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Levels of Microcontroller Integration in Power-Supply Design

By Keith Curtis
Principal Applications Engineer
Microchip Technology Inc.

ABSTRACT
In traditional “Switch Mode Power-Supply” design, topology is the major
determining factor in the design’s capabilities. Output voltage, isolation, and efficiency
are all significantly affected by this single design decision. Choosing the right topology
can mean the difference between success and failure in a design, so making the right
choice is critical.

With the advent of intelligent power-supply design, another major determining factor
has emerged, the level of integration between the microcontroller and the analog power
section of the design. Control, monitoring, communications and possible functions are
all controlled by how the microcontroller connects to the design.

This paper quantifies the levels of integration into four distinct categories that clearly
define capabilities, features and the impact on the analog section of the design. Using the
four categories as a guide, a designer can choose an appropriate level of integration (just
like choosing a topology) that is appropriate for the features and capabilities required of
the design. Armed with this information, designers can make intelligent choices in their
“intelligent power-supply” designs, rightsizing the microcontroller needed, and making
the appropriate changes in the design of the analog section.

INTRODUCTION
Twenty years ago, the most common definition of intelligent power-supply design
was making sure the linear regulator had a sufficient heat sink, and the filter capacitors
were large enough to guarantee the headroom requirement for the regulator. In the years
since then, many aspects of power-supply design have changed. Linear regulators made
way for switching regulators, power factor correction became more important, and
size/cost became a major factor in the design process.

A new aspect of power-supply design is now on the horizon, and it is changing the
definition of intelligent power-supply design. This new aspect is the introduction of
microcontrollers into power-supply design for management and communications. Where
control once meant a stable reference, it now means a programmable output voltage.
Where communications once meant the SHUTDOWN and POWERGOOD signals, it
now means bi-directional serial communications.

As with any great shift in design, there has been a great deal of confusion concerning
power-supply designs that include a microcontroller. This confusion is understandable,
as intelligent power-supply design can include everything from the concept of a
completely digital power supply using a DSP with no analog components, all they way
down to simple point-of-control additions to solve problems like sequencing and softstart.
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When discussing a switching power-supply design, one of the first characteristics

stated is the topology of the design. Choosing a topology (whether buck, forward, or
flyback) fixes not only the general design of the power supply, it also sets limits on both
the performance and operation of the design. What this paper endeavors to do is quantify
the level of integration between a power supply and microcontroller in much the same
way that topology quantifies the operation of the analog section of the design. This paper
also explores the advantages and disadvantages associated with each level.

FOUR REASONS FOR ADDING A MICROCONTROLLER

There are four basic reasons for adding a microcontroller to a switching power-supply
design: control of the design, monitoring of operation, communications with an external
entity, and the addition of deterministic functions.

• CONTROL OF THE DESIGN

Control is the most flexible of the four, and the basis for defining the four levels of
integration in a design. The level of control possible is dictated by the choice of
components in the analog sections of the design, available design expertise, and the
comfort level of the designer with digital design.

The primary purpose of control is to act in concert with communications to provide

remote control of the operation and performance of the design. Additionally, control
allows for operation with the programming for deterministic functions to implement
complex actions such as softstart, power sequencing, restart on error, and a slew rate
control for changes in the output voltage.

• MONITORING OF OPERATION
Monitoring is simpler and less intrusive than control, in that it only needs to sample
the various control signals within a power-supply design. While it may connect to
several points in a design, it takes no control over the design, so its threat level, as
perceived by analog designers, is thought to be low compared to the introduction of
control functions.

The purpose of monitoring, like control, is two fold. It operates in concert with the
communications system for remote reporting of operational information to a separate
entity, and providing source information to deterministic functions such as failure
detection and prediction, data logging, and load-dictated performance or topology
shifts such as continuous/discontinuous mode switching.
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• COMMUNICATIONS WITH AN EXTERNAL ENTITY

As we have seen above, communications combines with control and monitoring to
provide both remote reporting and remote control. However, communications also
plays a role in maintenance and inventory control by operating in concert with on-
system non-volatile storage to provide a repair history and operational record for the
power-supply design. Data logging of system parameters also provides the basis for
performance trend analysis, including the effects of temperature and aging on the
power supply.

• ADDING DETERMINISTIC FUNCTIONS

Deterministic functions are the so-called free benefit of integrating a microcontroller
into a power-supply design. Because the microcontroller already has control and
monitoring functions in the design, implementing simple sequential functions based
on that control and monitoring are simply a matter of additional software. Another
benefit of implementing deterministic functions in software is the programmability of
the design. Now, through simple programming at the end of the production line, the
exact performance of the features can be set in software, including the available
subset of features required for the specific product being manufactured. Stocking a
single design with multiple feature sets, determined by software, is an obvious benefit
in a market known for custom features and modifications for each customer and
project.

So, microcontrollers bring several advantages to power-supply design. The secret to

integrating a microcontroller successfully into a design is to choose the correct level of
integration for the features and functions required for the design. As each design is
somewhat unique in its requirements, we approach the problem by first defining four
discrete levels with broad descriptions, and then determining which level is appropriate
for a given design.

FOUR LEVELS OF MICROCONTROLLER INTEGRATION IN POWER-SUPPLY

DESIGN
The four levels of microcontroller integration differentiate based on the level and type
of control that the microcontroller can exert over the power-supply design. We use
control to differentiate because this is the most intrusive aspect of microcontroller
integration, and it has the greatest effect of the analog design (not to mention the required
level of expertise to implement).
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Level 1 integration combines a microcontroller with a largely unmodified analog

switching power-supply design. The microcontroller has only limited control over the
operation of the analog design, typically restricted to enable/shutdown control.
Monitoring by the microcontroller is only limited by the access provided by the analog
design. Even with this finite level of control, the combination of monitoring and the
programmable nature of the microcontroller allows a fairly broad capability in respect to
deterministic functionality. Using the monitoring capability, functions such as power up
and down sequencing, fault detection and prediction, and intelligent fault shutdown and
restart are possible. Through the communications channel, remote on /off, remote
reporting, data logging and inventory information management are also possible. Figure
1.0 shows a block diagram for a typical Level 1 integration.

Level 1 integration is also the most comfortable for traditional analog designers
because the basic power-supply design is still completely analog in nature. The design
format is familiar, and any reliability and performance issues are still analog based. This
level of integration also still relies largely on traditional analog design expertise, with
only entry-level design knowledge of microcontrollers needed. All of these aspects of a
Level 1 integration make it a logical first step for power-supply designers making their
way into intelligent power-supply design.

Another advantage to Level 1 integration is that it has the potential to actually reduce
complexity in the analog design. Complex combinations of RC networks and
comparators are no longer needed for failure-detection circuits, softstart, power-up
sequencing, and POWERGOOD output indicators. This reduction in complexity helps to
offset the additional cost of the microcontroller in the system.

Level 2 integration combines a microcontroller with a largely unmodified analog

switching power-supply design, with the exception that the microcontroller has control of
the reference signals used by the analog feedback loop. This means that the
microcontroller can dictate the reference voltage for the power supply, the current limit
control voltage, and the frequency of the PWM generator. This gives the microcontroller
all the on/off control of Level 1, plus the ability to proportionally control the output of the
power supply. Figure 2.0 shows a block diagram for a typical Level 2 integration.
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Monitoring by the microcontroller is identical to the monitoring ability of Level 1,

and again, is only limited by access to the appropriate system signals within the analog
design. This level of monitoring combined with the expanded control of Level 2, means
several new options for deterministic functions are possible. These include temperature
compensation of a lower-cost system voltage reference, non-volatile output calibration to
an external standard, output voltage slew-rate control, elevated current limits during
startup for capacitive loads, and ratiometric power up/down sequencing.

The added control capability correspondingly expands the ability to remotely control
the operation of the power-supply design, giving the controlling entity the ability to
perform operations such as compensate for system losses between the power supply and
its load, or operate as a secondary feedback loop to compensate for output voltage droop
with increased load current.

Level 2 integration is within the comfort tolerance for analog designers, because the
basic power-supply design is still analog in nature. The design format is still familiar and
most of the reliability and performance issues remain analog based. Digital control has
begun to affect reliability and performance, but the issues are relatively simple and
handled through good programming practice coupled with the normal supervisory
functions such as a Watch Dog Timer and Brown Out Reset – features typically found on
small microcontrollers. The range of digital control can also be limited to restrict the
potential for a runaway program to cause significant damage. The level of digital design
expertise is also still within the realm of entry to mid-level programming experience.
Together, Level 2 forms a logical next step in the evolution of a completely analog
power-supply design, to a design with more digital-control capabilities.
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Another advantage to Level 2 integration is that it also has the potential to actually
reduce complexity in the analog design. Complex combinations of op amps and one-
percent networks required for temperature compensation can be replaced with a simple
software routine that scales the reference voltage, based on the current temperature and
the stored temperature characteristics of the system voltage reference. The ability to
perform a one-time, non-volatile calibration to an external reference voltage eliminates
the traditional trim potentiometer, and opens up the possibility of calibration at multiple
temperatures during the burn-in process. This reduction in complexity, and potential
increase in system performance, helps to offset the additional cost of the microcontroller
in the system. In fact, small and extremely cost-effective microcontrollers with analog-
to-digital converters, comparators and other integrated analog functions are widely
available, and often result in a lower-cost implementation than a complex circuit of
analog devices.

Level 3 integration combines a microcontroller with a largely unmodified analog

switching power-supply design, with the exception that the microcontroller has control of
the configuration of the analog feedback loop. This means that the microcontroller can
change the topology of the power supply to accommodate different output voltage and
current requirements. The microcontroller also has the ability to switch between different
feedback mechanisms to shift from continuous to discontinuous modes of operation. All
this control is in addition to the control available with both Level 1 and Level 2 systems.
This gives the microcontroller all the on/off control of Level 1, the ability to
proportionally control the output of the power supply of Level 2, plus the ability to
reconfigure the supply as needed for changing load conditions. Figure 3.0 shows a block
diagram for a typical Level 3 integration.
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Monitoring by the microcontroller is identical to the monitoring ability of Levels 1

and 2, and again is only limited by access to the appropriate system signals within the
analog design. This level of monitoring, combined with the expanded control of Level 2,
means several new options for deterministic functions are possible. These include
dynamic reconfiguration of the feed back to accommodate continuous and discontinuous
current modes, switching in/out additional switching phases to accommodate higher
efficiencies in multiphase designs, and the swapping in of spare system components for
remote repair.

The added control capability correspondingly expands the ability to remotely control
the operation of the power-supply design, giving the controlling entity the ability to
perform operations such as remote diagnostics and repair, dynamic expansion of current
capability in anticipation of higher loads, and customization of the system dynamics for
load current transients.

Level 3 integration is at the upper end of the comfort tolerance for analog designers,
because the basic power-supply building blocks and overall system design is still analog
in nature. The design format is still familiar and most of the reliability and performance
issues are still analog based. Digital control has more effect on reliability and
performance than a Level 1 or 2 design, but the issues can still be handled through good
programming practices, coupled with the normal supervisory functions such as a Watch
Dog Timer and Brown Out Reset. The default configuration can also be specified
through the use of bias resistors placed to pull the analog steering switches to a safe
operating configuration. The level of digital design expertise is also still within the realm
of mid-level programming experience.

Another advantage to Level 3 integration is that it also has the potential to actually
reduce complexity in the analog design. Complex combinations of switches and control
logic can be replaced with a simple software routine designed to shift the design
configuration based on programmable limits in software. This means that the current
capability of a design can be adjusted by the number of phases in a multi-phase system,
an automated switch from continuous to discontinuous operation, or an automated switch
from diode switching to synchronous switching, based on system-load currents.

Level 4 integration makes a complete switch from analog feedback to digital DSP
feedback in the switching power-supply design. It still allows all the control of Levels 1
through 3, with the exception that switches in feedback and configuration are now a
matter of software configuration instead of hardware changes. This means that the
microcontroller not only has control over the operations, performance, and topology of
the system, but also real-time control over the response characteristics of the feedback
path. The microcontroller has the capability to provide non-linear response
characteristics, Infinite Impulse Response characteristics, and instantaneous offsets in the
error level as an acquisition aide. Figure 4.0 shows a block diagram for a typical Level 4
integration.
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Monitoring by the microcontroller is identical to the monitoring ability of Levels 1 -

3, and now is not limited by access to the appropriate system signals because all of the
feedback signals are already available inside the software-based feedback pathway. This
level of monitoring, combined with the expanded control of Level 3, means several new
options for deterministic functions are possible. These include direct power limiting,
acquisition aides to speed up output voltage changes, and adaptive response
characteristics that can anticipate changes in the load.

Level 4 integration is beyond the upper end of the comfort tolerance for most analog
designers, because the power-supply building blocks are completely implemented as DSP
software constructs. The model used to determine loop stability is still familiar, but the
implementation, reliability and performance specifications are entirely digitally based.
Digital control has much greater effect on reliability and performance than in a Level 1,
2, or 3 design, and the issues have to be handled through both hardware and software
safety systems built into the design. The level of digital design expertise is also well
beyond the realm of mid-level programming experience, moving into the realm of
advanced DSP programming. Level 4 is the last logical step in the evolution of a
completely analog power-supply design, representing a complete conversion of the
analog design into a digital replacement.

The digital nature of a Level 4 design does have some attractive aspects, all of the
loop characteristics are controlled by constants in the DSP/PID algorithms and can be
changed in real time. Because the constants are just data in memory, the feedback
characteristics do not change with supply voltage or temperature. And, the equivalent to
the charge present in integrating capacitors is just a data value in memory, so it can be
preset to any level to specify the DC error value in the filter.
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Another advantage to Level 4 integration is that it removes most, if not all, analog
components in the design. Complex combinations of op amps and feedback networks are
replaced with software routines in the microcontroller. Temperature dependence and
aging are also largely eliminated. The down side of this conversion to software is that the
processing power required in the microcontroller is significantly increased. Hardware
multiply functions are required to handle the filter throughput. And fast, high-resolution
ADC and PWM peripherals are required to drive the remaining analog components.

So, which level of integration is right for a design? Level 1 just gives the
microcontroller on/off control, and Level 4 puts the entire analog feedback system into
the digital realm. What is right for the design? Well, there are several factors that affect
this decision:
1. What are the customer’s requirements? Do they just need on/off control, or
proportional control of the output voltage? Do they need to shift topology to
achieve the output voltage range required? Does the feedback network
require special response characteristics that are impractical or impossible with
RC networks? The answers to these questions determine the minimum level
of integration.
2. What is the designers’ comfort level with digital design? Have the designers
written software before? Have they worked with microcontrollers before?
The answers to these questions determine whether the design group can
handle a high level of integration in the design.
3. What are the reliability requirements of the design? Moving up in integration
shifts reliability issues from analog components to digital components and
software. Software also introduces its own reliability issues that are unique.
This question is another criterion concerning the designer’s experience with
microcontrollers.
4. Is the design to be a one-time design, or is the plan to market the power
supply to several different customers? Adding microcontrollers to a design
allows customization by software at the end of the assembly line. If the
design needs the ability to be customized, increased integration can be
beneficial to the design.
5. What are the cost constraints of the design? Increased integration typically
drives up the cost of the microcontroller needed to handle the greater
throughput. If the purpose is to produce a very inexpensive design, the level
of integration may need to be limited.

If we break out each level in light of these questions, we have a good decision matrix
to determine the appropriate microcontroller for the design.

LEVEL 1.
Type of Control:
Monitoring:
Communications:
Power-Supply Design:
Traditional Designer Comfort:
Digital Design Experience:
Cost for Microcontroller:
Reliability Issues:
LEVEL 2.
Type of Control:
Monitoring:
Communications:
Power-Supply design:
Traditional Designer Comfort:
Digital Design Experience:
Cost for Microcontroller:
Reliability Issues:
LEVEL 3.
Type of Control:
Monitoring:
Communications:
Power-Supply Design:
Traditional Designer Comfort:
Digital Design Experience:
Cost for Microcontroller:
Reliability Issues:
LEVEL 4.
Type of Control:
Monitoring:
Communications:
Power-Supply Design:
Traditional Designer Comfort:
Digital Design Experience:
Cost for Microcontroller:
Reliability Issues:
10
On/Off
Input/Output Voltage/Current
As Needed
Traditional Analog Feedback Loop
High
Minimal Experience, Entry Level
Minimal (communications affect this)
Mostly analog with few if any
microcontroller issues.
Level 1 + Proportional Control
Input/Output Voltage/Current
As Needed
Traditional Analog Feedback Loop
With Control of the Reference Signals
Good
Mid-Level Experience
Moderate (communications affect this)
Mostly analog with default and failsafe
microcontroller issues.
Level 2 + Reconfiguration of Topology
Input/Output Voltage/Current
As Needed
Traditional Analog Feedback Loop
With Analog Switching for Topology Control
Moderate
Mid-Level Experience
Moderate to High (communications affect this)
Equally analog and digital with default and failsafe
microcontroller issues.
Full Digital Design
Input/Output Voltage/Current
As Needed
Analog Feedback Implemented in DSP
Low
DSP Design Experience
High (communications affect this)
All digital and software, with analog reliability of
MOSFETs, inductor, and capacitor.
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Once the above matrix has been considered, it then falls to the designer to choose the
level of integration that meets the control needs of the design, while minimizing the cost
and design experience required. This should produce the optimal level of integration for
the needs of the design.

The question of design experience should not be minimized. As with any new
technology, trying to apply it without the proper training will produce frustration, delays,
and a prejudice that are hard to overcome later. Fortunately, microcontroller-based
design is a mature technology, and microcontroller manufacturers are well versed in
training. A designer wishing to learn this new technology need only contact a
microcontroller manufacturer to find training, often near their location. Microcontroller
manufacturers are also well versed in developing robust, reliable hardware/software, and
can provide a wealth of help and training in this area.

All too often, a new technology introduced into an existing design discipline produces
two diametrically opposed viewpoints. Designers either hate the new technology and
apply it only under duress, or they love the technology and try to apply the most complex
version possible to every design. By quantifying the abilities of microcontroller control
to distinct levels of control, designers should be able to apply the appropriate level of
microcontroller integration for the needs of the design.

CONCLUSIONS
So, just as the input/output voltages, power level, and isolation needs of a desired
supply determines the appropriate topology for a power-supply design, knowing control
requirements, cost, and design experience can determine the appropriate level of
microcontroller integration. The challenge is to balance all the requirements such that the
right amount of control is achieved with the minimal impact on cost, both in material and
design time.

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