Efficiency Optimization in Digitally Controlled Flyback DC–DC Converters Over Wide Ranges of Operating Conditions

This paper presents an approach to efficiency optimization in digitally controlled flyback dc-dc converters over wide ranges of operating conditions. Efficiency is characterized and optimized based on power loss modeling and multivariable nonlinear constrained optimization over power-stage and controller parameters. A valley switching technique is adopted to reduce MOSFET turn-on switching loss in discontinuous conduction mode. An optimization procedure is formulated to minimize power loss weighted over a range of operating points, under a cost constraint. A lookup table-based digital controller is applied to achieve on-line efficiency optimization by programming switching frequencies and operating modes based on the efficiency optimization processes. The proposed on-line efficiency optimization approach is verified by experimental results on a low cost 65 W flyback dc-dc prototype.

[1]  Zhaoming Qian,et al.  A primary side controlled WLED driver compatible with Triac dimmer , 2011, 2011 Twenty-Sixth Annual IEEE Applied Power Electronics Conference and Exposition (APEC).

[2]  Gun-Woo Moon,et al.  Sawtooth burst mode control with minimum peak current in stand-by operation of power supply , 2011, 8th International Conference on Power Electronics - ECCE Asia.

[3]  Sang Hee Kang,et al.  Efficiency characterization and optimization in flyback DC-DC converters , 2010, 2010 IEEE Energy Conversion Congress and Exposition.

[4]  Qing Chen,et al.  A nonlinear optimization tool for the full-bridge zero-voltage-switched DC-DC converter , 1992, PESC '92 Record. 23rd Annual IEEE Power Electronics Specialists Conference.

[5]  Charles R. Sullivan,et al.  Accurate prediction of ferrite core loss with nonsinusoidal waveforms using only Steinmetz parameters , 2002, 2002 IEEE Workshop on Computers in Power Electronics, 2002. Proceedings..

[6]  Fu-Zen Chen,et al.  Digital Control for Improved Efficiency and Reduced Harmonic Distortion Over Wide Load Range in Boost PFC Rectifiers , 2010, IEEE Transactions on Power Electronics.

[7]  Young-Bae Park,et al.  A efficiency improvement methodology for active mode efficiency regulation , 2008, 2008 IEEE International Symposium on Electronics and the Environment.

[8]  J.A.A. Qahouq,et al.  Sensorless Current Sharing Analysis and Scheme For Multiphase Converters , 2008, IEEE Transactions on Power Electronics.

[9]  M. H. Pong,et al.  Current-driven synchronous rectification technique for flyback topology , 2001, 2001 IEEE 32nd Annual Power Electronics Specialists Conference (IEEE Cat. No.01CH37230).

[10]  Zhaoming Qian,et al.  A High Efficiency Flyback Converter With New Active Clamp Technique , 2010, IEEE Transactions on Power Electronics.

[11]  J. Biela,et al.  Exploring the pareto front of multi-objective single-phase PFC rectifier design optimization - 99.2% efficiency vs. 7kW/din3 power density , 2009, 2009 IEEE 6th International Power Electronics and Motion Control Conference.

[12]  Dragan Maksimovic,et al.  Sensorless Current Sharing in Digitally Controlled Two-Phase Buck DC-DC Converters , 2009, 2009 Twenty-Fourth Annual IEEE Applied Power Electronics Conference and Exposition.

[13]  Xinke Wu,et al.  An Adaptive Blanking Time Control Scheme for an Audible Noise-Free Quasi-Resonant Flyback Converter , 2011, IEEE Transactions on Power Electronics.

[14]  Fred C. Lee,et al.  Utilization of an active-clamp circuit to achieve soft switching in flyback converters , 1994, Proceedings of 1994 Power Electronics Specialist Conference - PESC'94.

[15]  A. Prodic,et al.  Self-tuning digital current estimator for low-power switching converters , 2008, 2008 Twenty-Third Annual IEEE Applied Power Electronics Conference and Exposition.

[16]  Phoivos D. Ziogas,et al.  A novel approach for minimizing high-frequency transformer copper losses , 1988 .

[17]  Eun-Soo Kim,et al.  A study of novel flyback converter with very low power consumption at the standby operating mode , 2010, 2010 Twenty-Fifth Annual IEEE Applied Power Electronics Conference and Exposition (APEC).

[18]  Fred C. Lee,et al.  Optimizing design for low voltage DC-DC converters , 1997, Proceedings of APEC 97 - Applied Power Electronics Conference.

[19]  Der-Cherng Liaw,et al.  An observer design for primary-side control of flyback converter , 2010, 2010 International Conference on System Science and Engineering.

[20]  I. Batarseh,et al.  Maximum Efficiency Point Tracking (MEPT) Method and Digital Dead Time Control Implementation , 2006, IEEE Transactions on Power Electronics.

[21]  Hang-Seok Choi,et al.  Techniques to minimize Power Consumption of SMPS in Standby Mode , 2005, 2005 IEEE 36th Power Electronics Specialists Conference.

[22]  Paolo Mattavelli,et al.  Design optimization of soft-switched insulated DC/DC converters with active voltage clamp , 1996, IAS '96. Conference Record of the 1996 IEEE Industry Applications Conference Thirty-First IAS Annual Meeting.

[23]  Ying-Yu Tzou,et al.  Primary-side sensing error analysis for flyback converters , 2009, 2009 IEEE 6th International Power Electronics and Motion Control Conference.

[24]  Wai Tung Ng,et al.  Predictive Efficiency Optimization for DC–DC Converters With Highly Dynamic Digital Loads , 2008, IEEE Transactions on Power Electronics.

[25]  Tsorng-Juu Liang,et al.  Design and implementation of interleaved quasi-resonant DC-DC flyback converter , 2009, 2009 International Conference on Power Electronics and Drive Systems (PEDS).

[26]  Charles R. Sullivan,et al.  Computationally efficient winding loss calculation with multiple windings, arbitrary waveforms, and two-dimensional or three-dimensional field geometry , 2001 .

[27]  Robert W. Erickson,et al.  Fundamentals of Power Electronics , 2001 .

[28]  Milan M. Jovanovic,et al.  Design considerations and performance evaluations of synchronous rectification in flyback converters , 1998 .

[29]  Yu-Kang Lo,et al.  Active-Clamping ZVS Flyback Converter Employing Two Transformers , 2007, IEEE Transactions on Power Electronics.

[30]  Yong-Bin Kim,et al.  A high-efficiency fully digital synchronous buck converter power delivery system based on a finite-state machine , 2006, IEEE Transactions on Very Large Scale Integration (VLSI) Systems.

[31]  A.V. Peterchev,et al.  Digital Multimode Buck Converter Control With Loss-Minimizing Synchronous Rectifier Adaptation , 2006, IEEE Transactions on Power Electronics.

[32]  M. Jovanovic,et al.  Adaptive off-time control for variable-frequency, soft-switched flyback converter at light loads , 2002 .

[33]  Dragan Maksimovic,et al.  Average Inductor Current Sensor for Digitally Controlled Switched-Mode Power Supplies , 2012, IEEE Transactions on Power Electronics.

[34]  A. Barrado,et al.  Utilization of the power losses map in the design of DC/DC converters , 1998, PESC 98 Record. 29th Annual IEEE Power Electronics Specialists Conference (Cat. No.98CH36196).

[35]  Dragan Maksimovic,et al.  Single comparator based A/D converter for output voltage sensing in power factor correction rectifiers , 2009, 2009 IEEE Energy Conversion Congress and Exposition.

[36]  Fred C. Lee,et al.  Design optimization of an off-line input harmonic current corrected flyback converter , 1999, APEC '99. Fourteenth Annual Applied Power Electronics Conference and Exposition. 1999 Conference Proceedings (Cat. No.99CH36285).

[37]  Y. Hsieh,et al.  An Interleaved Flyback Converter Featured With Zero-Voltage Transition , 2011, IEEE transactions on power electronics.

[38]  Dragan Maksimovic,et al.  Sensorless optimization of dead times in dc–dc converters with synchronous rectifiers , 2006, IEEE Transactions on Power Electronics.

[39]  N. Barry,et al.  Primary side control circuit of a flyback converter , 2001, APEC 2001. Sixteenth Annual IEEE Applied Power Electronics Conference and Exposition (Cat. No.01CH37181).

[40]  Wuhua Li,et al.  Primary-side controlled flyback converter with current compensation in micro-power applications , 2009, 2009 IEEE 6th International Power Electronics and Motion Control Conference.

[41]  Oscar Garcia,et al.  Optimizing the winding strategy of the transformer in a flyback converter , 1996, PESC Record. 27th Annual IEEE Power Electronics Specialists Conference.

[42]  Yong Li,et al.  A low-cost adaptive multi-mode digital control solution maximizing AC/DC power supply efficiency , 2010, 2010 Twenty-Fifth Annual IEEE Applied Power Electronics Conference and Exposition (APEC).

[43]  Ying-Yu Tzou,et al.  Digital primary-side sensing control for flyback converters , 2009, 2009 International Conference on Power Electronics and Drive Systems (PEDS).

[44]  J.W. Kolar,et al.  Impact of Power Density Maximization on Efficiency of DC–DC Converter Systems , 2009, IEEE Transactions on Power Electronics.

[45]  Robert W. Erickson,et al.  A Microinverter for Building-Integrated Photovoltaics , 2009, 2009 Twenty-Fourth Annual IEEE Applied Power Electronics Conference and Exposition.

[46]  Sang Hee Kang,et al.  On-line efficiency optimization in flyback dc-dc converters over wide ranges of operating conditions , 2011, 2011 Twenty-Sixth Annual IEEE Applied Power Electronics Conference and Exposition (APEC).

[47]  Guang Hua,et al.  A high efficiency gate-driving scheme of synchronous rectifiers in Wide-Input-Voltage-Range CCM Flyback Converter , 2006 .

[48]  Reuben Lee.  Electronic transformers and circuits. , 1988 .

[49]  Milan M. Jovanovic,et al.  Performance evaluation of 70-W two-stage adapters for notebook computers , 1999, APEC '99. Fourteenth Annual Applied Power Electronics Conference and Exposition. 1999 Conference Proceedings (Cat. No.99CH36285).