POWER CONVERTERS
Managing cold cranking
in automotives
By Hannes Estl
Systems Engineer
Texas Instruments
The widely varying voltage of the
12V automotive board net can
present a challenge for automo-
tive electronic applications. With
voltages ranging from 3.5V to
28V (45V), simple power supply
solutions such as linear voltage
regulators, buck or boost DC/DC
converters are not always appli-
cable to provide the desired elec-
tronic control unit (ECU) supply
voltages. A buck-boost converter
topology can solve this dilemma
without the need for magneti-
cally coupled coils (transformers
such as a SEPIC or flyback con-
verter), offering a cost-effective,
flexible system solution.
For many applications and
ECUs in the automotive environ-
ment, the voltage supplied by
the battery and alternator is not
adequate. It first needs to be
converted to the right voltage
level. DC/DC switching voltage
regulators and linear voltage
regulators are a widely used so-
lution to achieve this goal. This
article focuses on switching volt-
age regulators only, as linear solu-
tions can not be used to generate
output voltages higher than the
supplied input voltage.
The most common topology
is the buck converter (Figure 1).
By requiring only a single induc-
tance, a diode and a switch it’s
one of the simplest and most
cost-effective switching DC/DC
solutions. There is a drawback,
however, which is the limitation
to generate only output voltages
lower than the input voltage. If a
higher output versus input volt-
age is required, the “inverse” to-
pology or the boost converter can
be used (Figure 2). The topology
requires similar components, but
provides output voltages greater
than the input voltage.
 eetindia.com | EE Times-India
As the automotive board
net voltage can vary within a
wide range (low as 3.5V during
cranking and up to 45V during
a clamped load dump event), a
cross over of input and output
voltage levels in some ECU ap-
plications is inevitable. The loss
of functionality during cranking
(starting the engine) is not ac-
ceptable, especially for power Figure 1: Basic buck converter
train applications or some navi-
gation and infotainment systems.
This problem could be solved
with solutions like a flyback con-
verter or SEPIC topology, but the
additional cost and space for the
required transformer type induc-
tances makes them less attractive
to customers.
A solution that can provide
both constant output voltage, Figure 2: Basic boost converter
even if the input voltage crosses
the output voltage value, as well
as simple design with only a
single coil is the buck-boost to-
pology. It combines the buck and
boost converter in one topology.
A seamless transition between
the two different modes allows
a stable, uninterrupted output
voltage under all input voltage
conditions. Figure 3: Non-synchronous buck-boost converter
As two different topologies
are combined, two switches and
two diodes are required for the
non-synchronous buck-boost
converter (Figure 3), compared
to one switch and one diode for
the simple buck or simple boost.
To increase overall system ef-
ficiency, the two diodes can be
replaced by switches. The topol-
ogy now looks similar to a full H- Figure 4: Synchronous buck-boost converter
bridge with inductor (Figure 4).
The general function of these Buck mode operation current to flow from the inductor
devices can be subdivided into For operation in buck mode the to the output capacitor. Switch
three modes of operation: input voltage always must be B2 must be open to avoid a short
1. Buck mode for input voltages above the output voltage. The from the output to GND.
above the output voltage function is similar to the basic During the “ON time” switch,
2. Boost mode for input voltages buck topology. The converters A1 is closed to charge the induc-
below the output voltage boost switches (B1 and B2) do not tance (Figure 5). In this cycle
3. Transition for input voltage in switch during this mode. Switch the current flows from the input
the range of output voltage B1 is always closed. This allows through switch A1, the coil, and
Figure 5:Buck converter current flow during ON phase Figure 8: Boost converter current clow during ON phase

Figure 6: Buck converter current flow during free wheeling phase Figure 9: Boost-converter current flow during free wheeling phase

Figure 7: Current waveforms during the buck switching phases Figure 10: Current waveforms during the boost switching phase.

switch B1 into the output ca-
pacitor.
In the second phase of the
cycle (OFF time) switch A1 is
opened, and switch A2 is closed
(Figure 6). The magnetically
charged coil forces a current from
GND through switch A2, the coil
and switch B1 into the output ca-
pacitor (also called free wheeling).
In a non-synchronous topol-
ogy, switch A2 is replaced with a
diode as passive free wheeling el-
ement. This reduces the number
of required drivers and FETs, but
decreases the efficiency of the
converter. The switching duty cy-
cle in this operation is depending
on the input-to-output voltage
ratio shown in this equation:
U OUT t ON t B2 is closed to charge the induc-
= = ON = D
U IN t ON + t OFF TS
Boost mode operation
For boost mode operation, the in-
put voltage always must be below
the output voltage. The device
operates in basic boost topology.
The converter’s buck switches (A1
and A2) are not switching during
this mode. Switch A1 is always
closed to allow current flow from
the input into the inductor. Switch
A2 must be open to avoid short-
ing the input to GND.
During the “ON time” switch
tor (Figure 8). In this cycle the cur-
rent flows from the input through
switch A1, the coil and Switch B2
into GND.
In the second phase of the cycle
(OFF time) switch B2 is opened and
switch B1 is closed (Figure 9). The
magnetically charged coil forces
a current from the input through
switch A1, the coil and switch B1
into the output capacitor.
For a non-synchronous topol-
ogy, switch B1 is replaced with a
diode as passive free wheeling el-
ement. The consequences are the
same as described in “buck mode
operation.” The switching duty cy-
cle in this operation also depends
on the input-to-output voltage
ratio computed as follows:
U OUT t ON + t OFF TS 1
= = =
U IN t OFF TS − t ON 1− D
Transition operation
When the input and output volt-
ages are nearly the same, nei-
ther basic buck mode nor basic

 eetindia.com | EE Times-India
Figure 11: Current and voltage waveforms during different switching phases and modes of operation

boost mode alone can maintain
a stable closed loop controlled
output voltage. One possibility
is to switch over from one mode
to another at a certain input
voltage level (the threshold
voltage has a hysteresis for sta-
bility). Another way would be to
operate both, buck and boost, in
altering switching clock cycles to
ensure stable output voltage as
well as good transient response.
A variety of products are
available that can help custom-
ers deal with the challenges of
the wide 12V board net voltage
range including cold start condi-
tions, load dump or battery run-
down. With a fully integrated
5V, 1A buck-boost converter, a
stable output voltage can be
maintained without the need for
costly, bulky transformer-type in-
ductances. Thus, full application
operation under a wide range
of battery voltage conditions is
ensured.

 eetindia.com | EE Times-India