AN2389 Application note
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- Gavin Morton
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1 Application note An MCU-based low cost non-inverting buck-boost converter for battery chargers Introduction As the demand for rechargeable batteries increases, so does the demand for battery chargers. There are different kinds of design solutions available for implementing battery chargers. Some of them are dedicated hardware based solutions and some are microcontroller based solutions. In a microcontroller based solution, you have the flexibility of using the same hardware for charging different batteries and making only slight changes in the software. But there are still some challenges and one of the major challenges is to have a suitable input power supply available. Generally the Buck converter topology is used as a DC- DC converter to provide the controlled output power supply to the batteries. But in this case a problem may arise, for example, if you want to charge a 4.2V Li-ion batteries from a 5V supply due to the presence of the protection diode and other small drops across other components. This drop is generally about 1V which makes it very difficult to provide 4.2V to the Li-ion batteries using the buck converter topology. This application note describes a simple technique for implementing a non-inverting buckboost converter which requires only one inductor. This converter is basically the result of cascading a Buck converter with a Boost converter. This converter can be controlled by two PWM signals from the microcontroller and can be used as a Buck converter or Boost converter whenever required. So this solution combined with the flexibility of the ST7 microcontroller can be used to charge a wide range of the batteries using the same hardware. The example used in this application note is specific to battery chargers but this DC-DC converter can be very useful for portable applications in general or any application which uses rechargeable batteries. August 2007 Rev 1 1/16
2 Contents AN2389 Contents 1 Circuit diagram Theory of operation Buck-boost implementation Buck converter implementation Boost converter implementation Selection of components Inductor selection Capacitor selection Application in battery charger Theory of operation Software flowchart Test environment and results Conclusion References Revision history /16
3 Circuit diagram 1 Circuit diagram The diagram in Figure 1 shows the structure of the modified buck-boost converter. Figure 1. Modified buck-boost converter PWM1 L d2 P+ SW1 d1 PWM2 SW2 C V IN V OUT P- 3/16
4 Theory of operation AN Theory of operation You can use this converter as buck-boost converter, as a buck converter or as a boost converter by selecting different combinations of switches SW1 and SW2 driven by the PWM1 and PWM2 signals output by the ST7 microcontroller. 2.1 Buck-boost implementation This converter can be used as a non inverting buck-boost converter by selecting the operating mode from Table 1 which briefly describes the converter modes.. Table 1. Operating modes based on switch combinations Phase SW1 (PWM1) SW2 (PWM2) Operating modes 1 OFF OFF BUCK 2 OFF ON N/A 3 ON OFF BUCK-BOOST 4 ON ON BOOST If we look at phase 2 in Table 1, here the switch SW1(PWM1) is OFF and switch SW2 (PWM2) is ON. This condition never occurs either in a buck converter or in boost converter. So you should always take care in your software that this condition must not happen. To avoid this, if we assume that initially both switches are in OFF condition then you should use the following guidelines to manage the PWM signals driving the two switches. 1. Keep the frequency of both PWM signals the same, to better control when synchronizing the two PWM signals using the next three guidelines. 2. The duty cycle D1 of control signal PWM1, must be greater than the duty cycle D2 of control signal PWM2. 3. PWM1 should be enabled before the PWM2 signal. 4. PWM1 should be disabled after the PWM2 signal. 4/16
5 Theory of operation Figure 2. Timing diagram for two PWM signals Phase 3 PWM1 PWM2 Phase 4 Phase 1 Figure 2 shows a timing example for the two PWM signals based on the above guidelines. Here phase 2 does not occur. If the duty cycles of the two PWM signals driving SW1(PWM1) and SW2 (PWM2) are D1 and D2 respectively and if we exclude the saturation voltage of the switches from our calculation and if the drop across the diodes is V d1 and V d2 respectively, then the output voltage Vout is given by the following formula: V out = [ V in * D1 - V d1 * ( 1 - D1) ] / ( 1 - D2) - V d2 As mentioned in [2], theoretically this converter works linearly over a gain range of 0-200% of the input voltage. 5/16
6 Theory of operation AN Buck converter implementation If you keep SW2 always in OFF condition and drive SW1 (PWM1) with a PWM signal from the microcontroller then the circuit works like a buck converter, except that you have an additional diode drop V d2 due to diode d2. Figure 3. Buck converter implementation PWM1 L d2 P+ d1 OFF SW2 C V IN V OUT P- If the duty cycle of the PWM signal driving SW1 (PWM1) is D1, the output voltage will be given by: V out = V in * D1 - V d1 ( 1 - D1) - V d2 6/16
7 Theory of operation 2.3 Boost converter implementation Again if you keep switch SW1 (PWM1) always in ON condition and drive the Switch SW2 (PWM2) with a PWM signal generated by the microcontroller, then the combination works as a boost converter except that you have an additional free wheeling diode D1 which you can ignore. Figure 4. Boost converter implementation ON L d2 P+ SW1 d1 PWM2 SW2 C V IN V OUT P- If the input voltage is V in, the duty cycle of the PWM signal driving PWM2 is D2 and the drop across the diode d2 is V d2, then the output voltage V out is given by: V out = V in / ( 1 - D2) - V d2 7/16
8 Selection of components AN Selection of components The inductor and capacitor can be selected using the formulae given below. 3.1 Inductor selection The minimum value of the inductor can be selected by choosing the maximum of the values given by the following two formulae: Lmin = T * [ ( V in - V sat1 ) * D1 - V sat2 * D2 - V out * (D1 - D2)] 2 * I out (1) Lmin = T * [ V d1 + V out ] * ( 1 - D1) 2 * I out (2) Here V sat1 and V sat2 are the saturation voltages of the two switches SW1 and SW2. Iout and Vout are the maximum output current and voltage respectively. V d1 and V d2 is the drop across diodes d1 and d2. The duty cycles of the PWM signals driving SW1 and SW2 are D1 and D2 respectively. 3.2 Capacitor selection The minimum of the capacitor value can be selected by using the following formula, assuming a variation in Vout of 1% or less Cmin = 100 * I out * (1 - D1) * T V out (3) In practice, we take inductor and capacitor values that are larger than the values calculated using the above formulae. 8/16
9 Application in battery charger 4 Application in battery charger We can use the modified non-inverting buck-boost converter in a combination of different modes as required by the application. 4.1 Theory of operation The DC-DC converter uses a combination of buck-boost converter and boost converter mode to charge the Li-ion battery. In case of Li-ion, the constant current constant voltage (CC CV) charging algorithm is used to charge the battery. Here we have chosen the input voltage just enough to show the functionality of the converter in buck-boost mode and boost mode. Initially the converter works in Buck-Boost converter mode to charge the battery in constant current mode by keeping the duty cycle of PWM2 constant and varying the duty cycle of PWM1. As soon as there is an overflow condition for the duty cycle of PWM1. The converter switches from buck-boost converter mode to boost converter mode. And then duty cycle of PWM2 is varied to follow the algorithm while SW1 remains in ON condition. Following section shows the software flow chart for this combination. 9/16
10 Application in battery charger AN Software flowchart There are many ways in which you can control the operation of this circuit. An example algorithm which can be used for in Li-ion battery charger is given below- Figure 5. Li-ion battery charger flowchart INITIALIZE THE PWM SIGNALS WITH DUTY CYCLE D1 AND D2. WORKS IN BUCK-BOOST MODE. KEEP D2 FIXED AND VARY D1 TO KEEP THE CURRENT CONSTANT. IS THERE A OVERFLOW IN D1? No YES WORKS IN BOOST MODE. KEEP SW1 ALWAYS ON AND VARY THE D2 TO CONTINUE THE ALGORITHM BY KEEP -ING THE CURRENT OR VOLTAGE CONSTANT AS REQUIRED. END 10/16
11 Test environment and results 5 Test environment and results We used this buck-boost converter in the universal battery charger evaluation board described in AN2390. Figure 6 below shows the general battery charger circuit using the non-inverting buck-boost converter circuit mentioned in this application note. For simplicity, this figure does not show all the connections. Figure 6. General circuit-based battery charger PWM1 L d2 P+ SW1 I BAT Battery V IN d1 PWM2 SW2 C V OUT V BAT R S P- Sense resistor Here some results are shown for charging the Li-ion battery using this converter in buckboost mode. The above charger is is intended for charging a single Li-ion or two NiMH in series using a 5V supply input. Details on the implementation are given in AN2390 where you can find results for NiMH batteries as well as for a charger used simply in buck converter mode. Some parameter values are as follows: V in = 5V, I in (MAX) = 2A, V sat1 = V sat2 = 0.3V, V d1 = V d2 = 0.5V. and PWM frequency for both PWM1 and PWM2 = 16KHz. Also let s say the maximum value of V out = 5.5V and I out = 1.2A and the maximum duty cycle of D1 is 95% and D2 is equal to 30%. Then using the formulas given in Section 3: Lmin = 21 uh (from equation 1) or 10 uh (from equation 2). So we should choose a value larger than 21 uh. Cmin = 70uF (from equation 3). So we need to choose a value higher than 70 uf. In this example, L = 75 uh, C = 470 uf are taken, which are larger than the values calculated using the formulas hence will support the application. The following table shows some of the readings taken for different values of the duty cycles D1 and D2. 11/16
12 Test environment and results AN2389 I Table 2. Input vs output Sl No V in (V) I in (A) V out (V) I out (A) In above results, we have not added V sat (0.3V), diode drop (0.5V) and the drop across the series resistor (connected to measure battery current) as shown in Figure 6 to get the actual output voltage of the non-inverting buck-boost converter. For example it is given that V out (battery voltage) = 4.2V, but the actual output voltage of the converter is equal to: V out 4.2V (Battery Voltage V bat ) + 0.3V(Switch Drop V sat1 )+ 0.5V(Protection Diode V d2 )+ 0.4V (Drop across Sense resistor) = 5.4V. So we are able to achieve 5.4V from a 5V supply thus validating the concept. 12/16
13 Conclusion 6 Conclusion This application note describes a simple but very useful technique for implementing a microcontroller controlled low cost non-inverting buck-boost converter. This converter can be used as a buck converter or as a boost converter or as a buck-boost converter. The example shows the application of this converter in a battery charger. However it can also be used in other portable applications or any application getting its power from a rechargeable battery. Or you could use this technique to make a USB charger to charge Li-ion batteries or 3 or more NiMH Cells in series. 13/16
14 References AN References [1] AN2390: A flexible universal battery charger, STMicroelectronics [2] A noninverting buck-boost converter with reduced components using a microcontroller by Robert S. Weissbach and Kevin M. Torres, IEEE members. 14/16
15 Revision history 8 Revision history Table 3. Document revision history Date Revision Changes 21-Aug Initial release. 15/16
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STGB10NB37LZ STGP10NB37LZ 10 A - 410 V internally clamped IGBT Features Low threshold voltage Low on-voltage drop Low gate charge TAB TAB High current capability High voltage clamping feature Applications
STB75NF75 STP75NF75 - STP75NF75FP
STB75NF75 STP75NF75 - STP75NF75FP N-channel 75V - 0.0095Ω - 80A - TO-220 - TO-220FP - D 2 PAK STripFET II Power MOSFET General features Type V DSS R DS(on) I D STB75NF75 75V
SPC5-CRYP-LIB. SPC5 Software Cryptography Library. Description. Features. SHA-512 Random engine based on DRBG-AES-128
SPC5 Software Cryptography Library Data brief SHA-512 Random engine based on DRBG-AES-128 RSA signature functions with PKCS#1v1.5 ECC (Elliptic Curve Cryptography): Key generation Scalar multiplication
AN820 APPLICATION NOTE INPUT/OUTPUT PROTECTION FOR AUTOMOTIVE COMPUTER
AN820 APPLICATION NOTE INPUT/OUTPUT PROTECTION FOR AUTOMOTIE COMPUTER INTRODUCTION In cars, the number of functions carried out by electronic components has greatly increased during the last 10 years.
STCS2A. 2 A max constant current LED driver. Features. Applications. Description
2 A max constant current LED driver Features Up to 40 V input voltage Less than 0.5 V voltage overhead Up to 2 A output current PWM dimming pin Shutdown pin LED disconnection diagnostic Slope control with
LM2901. Low-power quad voltage comparator. Features. Description
Low-power quad voltage comparator Features Wide single supply voltage range or dual supplies for all devices: +2 V to +36 V or ±1 V to ±18 V Very low supply current (1.1 ma) independent of supply voltage
UM1790 User manual. Getting started with STM32L053 discovery kit software development tools. Introduction
User manual Getting started with STM32L053 discovery kit software development tools Introduction This document describes the software environment recommendations required to build an application using
ST19NP18-TPM-I2C. Trusted Platform Module (TPM) with I²C Interface. Features
Trusted Platform Module (TPM) with I²C Interface Data brief Features Single-chip Trusted Platform Module (TPM) Embedded TPM 1.2 firmware I²C communication interface (Slave mode) Architecture based on ST19N
STLM20. Ultra-low current 2.4 V precision analog temperature sensor. Features. Applications
Ultra-low current 2.4 V precision analog temperature sensor Features Precision analog voltage output temperature sensor ±1.5 C maximum temperature accuracy at 25 C (±0.5 C typical) Ultra-low quiescent
UM1727 User manual. Getting started with STM32 Nucleo board software development tools. Introduction
User manual Getting started with STM32 Nucleo board software development tools Introduction The STM32 Nucleo board (NUCLEO-F030R8, NUCLEO-F072RB, NUCLEO-F103RB, NUCLEO-F302R8, NUCLEO-F401RE, NUCLEO-L152RE)
AN3270 Application note
Application note Using the STM8L16x AES hardware accelerator Introduction The purpose of cryptography is to protect sensitive data to avoid it being read by unauthorized persons. There are many algorithms
TDA2004R. 10 + 10 W stereo amplifier for car radio. Features. Description
10 + 10 W stereo amplifier for car radio Features Low distortion Low noise Protection against: Output AC short circuit to ground Overrating chip temperature Load dump voltage surge Fortuitous open ground
STOD2540. PMOLED display power supply. Features. Application. Description
PMOLED display power supply Features Inductor switches boost controller PFM mode control High efficiency over wide range of load (1 ma to 40 ma) Integrated load disconnect switch Over voltage protection
STP10NK80ZFP STP10NK80Z - STW10NK80Z
STP10NK80ZFP STP10NK80Z - STW10NK80Z N-channel 800V - 0.78Ω - 9A - TO-220/FP-TO-247 Zener-protected supermesh TM MOSFET General features Type V DSS R DS(on) I D Pw STP10NK80Z 800V
AN3990 Application note
Application note Upgrading STM32F4DISCOVERY board firmware using a USB key Introduction An important requirement for most Flash memory-based systems is the ability to update the firmware installed in the
VN03. ISO high side smart power solid state relay PENTAWATT. Features. Description. www.tvsat.com.pl
ISO high side smart power solid state relay Features Type V DSS R DS(on) I n (1) Maximum continuous output current (a) : 4A @ Tc= 25 C 5V logic level compatible input Thermal shutdown Under voltage protection
UM1680 User manual. Getting started with STM32F429 Discovery software development tools. Introduction
User manual Getting started with STM32F429 Discovery software development tools Introduction This document describes the software environment and development recommendations required to build an application
AN235 Application note
Application note Stepper motor driving By Thomas Hopkins Introduction Dedicated integrated circuits have dramatically simplified stepper motor driving. To apply these ICs, designers need little specific
AN4128 Application note
Application note Demonstration board for Bluetooth module class 1 SBT2632C1A.AT2 Introduction This document describes the STEVAL-SPBT4ATV3 demonstration board (dongle) for the Bluetooth class 1 SPBT2632C1A.AT2
STTH3R02QRL. Ultrafast recovery diode. Main product characteristics. Features and benefits. Description. Order codes DO-15 STTH3R02Q DO-201AD STTH3R02
Ultrafast recovery diode Main product characteristics I F(V) 3 V RRM 2 V T j (max) V F (typ) 175 C.7 V K t rr (typ) 16 ns Features and benefits Very low conduction losses Negligible switching losses K
STDP2690. Advanced DisplayPort to DisplayPort (dual mode) converter. Features. Applications
Advanced DisplayPort to DisplayPort (dual mode) converter Data brief Features DisplayPort dual-mode transmitter DP 1.2a compliant Link rate HBR2/HBR/RBR 1, 2, or 4 lanes AUX CH 1 Mbps Supports edp operation
AN438 APPLICATION NOTE SAFETY PRECAUTIONS FOR DEVELOPMENT TOOL TRIAC + MICROCONTROLLER
AN438 APPLICATION NOTE SAFETY PRECAUTIONS FOR DEVELOPMENT TOOL TRIAC + MICROCONTROLLER INTRODUCTION The goal of this paper is to analyse the different ways to configure a micro-controller and a development
AN974 APPLICATION NOTE
AN974 APPLICATION NOTE Real time clock with ST7 Timer Output Compare By MCD Application Team 1 INTRODUCTION The purpose of this note is to present how to use the ST7 Timer output compare function. As an
Obsolete Product(s) - Obsolete Product(s)
Low-power combo DVB-T/T2/C/S/S2 single-chip receiver Features DVB-T2 demodulation: Compliant with ETSI EN302755 DTG v7 and Nordig Unified v2.3 compliant 1.7, 5, 6, 7 and 8 MHz normal and extended BW signals
STTH110. High voltage ultrafast rectifier. Description. Features
High voltage ultrafast rectifier Datasheet - production data K Description The STTH110, which is using ST ultrafast high voltage planar technology, is especially suited for free-wheeling, clamping, snubbering,
STB4NK60Z, STB4NK60Z-1, STD4NK60Z STD4NK60Z-1, STP4NK60Z,STP4NK60ZFP
STB4NK60Z, STB4NK60Z-1, STD4NK60Z STD4NK60Z-1, STP4NK60Z,STP4NK60ZFP N-channel 600 V - 1.76 Ω - 4 A SuperMESH Power MOSFET DPAK - D 2 PAK - IPAK - I 2 PAK - TO-220 - TO-220FP Features Type V DSS R DS(on)
Low power offline switched-mode power supply primary switcher. 60kHz OSCILLATOR PWM LATCH Q R4 S FF R3 R1 R2 + BLANKING + OVERVOLTAGE LATCH
Low power offline switched-mode power supply primary switcher Features Fixed 60 khz switching frequency 9 V to 38 V wide range V DD voltage Current mode control Auxiliary undervoltage lockout with hysteresis
M4T28-BR12SH M4T32-BR12SH
M4T28-BR12SH M4T32-BR12SH TIMEKEEPER SNAPHAT (battery and crystal) Features Provides battery backup power for non-volatile TIMEKEEPER and supervisor devices in the 28- or 44-pin SNAPHAT SOIC package Removable
AN2328 Application note
Application note HID device coding example Introduction This application note describes how to lookup and use HID devices under Windows. This note is related to the MEMS Evaluation boards which are usually
AN1819 APPLICATION NOTE Bad Block Management in Single Level Cell NAND Flash Memories
APPLICATION NOTE Bad Block Management in Single Level Cell NAND Flash Memories This Application Note explains how to recognize factory generated Bad Blocks, and to manage Bad Blocks that develop during
AN3327 Application note
AN3327 Application note L9942 back EMF stall detection algorithm Introduction The L9942 is an integrated stepper motor driver for bipolar stepper motors used primarily in automotive head lamp leveling.