 Ground

A
12V
I_Lim D9 U6 Out
Ground Input
12V +
R4 CS1050
C C
R
- C7
0.1 uF
U1A

4
+ C8
C9 100u 3
+

B
0.1 uF 1
Vout
- 2

11
LM324

U5 G2 D5 12V
13
15

R7
5 11
VCC
VCC

CT OUTA
OUTB 14
Ct Rd
7 4 31DQ04
Rt 470 DISC OSC + C13
6 D6 C14 100u
RT 0.1 uF
VREF 16
B
SG3525A
Poly B
I_Lim 10 SD
C5 31DQ04
+

SYNC 3
R6 1 -V
RC Filters 9 G1 D7
GND
CSS

COMP R11
Close to
+V 2
SG3525
12

R1
8

31DQ04

Css + D8
C6
+

R12 C18 R13 R2

Vout
31DQ04
22n
1.0K 150k

A Ct, Rt, Rd set the ramp frequency A

Css is the soft start capacitor ECE Department

5500 Wabash Avenue
Terre Haute, IN 47803
Figure 1 Ph: (812) 877-8512
FAX: (253) 369-9536

Name: Marc E. Herniter Class: ECE 456

Size Document Name Rev
Custom ?
12 Volt to 25 Volt Boost Converter
Date: Tuesday, November 26, 2002 Sheet 1 of 1
5 4 3 2 1
 5 4 3 2 1

D D

J1

D12
Output
Positive Input Output
12V PE-51518 Voltage
L1
J2 1 2
335U
+ C1 C2 R3
+ C3 Q2 4700U 0.1u
C4 IRF540 Q3 Poly
0.1u G2
Input 12 - 14 Volts IRF540
G1
Poly
C C

J4
J3 R5

Ground

A
U6 Out
Ground Input
+
CS1050
-

B B

Figure 2

A A

ECE Department
5500 Wabash Avenue
Terre Haute, IN 47803
Ph: (812) 877-8512
FAX: (253) 369-9536

Name: Marc E. Herniter Class: ECE 456

Size Document Name Rev
Custom 1
Power Portion of Boost Regulator
Date: Tuesday, November 26, 2002 Sheet 1 of 1
5 4 3 2 1
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
 ECE 456
Boost Regulator Design - Continuous Mode Operation
For First Lab Project
−6
µs ≡ 10 ⋅ sec

Specify Input Voltage VD := 5⋅ volt Specify Output Voltage Vo := 10⋅ volt

Specify Switching Frequency FS := 20⋅ kHz

1
TS := TS = 50 µs
FS

Specify the Assumed Efficiency Eff := 100%

Specify the Max output Current

20⋅ watt
The output Power is Pout :=
Eff

Pout
The output current is Io := Io = 2 amp
Vo

Find Ton and Toff

Toff := 1 ⋅ µs Ton := 1 ⋅ µs

Given

Ton Vo − VD
=
TS Vo

Ton + Toff = TS

 Ton 
  := Find( Ton , Toff ) Ton = 25 µs Toff = 25 µs
 Toff 
Ton
D := D = 50 %
TS
 Find the range of Inductors that will operate in continuous mode

Specify the minimum current we want the supply to operate in the continuous mode

Io
Imin :=
10

VD⋅ Ton VD
L := ⋅
2⋅ Imin Vo

For Continuous Mode, We need L greater than L = 156.25 µH

Choose the Inductor L := 335⋅ µH Pulse Engineering PE-51518

Find the Min and max inductor currents

I1 := 1⋅ amp I2 := 1⋅ amp

Given

I1 + I2 Io
=
2 1−D
Ton
I1 − I2 = VD⋅
L

 I1 
  := Find( I1 , I2) I1 = 4.187 amp I2 = 3.813 amp
 I2 

Now choose the capacitor

−3
Energy dissipated per cycle Eo := Vo⋅ Io⋅ TS Eo = 1 × 10 joule

Specify the ripple desired. VCR := 100⋅ mV

Initial Guess C := 1000⋅ µF

 Given

⋅ C⋅ ( Vo + VCR) −
1 2 1 2
⋅ C⋅ Vo = Eo
2 2

C := Find( C)

C = 995.025 µF
Choose the next standard value C := 2200⋅ µF

Calculate the ripple with the chosen capacitor.

Given

⋅ C⋅ ( Vo + VCR) −
1 2 1 2
⋅ C⋅ Vo = Eo
2 2

VCR := Find( VCR) VCR = 45.352 mV

Choose the filter capacitor using ESR Calculations.

Assume that the major component of the ripple comes from the capacitor ESR

Specify the ripple due to the ESR VCR := 100⋅ mV

VCR
ESR := ESR = 0.024 Ω
I1

For all electrolytic caps, assume that ESR*C=80µs

80⋅ µs 3
C := C = 3.349 × 10 µF
ESR

Choose the next size std capacitor C := 4700⋅ µF

Calculate the Capacitor RMS Ripple Current

I1 + I2
Ix := Ix = 4 amp
2

 ⌠ Ton T
⌠ S 
Irms :=
1 
⋅  Io dt +  ( Io − Ix) dt
2 2
TS  ⌡ ⌡T 
 0⋅ sec on 

Irms = 2 amp

Summary

I1 + I2
L = 335 µH I2 = 3.813 amp I1 = 4.187 amp = 4 amp
2

Ton = 25 µs Toff = 25 µs

VD = 5 volt Vo = 10 volt Io = 2 amp

C = 4700 µF VCR = 100 mV Irms = 2 amp

Cap Voltage = Vo = 10 volt

 5 4 3 2 1

D D

C C

Vo
+ IC= 6

Vcc L1 D4

335u
+ IC = 0 Control

+
V2
S1 C1 Load

+
DC = 5
- +
+ 2200u 5
+ V5 - -
Sx
- PULSE_WIDTH = 26u
B 0 PERIOD = 50u B

FALL_TIME = 1n 0 0
0 RISE_TIME = 1n 0 0

Model = Sx VSWITCH Roff=1e6 Ron=1m Voff=1 Von=4.0

ECE Department
5500 Wabash Avenue
A Terre Haute, IN 47803 A
Ph: (812) 877-8512
FAX: (253) 369-9536

Name: Marc E. Herniter Class: ECE 250 or ECE 351

Size Document Name Rev
A 1
Boost Converter - Fixed PulseWidth
Date: Wednesday, December 04, 2002 Sheet 1 of 1
5 4 3 2 1
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 12:24:24 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
15V

(82.445m,10.002)
(82.445m,10.002)

10V

SEL>>
5V
v(vO)
12A

8A

4A

0A
0s 20ms 40ms 60ms 80ms 100ms
I(L1)
Time
Date: December 04, 2002 Page 1 Time: 13:09:38
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 12:24:24 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
10.05V

(81.000m,10.007)
(81.000m,10.007)

10.00V

9.95V
(81.126m,9.984)
(81.126m,9.984)
SEL>>

v(vO)
4.654A
(80.876m,4.3597)
(80.876m,4.3597)

4.400A

4.000A

(81.050m,3.9720)
(81.050m,3.9720)
3.617A
80.8268ms 80.9000ms 81.0000ms 81.1000ms 81.2000ms 81.3000ms
I(L1)
Time
Date: December 04, 2002 Page 1 Time: 13:12:28
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 12:24:24 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
5.0V

2.5V

SEL>>
0V
V(CONTROL)

10.0313V

10.0000V

9.9688V

9.9375V
v(vO)
(80.876m,4.3597)

4.375A

4.063A

3.750A

80.8268ms 80.9000ms 81.0000ms 81.1000ms 81.2000ms 81.3000ms

I(L1)
Time
Date: December 04, 2002 Page 1 Time: 13:14:35
 5 4 3 2 1

D D

C C

Vo
+ IC= 6

Vcc L1 D4
PARAMETERS:
R_val = 5
335u
+ IC = 0 Control

+
V2
S1 C1 Load

+
DC = 5
- +
+ 2200u {R_val}
+ V5 - -
Sx
- PULSE_WIDTH = 26u
B 0 PERIOD = 50u B

FALL_TIME = 1n 0 0
0 RISE_TIME = 1n 0 0

Model = Sx VSWITCH Roff=1e6 Ron=1m Voff=1 Von=4.0

ECE Department
5500 Wabash Avenue
A Terre Haute, IN 47803 A
Ph: (812) 877-8512
FAX: (253) 369-9536

Name: Marc E. Herniter Class: ECE 250 or ECE 351

Size Document Name Rev
A 1
Boost Converter - Fixed PulseWidth
Date: Wednesday, December 04, 2002 Sheet 1 of 1
5 4 3 2 1
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 13:25:32 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
12V

10V

8V

6V
v(vO)
10A

5A

0A

SEL>>
-5A
0s 20ms 40ms 60ms 80ms 100ms
I(L1)
Time
Date: December 04, 2002 Page 1 Time: 13:28:31
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 13:25:32 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
10.555V

10.400V

10.200V

10.000V

SEL>>
9.832V
v(vO)
4.731A

3.750A

2.500A

1.557A
85.4811ms 85.5200ms 85.5600ms 85.6000ms 85.6400ms 85.6800ms
I(L1)
Time
Date: December 04, 2002 Page 1 Time: 13:30:31
 5 4 3 2 1

D D

C C

Vo
+ IC= 8

Vcc L1 D4
PARAMETERS:
L_val = 300U
{L_val}
+ IC = 0 Control

+
V2
S1 C1 Load

+
DC = 5
- +
+ 2200u 5
+ V5 - -
Sx
- PULSE_WIDTH = 26u
B 0 PERIOD = 50u B

FALL_TIME = 1n 0 0
0 RISE_TIME = 1n 0 0

Model = Sx VSWITCH Roff=1e6 Ron=1m Voff=1 Von=4.0

ECE Department
5500 Wabash Avenue
A Terre Haute, IN 47803 A
Ph: (812) 877-8512
FAX: (253) 369-9536

Name: Marc E. Herniter Class: ECE 250 or ECE 351

Size Document Name Rev
A 1
Boost Converter - Fixed PulseWidth
Date: Wednesday, December 04, 2002 Sheet 1 of 1
5 4 3 2 1
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 14:07:46 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
12V

10V

8V

SEL>>
6V
v(vO)
12A

8A

4A

0A
0s 20ms 40ms 60ms 80ms 100ms
I(L1)
Time
Date: December 04, 2002 Page 1 Time: 14:12:14
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 14:07:46 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
10.04V

10.02V

10.00V

9.98V
v(vO)
4.978A

4.500A

4.000A

SEL>>
3.458A
75.20ms 75.24ms 75.28ms 75.32ms 75.36ms
I(L1)
Time
Date: December 04, 2002 Page 1 Time: 14:13:06
 ECE 456
Boost Regulator Design - Continuous Mode Operation
For First Lab Project
−6
µs ≡ 10 ⋅ sec

Specify Input Voltage VD := 5⋅ volt Specify Output Voltage Vo := 10⋅ volt

Specify Switching Frequency FS := 200⋅ kHz

1
TS := TS = 5 µs
FS

Specify the Assumed Efficiency Eff := 100%

Specify the Max output Current

20⋅ watt
The output Power is Pout :=
Eff

Pout
The output current is Io := Io = 2 amp
Vo

Find Ton and Toff

Toff := 1 ⋅ µs Ton := 1 ⋅ µs

Given

Ton Vo − VD
=
TS Vo

Ton + Toff = TS

 Ton 
  := Find( Ton , Toff ) Ton = 2.5 µs Toff = 2.5 µs
 Toff 
Ton
D := D = 50 %
TS
 Find the range of Inductors that will operate in continuous mode

Specify the minimum current we want the supply to operate in the continuous mode

Io
Imin :=
10

VD⋅ Ton VD
L := ⋅
2⋅ Imin Vo

For Continuous Mode, We need L greater than L = 15.625 µH

Choose the Inductor L := 33.5⋅ µH Pulse Engineering PE-51518

Find the Min and max inductor currents

I1 := 1⋅ amp I2 := 1⋅ amp

Given

I1 + I2 Io
=
2 1−D
Ton
I1 − I2 = VD⋅
L

 I1 
  := Find( I1 , I2) I1 = 4.187 amp I2 = 3.813 amp
 I2 

Now choose the capacitor

−4
Energy dissipated per cycle Eo := Vo⋅ Io⋅ TS Eo = 1 × 10 joule

Specify the ripple desired. VCR := 100⋅ mV

Initial Guess C := 1000⋅ µF

 Given

⋅ C⋅ ( Vo + VCR) −
1 2 1 2
⋅ C⋅ Vo = Eo
2 2

C := Find( C)

C = 99.502 µF
Choose the next standard value C := 100⋅ µF

Calculate the ripple with the chosen capacitor.

Given

⋅ C⋅ ( Vo + VCR) −
1 2 1 2
⋅ C⋅ Vo = Eo
2 2

VCR := Find( VCR) VCR = 99.505 mV

Choose the filter capacitor using ESR Calculations.

Assume that the major component of the ripple comes from the capacitor ESR

Specify the ripple due to the ESR VCR := 100⋅ mV

VCR
ESR := ESR = 0.024 Ω
I1

For all electrolytic caps, assume that ESR*C=80µs

80⋅ µs 3
C := C = 3.349 × 10 µF
ESR

Choose the next size std capacitor C := 4700⋅ µF

Calculate the Capacitor RMS Ripple Current

I1 + I2
Ix := Ix = 4 amp
2

 ⌠ Ton T
⌠ S 
Irms :=
1 
⋅  Io dt +  ( Io − Ix) dt
2 2
TS  ⌡ ⌡T 
 0⋅ sec on 

Irms = 2 amp

Summary

I1 + I2
L = 33.5 µH I2 = 3.813 amp I1 = 4.187 amp = 4 amp
2

Ton = 2.5 µs Toff = 2.5 µs

VD = 5 volt Vo = 10 volt Io = 2 amp

C = 4700 µF VCR = 100 mV Irms = 2 amp

Cap Voltage = Vo = 10 volt

 5 4 3 2 1

D D

C C

Vo
+ IC= 8

Vcc L1 D4

33.5u
+ IC = 0 Control

+
V2
S1 C1 Load

+
DC = 5
- +
+ 2200u 5
+ V5 - -
Sx
- PULSE_WIDTH = 2.6u
B 0 PERIOD = 5.0u B

FALL_TIME = 1n 0 0
0 RISE_TIME = 1n 0 0

Model = Sx VSWITCH Roff=1e6 Ron=1m Voff=1 Von=4.0

ECE Department
5500 Wabash Avenue
A Terre Haute, IN 47803 A
Ph: (812) 877-8512
FAX: (253) 369-9536

Name: Marc E. Herniter Class: ECE 250 or ECE 351

Size Document Name Rev
A 1
Boost Converter - Fixed PulseWidth
Date: Wednesday, December 04, 2002 Sheet 1 of 1
5 4 3 2 1
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 14:21:04 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
12V

10V

8V

6V
v(vO)
15A

10A

5A

SEL>>
0A
0s 20ms 40ms 60ms 80ms 100ms
I(L1)
Time
Date: December 04, 2002 Page 1 Time: 14:29:05
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 14:21:04 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
10.00452V

10.00250V

10.00000V

9.99750V

SEL>>
9.99523V
v(vO)
4.547A

4.400A

4.200A

4.000A

3.839A
48.680ms 48.685ms 48.690ms 48.695ms 48.700ms 48.705ms 48.710ms 48.715ms
I(L1)
Time
Date: December 04, 2002 Page 1 Time: 14:30:31
 5 4 3 2 1

D D

C C

Vo
+ IC= 8

Vcc L1 R5 D5

+
0.095
335u MUR420

+
+ IC = 0 Control ESR
0.017

+
V2
DC = 5 S1 Load
- +
+ 5
+ V5 C1

+
- -
Sx 2200u
- PULSE_WIDTH = 30u
B 0 PERIOD = 50u B

FALL_TIME = 1n 0 0
0 RISE_TIME = 1n 0 0

Model = Sx VSWITCH Roff=1e6 Ron=10m Voff=1 Von=4.0

ECE Department
5500 Wabash Avenue
A Terre Haute, IN 47803 A
Ph: (812) 877-8512
FAX: (253) 369-9536

Name: Marc E. Herniter Class: ECE 250 or ECE 351

Size Document Name Rev
A 1
Boost Converter - Fixed PulseWidth
Date: Wednesday, December 04, 2002 Sheet 1 of 1
5 4 3 2 1
TOROIDAL INDUCTORS
HIGH CURRENT

Cost-effective designs
Semi-encapsulated construction
Maximum operation temperature of
130°C (Ambient + Rise)
A 2:1 inductance swing from zero to
maximum current

Electrical Specifications @ 25°C

REFERENCE OPERATING VALUES DESIGN CONTROL VALUES
Inductance ETOP1 Energy Inductance 50 kHz Lead
Part IDC DCR Size
Typical (V-µSec) Storage No DC (µH) Test mV Diameter
Number (AMPS) (Ω MAX) Code
(µH)2 (µJ MIN)3 (±20%) No DC5 (in ±.003)
20 kHz 40 kHz
PE-51506 17.0 17.0 190 130 2460 40.0 140 0.0065 3 0.081
PE-51507 32.0 16.0 290 200 4100 70.7 270 0.0092 4 0.081
PE-51508 60.0 16.0 390 270 7700 120.0 470 0.012 5 0.081
PE-51509 14.0 10.0 135 95 700 28.5 73 0.009 1 0.057
PE-51510 23.0 11.0 170 120 1400 43.5 130 0.012 2 0.057
PE-51511 43.0 10.0 280 195 2150 85.5 210 0.018 3 0.057
PE-51512 90.0 10.0 430 300 4500 158.0 420 0.028 4 0.057
PE-51513 144.0 10.0 570 400 7200 262.0 700 0.032 5 0.057
PE-51514 32.0 6.6 200 140 700 60.5 110 0.025 1 0.040
PE-51515 52.0 7.0 230 160 1275 92.0 190 0.032 2 0.040
PE-51516 98.0 6.0 400 280 1765 188.0 310 0.048 3 0.040
PE-51517 175.0 6.0 620 425 3150 315.0 560 0.068 4 0.040
PE-51518 335.0 6.0 840 580 6030 571.0 1000 0.095 5 0.040
PE-51520 400 3.6 600 420 2700 688.0 640 0.130 3 0.036
NOTES:
1. To prevent excessive temperature rise, limit ETOP to the rated ETOP specified.
This is not a saturation limit. Temperature rise of inductors is 40°C MAX at
Mechanicals
MAX current and rated ETOP.
2. A 2:1 nominal inductance swing from no IDC to operating IDC gives improved
protection against current discontinuities at light loading. Inductance increases
with greater ETOP. Reference values occur at IDC and low flux density.
3. LI2 rating is the ability of the inductor to store energy. H MAX
2
4. Design control test voltage is critical. Inductance increases with voltage.
E MIN PE-515XX
DATE CODE
COUNTRY OF ORIGIN

G MAX
B MAX D
Size ± .010 F MIN
Code 1 2 3 4 5
1 3
A 1.20/30,48 1.44/36,57 1.60/40,64 1.95/49,53 2.30/58,42 1
B 0.60/15,24 0.80/20,32 0.80/20,32 0.91/23,11 1.11/28,19 C ± .010 Lead Dia.
C 0.40/10,16 0.60/15,24 0.60/15,24 0.70/17,78 0.90/22,85 (3 PLCs)
2
D 0.80/20,32 0.90/22,86 0.90/22,86 1.20/30,48 1.50/38,10
E 0.45/11,43 0.70/17,78 0.70/17,78 0.90/22,86 1.00/25,40 2
A MAX
F 0.20/5,08 0.20/5,08 0.20/5,08 0.20/5,08 0.20/5,08 3 No Internal
Connections
G .015/0,381 0.03/0,76 0.03/0,76 0.03/0,76 0.03/0,76
H 1.20/30,48 1.44/36,57 1.72/43,68 2.00/50,80 2.30/58,42 Dimensions: Inches
mm
Unless otherwise specified, all tolerances are ± .010
0,25

US 858 674 8100 • UK 44 1483 401 700 • France 33 3 84 35 04 04 • Singapore 65 287 8998 • Taiwan 886 2 2698 0228 • Hong Kong 852 2788 6588 • http://www.pulseeng.com

PC500.B (5/02) 36
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 14:38:44 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
15V

10V

SEL>>
5V
v(vO)
10A

5A

0A
0s 20ms 40ms 60ms 80ms 100ms
I(L1)
Time
Date: December 04, 2002 Page 1 Time: 14:42:02
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 14:38:44 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
12.39V

10.00V

7.50V

SEL>>
5.55V
v(vO)
5.389A

5.250A

5.000A

4.750A
48.1151ms 48.1500ms 48.2000ms 48.2500ms 48.3000ms 48.3500ms
I(L1)
Time
Date: December 04, 2002 Page 1 Time: 14:43:07
 ** Profile: "SCHEMATIC1-Transient" [ C:\WEBSITE\ROSE_CLASSES\ECE456\NOTES\ORCAD\Boost Converter\bo...
Date/Time run: 12/04/02 14:38:44 Temperature: 27.0
(A) boost converter-SCHEMATIC1-Transient.dat (active)
10.298V

10.200V

10.000V

SEL>>
9.783V
v(vO)
5.389A

5.250A

5.000A

4.750A
48.1178ms 48.1500ms 48.2000ms 48.2500ms 48.3000ms
I(L1)
Time
Date: December 04, 2002 Page 1 Time: 14:43:35
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
 EE 456
Boost Regulator Design - Discontinuous Mode
Operation
µS 10 . sec
6
Specify Output Voltage Vo 50 . volt

Specify Input Voltage VD 5 . volt

Specify Switching Frequency FS 20 . kHz

1
TS
T S = 5 . 10
5
FS sec

Specify the Max Output Power and Efficiency P out 10 . watt Eff 90 . %

Calculated the power for the design

P out
P design P design = 11.111 watt
Eff

Calculate the output current

P design
I out I out = 0.222 amp
Vo

Find Ton and Toff

T off 1 . sec T on 1 . sec

Copyright 2000 Marc E. Herniter

 Given

T on V o V D
T off VD

T on T off 0.8 . T S

T on
find T on , T off
T off

T on = 36 µS T off = 4 µS

Find the range of Inductors that will operate in discontinuous mode

V D . T on V D
L .
.
2 I out V o

For Discontinuous Mode, We need L less than L = 40.5 µH

FInd the inductor Value

V D . T on
2
L . T T off L = 32.4 µH
. . .
2 V o T S I out on

Choose a standard size inductor L 30 . µH

Copyright 2000 Marc E. Herniter

 FInd the peak current

T on
I2 VD . I 2 = 6 amp
L

Choose the filter capacitor.

Assume that the major component of the ripple comes from the capacitor ESR

Specify the ripple due to the ESR V RR .05 . volt

V RR
ESR ESR = 0.00833 Ω
I2

For all electrolytic caps, assume that ESR*C=80µs

80 . 10 . sec
6
C = 9.6 . 10 µF
3
C
ESR

Choose the next size std capacitor C 10000 . µF

80 . 10 . sec
6
ESR
C

Calculate the new ESR with the chosen capacitor

ESR = 8 . 10
3
Ω

Copyright 2000 Marc E. Herniter

 Calculate the Capacitor RMS Ripple Current
I2
Ix I x = 3 amp
2

T on TS
1 . 2 2
I rms I out dt I out Ix dt
TS
0 . sec T on

I rms = 1.482 amp

Summary

L = 30 µH I 2 = 6 amp

T on = 36 µS T off = 4 µS

V D = 5 volt V o = 50 volt I out = 0.222 amp

C = 1 . 10 µF
4
V RR = 50 mV I rms = 1.482 amp

= o = 50 volt
Cap Voltage V

Copyright 2000 Marc E. Herniter

Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter
Copyright 2000 Marc E. Herniter