High density, high efficiency, light weight MIL-COTS DC-DC solutions.

Transcription

1 High density, high efficiency, light weight MIL-COTS DC-DC solutions. CMSE 08, Portsmouth UK, June 10 th -12 th 2008 Arthur Jordan

2 Abstract Scope: DC-DC power conversion from 270V or 28V down to 0.8V-50V, from 30W to 3kW. Data-processing, communications and solid-state lighting solutions. Air-, ship-, vehicle-borne systems or man-carried / -wearable applications. Content: The separation or factorization - of regulation & voltage transformation functions in a DC-DC converter creates new high power, small size power components which can be arranged in a variety of configurations to reduces distribution losses, reduce duplicated functions and reduce power dissipation at the Point-of-Load while increasing total system efficiency. These flexible building blocks, known as V I Chips provide key advantages to the power designer with their industry leading power density, high efficiency, design flexibility, speed (fast response) and size. Several packaging options allow for optimum mechanical / thermal design. The paper will introduce the topologies used within the new building block power components (Sine Amplitude Converter and Non-isolated Buck-Boost) and present system application comparisons between traditional and Factorized Power architectures. For example: 28VIN to 3.3V, 40A MIL-COTs DC-DC converter with 20% more power and 2/3 less space than the original design. Single-slot MIL-COTS 28VIN VME power card with 50% more power in ½ the size and 2/3 weight reduction. 100W at 3.3V from 270VDC with MIL-STD 704 performance Efficiency, transient response and EMI filter performance will be presented. 2

3 Vicor & V I Chip Headquarters & manufacturing: Andover, MA 1,100 employees worldwide Sales and Technical Support Centers: US (CA, TX, IL), France, Hong Kong, Germany, Italy, UK, Japan 100+ patents 8,000 active customers $200M revenue (2007) V I Chip Inc. is a wholly owned subsidiary of Vicor 3

4 Product Milestones MIL-COTS V I Chips First Full-brick 100 W First ½-brick 100 W Full-brick 600 W ½ brick 300 W ¼brick 150 W Factorized Power Architecture introduced V I Chips 300 W

5 Factorized Power Architecture (FPA) and V I Chips Factorized Power Architecture Separation of power conversion stages: Regulation & Voltage Transformation Reduces distribution losses in a system Reduces duplicated functions in the DC-DC conversion path Reduces power dissipation at the load while increasing total system efficiency A holistic approach vs. traditional design compromises Flexible building blocks: V I Chips Small, powerful components for DC-DC conversion Provide key advantages to the power designer Industry leading power density (size & weight) High Efficiency Design flexibility Speed (fast response) 5

6 Sine Amplitude Converter (SAC) Resonant Full Bridge Primary ZVS, ZCS, >1 Mhz switching frequency Synchronous Secondary Rectification +IN D P P D P D +OUT SAC Control D Cres -OUT -IN D D D P=Power Transformer D=Drive Transformer Operates as: Isolated, unregulated voltage transformer / current multiplier Output voltage determined by transformer K-factor Used in Bus Converter Module (BCM) Voltage Transformation Module (VTM) U.S. and Foreign Patents and Patents Pending 6

7 SAC Performance (Bus Converters) Proprietary topology allows high efficiency and extremely small size Size 1.28 x 0.87 x 0.26 in Weight 0.5 oz / 15 g each Bus Converter performance: * * MIL-COTS meets MIL-STD-704D-F ( V, 50ms ride-through) 7

8 Buck-Boost Regulator Non-isolated buck-boost ZVS, >1 Mhz switching frequency Creates: Regulated DC output from wide range unregulated input Used in Pre-Regulator Module (PRM) U.S. and Foreign Patents and Patents Pending 8

9 Buck-Boost Performance (Pre-Regulators) Same size and weight as SAC Buck-Boost Regulator performance: 9

10 SAC Performance (Voltage Transformers) Same size and weight as BCMs / PRMs Output of Pre-Regulator (PRM) is the input to the Voltage Transformer (VTM) Voltage Transformer performance: 10

11 DC-DC Conversion Unregulated = BCM (Bus Converter) Load Source OR POL Regulated = PRM (Regulator) + VTM (Transformer) Source Load 11

12 PRM & VTM: Operation & Regulation Source Unregulated Wide Range Input Regulated Factorized Bus K-factor Regulated V f K Load V f PRM controls the Factorized Bus voltage (V f ) to regulate the VTM input VTM transforms and isolates at the POL Result: Efficient distribution, regulation, transformation and isolation 12

13 PRM & VTM: Operation & Regulation Source Unregulated Wide Range Input Regulated Factorized Bus K-factor Regulated V f K Load 3 5% V f Local Loop PRM controls the Factorized Bus voltage (V f ) to regulate the VTM input VTM transforms and isolates at the POL Result: Efficient distribution, regulation, transformation and isolation 13

14 PRM & VTM: Operation & Regulation Source Unregulated Wide Range Input Regulated Factorized Bus K-factor Regulated V f K Load 1 2% V f Adaptive Loop PRM controls the Factorized Bus voltage (V f ) to regulate the VTM input VTM transforms and isolates at the POL Result: Efficient distribution, regulation, transformation and isolation 14

15 PRM & VTM: Operation & Regulation Source Unregulated Wide Range Input Regulated Factorized Bus K-factor Regulated V f K Load 0.2% V f Remote Loop PRM controls the Factorized Bus voltage (V f ) to regulate the VTM input VTM transforms and isolates at the POL Result: Efficient distribution, regulation, transformation and isolation 15

16 Closed Loop with MIL-COTS PRM (Dependent Outputs) V f = 36 Vdc e.g. K=1/ Vdc Load Vdc +/- x% e.g. K=1/3 12 Vdc +/- x% Load 2 Multiple VTMs from a single PRM See Application Note AN:

17 Closed Loop (Independently Regulated Outputs) V f = 43.2 Vdc e.g. K=1/ Vdc Load Vdc +/- x% e.g. K=1/8 V f = 40 Vdc +/- y% -5 Vdc Use one VTM per PRM for independently regulated outputs Use different grounding point for negative voltages Load 2 17

18 Load Bulk Capacitance Elimination / Reduction VTM voltage transformer is also a low impedance current multiplier <1 mohm from DC to 1MHz Bulk capacitance at the load can be eliminated / reduced Move POL Capacitance to input of VTM Reduce capacitance by 1/K^2 Additional space and cost savings e.g. K=1/32 Source Load Source 1uF here 1,000uF here Load 18

19 Fast Transient Response Load step with 100 μf input capacitance and no output capacitance (MV036F120M010) 19

20 MIL-COTS Application Example: 3.3V, 30A from 28V Unregulated 28 V (4 A, 112 W) 95% V f 39.6 V (2.7 A, 106 W) K=1/ % Regulated Load 3.3 V ( 30.3 A, 100 W ) 100W load draws only 112W from the main distribution bus Overall efficiency = 89.3% With reduction in bulk capacitors, heatsinks, etc. Powertrain pcb area only 2.23 in 2 20

21 MIL-COTS Application Example: 3.3V, 30A from 270V Unreg. 270V (0.44 A, 118 W) K=1/8 95% 95% Unreg. V f 33.75V (3.3A, 112W) 39.6V (2.7A, 106W) K=1/ % Load Reg. 3.3V (30.3A, 100W) 100W load draws only 118W from the main 270V (aircraft) distribution bus MIL-STD-704D/F (125V 350V ride-through) Overall efficiency = 85.3% from 270V to 3.3V Powertrain pcb area only 3.4 in 2 With reduction in bulk capacitors, heatsinks, etc. As the HV BCM is capable of 240W (i.e. only 50% utilized), a second PRM+VTM combination could be added for an additional output / load HV distribution benefits (270V vs. ~28V) 99% reduction in I 2 R loss Smaller connectors, etc. Place VTM directly at load and factorize (place) the PRM at the HV BCM 21

22 MIL-COTS V I Chip EMI (no filter) Military COTS V I Chips tested to MIL-STD-461E levels, CE102 (no filter) Out of tolerance at frequencies above 1 MHz (V I Chip switching frequency) Out of Tolerance MIL-STD-461E, CE 102 Threshold 22

23 MIL-COTS V I Chip EMI (with filter) MIL-COTS V I Chips tested to MIL-STD-461E levels, CE102 with filter and Y-capacitors Greatly reduced EMI signature Within Tolerance MIL-STD-461E, CE 102 Threshold 23

24 Filter Waveforms (M-FIAM7 + V I Chips, MIL-STD-1275A/B/D) 100 V surge as per MIL-STD-1275B 100 V surge clamped to 50 V Output from the M-FIAM7 shuts off after 50 ms 24

25 MIL-COTS Application Example: Single-Slot 550W VME 28 V IN, 4 Outputs P OUT = 550 W (+66%) Efficiency = 85% (+7% pts) Weight = 2.4 lbs (-30%) Size = Single VME (-50%) Meets: MIL-STD-461E (EMI) MIL-STD-704F (28V IN ) MIL-STD-810 F (516.5/1) (Vibration) 6x PRMs, 6 VTMs & 2x MFIAM Filters Photographs courtesy of Aegis. Unit available for purchase - contact William H. Dockery of Aegis Power Systems Inc., 805 Greenlawn Road, Murphy, NC Tel: x102, bdockery@aegispower.com, 25

26 Conclusion Factorized Power Architecture (FPA) Factorization (separation) of regulation & voltage transformation functions in a DC-DC converter Enables reduction of distribution losses, reduction of duplicated functions, reduced power dissipation at the load while increasing total system efficiency. V I Chips Flexible power components which provide key advantages: Power density, high efficiency, design flexibility, speed (fast response) and size. Topologies: Sine Amplitude Converter Non-isolated Buck-Boost MIL-COTS Application examples Improved efficiency Light weight Smaller size Thank You Comments / Questions? 26