Lab 3: Boost Converter Project:

Overview, Inductor Design and PWM Circuit Design

Objective:
This is the first lab for the boost converter design project. You will get familiar with the specifications and the building blocks of the boost converter: the power stage and the PWM control circuit. You will also design and make the inductor. 2. Pre -Lab: Read through the lab notes and the datasheet for SG3524 and OP42213 core. 1) Design a 100uH inductor and a 200uH inductor: Given the parameter as below: Core: 0P42213 core from MAGNETICS Inc. Wire: AWG 22 magnetic wire Calculate the following parameters for the inductor design: 1) The number of turns necessary to achieve the inductance value. We will use a piece of paper as air gap, so the effective air gap about 0.2mm (two times the thickness of a piece of paper) 2) The total wire length of the windings. 3) The number of conductors needed for a current density of less than 5 A/mm2 . Do we need multiple wires? 4) Will the number of turns fit in the core? 5) Calculate the skin depth at 200 KHz, and compare it to the wire diameter. 6) Estimate the copper loss and core loss of the inductor you designed. 2) Design the PWM driving circuit parameters and understand the operation of SG3524 1) From the data sheet, determine appropriate values for Rt and Ct to achieve the 1 .1 correct switching frequency, assume Ct = 1nF. Use the formula f s = . RtCt 2) What is the function of the compensation pin 9 of SG3524? What do we do if we decide to use an external operational amplifier instead of the internal error amplifier?

3. Lab Request 1) Build the inductor based on your calculation of the pre-lab, measure the inductance of the inductor to verify your design 2) Understand the operation of the SG3524 PWM controller 3) Understand the operation of the whole boost converter circuits 4. Lab 3 report 1) Write the detail calculation of your inductor design 2) Draw the open-loop schematics of the boost converter project based on the requirement of the boost converter design project, the datasheet of SG3524 and the MOSFET Driver IR4427.

Overview of the Boost Converter Design Project 1. The specifications The specifications of the boost converter are as following: Input voltage: 20V~40V. Output voltage: 70V. Rated output power: 20 Watts. Output voltage ripple: < 0.2% Switching Frequency: 200kHz. Conduction Mode: Continuous Conduction Mode (CCM) at 20Watts rated power, may go to DCM mode at lower power Major components for the power stage: MOSFET: IRF510 DIODE: MUR415 Inductor: Made by you own! Output Capacitor: 100uF electrolytic capacitor Major components for PWM Control and Driving Circuit: PWM controller: The famous SG3524 MOSFET driver: IR4427 2. Reference design of the Boost Converter Project 1) Block Diagram of the Boost Converter

2) Reference Schematics for the Close-loop Boost Converter

Please read the schematics carefully, there may be some mistakes inside!

Reference part list

Label Capacitors timing cap bypass cap bypass cap output cap output cap snubber cap compensation cap soft start cap Resistors timing R driver R driver R feedback R feedback R snubber R duty ratio adjust compensation Ct Cb2, Cb4, Cb5 Cb1, Cb3 Co1 Co2 Cr Ccomp Csoft Value/Character 1nF ceramic 0.47 F ceramic 50V 4.7 F electrolyti 50V 100 F electrolytic 100V 0.68 F polyester 100V 330pF ceramic 4.7 F electrolyti 50V 4.7 F electrolyti 50V Quantity 1 3 3 1 1 1 1 1

Rt Rd Rdr Rf1 Rf2 Rr Rpoti Rcomp

5.6k 1/4 W 4.7k 1/4 W 10 1/4 W 27k 1/4 W 1k 1/4 W 50 3W 10k 10k

1 1 1 1 1 1 1 1

IC's and Semiconductors PWM controller UC3524 driver IR4427 MOSFET IRF510 diode MUR415 diode 1N4148 Magnetic parts core bobbin clamp winding wire Accessories socket socket breadboard banana plug banana plug banana plug breadboard stands heat sink

PWM controller MOSFET driver 5A 100V 4A 150V fast signal diode

1 1 1 1 1

0P42213-UG B-2213 PC-2213 22 AWG

magnetic core bobbin clamp AWG 22 magnetic wire

1 1 1 enough

16Dip 8Dip

16pin dip 8pin dip black red white bolts nuts heat sink bolt nut

1 1 1 1 3 1 4 4 1 1 1

3. Inductor Design Procedure For the inductor design, we will use area product design method. For DC-biased inductor, like the filter inductor, we need three parameters to choose the right core and get the parameters for the inductor. 1) the DC current I 2) the ripple ?i /IL L 3) the current density J 4) the inductance L 5) the switching frequency fs Major parameter fo r the core MAGNETICS 0P-42213 Saturation flux density: Bs = 0.39 T (tesla) or 3900 Gs (gauss) Area product: Ap = 0.187 cm4 Effective Core area: Ac = 0.639 cm2 Magnetic path length: Lcore=3.12cm Window area: Wa = 0.292 cm2 Mean length per turn MLT t =0.145 feet or 44.2mm Design procedure using AP (area product) method: LI 2 1) Pick the core so that Ap , normally J =2.5 10 A /mm2 , here we choose BJK the winding factor k to be about 0.5, B should be less than the saturation flux density Bs to avoid saturation. For the project, we choose J = 5 A/mm2 and B to be about 0.3T. LI 2) Determine the number of turns N = . BAC I 3) Determine the wire cross section area Aw , choose the right wire size. Make J sure NAw Wa so that the wire can fit in the core. Another constraint for the wire is that the radius of the wire r is smaller than d (the skin depth due to skin effect).

r< =

0 f S

Conductivity of copper ? = 1.72x 10-8 Om at room temperature. However, we normally consider the worst case situation, we will use the conductivity at 100 degree Celsius ? = 2.2 x 10-8 Om. Permeability 0 = 4p x 10-7 H/m I If we have Aw < , we will need multiple wires. J Determine the number of wires m to make mAw >
I J

4) Calculate the air gap 0 N 2 AC Lg = L In the project, we will use a piece of paper as the air gap to avoid saturation of the core, therefore Lg will be about 0.2mm (two times the depth of the paper). You may need to recalculate the number of turns N because of this. 5) Using the MLT (mean length per turn) t to find the copper loss. t Pcu = ( N )I 2 Aw 6) Calculate the core loss c Pcore = af s B d , a = 0.0434, c = 1.63, d = 2.62 for 0P-42213 core. 4. SG3524 PWM controller

Please read the datasheet for the function of SG3524. SG3524 is one of the most popular PWM control ICs in the market, designed by the Orange County company Silicon General in the late 1970s. Silicon General was later bought out by Unitrode (now part of Texas Instruments). Now SG3524 are available from

companies like TI, Intersil, Philips and ST It was designed for push-pull topology. However it is able to be used for other topology as well.

5. MOSFET driver IR4427 Please read the datasheet for the function of IR4427. The gate to source of input capacitance of IRF510 MOSFET is quite large. The MOSFET drivers are capable of sinking/sourcing high peak currents to enable fast transient. Normally the MOSFET driver can take logic input signals and drive a large external MOSFET.

6. MOSFET IRF510 and Diode MUR415 Please read the datasheet for the parameters of IRF510 and MUR415.