Power Electronics Notes 07C Boost Converter Design Example

Marc T. Thompson, Ph.D. Thompson Consulting, Inc. 9 Jacob Gates Road Harvard, MA 01451 Phone: (978) 456-7722 Fax: (888) 538-3824 Email: marctt@thompsonrd.com Web: http://www.thompsonrd.com

Marc Thompson, 2008 M. T. Thompson, 2008

Boost Converter Design Example

Summary
Design a boost converter with the following specifications: Input voltage: 12V Output: 24V @ 1A, 24 Watts Continuous conduction mode Inductor and capacitors: selected from following datasheets Switching frequency 100 kHz Output voltage ripple < 50 mV-pp Evaluate output ripple and estimate efficiency of converter

M. T. Thompson, 2008

Boost Converter Design Example

Step-Up (Boost) DC-DC Converter

Output voltage is higher than the input, without a phase inversion

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Boost Converter Design Example

Boost Converter Waveforms

Continuous current conduction mode
Switch closed:

di L VCC dt L
Switch open:

di L VCC v o dt L
Inductor Volt-second balance: VCC DT (VCC Vo )(1 D)T 0 L L V Vo CC 1 D

M. T. Thompson, 2008

Boost Converter Design Example

Boost: Limits of Cont./Discont. Conduction

The output voltage is held constant For low load current, current conduction becomes discontinuous

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Boost Converter Design Example

Boost Converter: Discont. Conduction

Occurs at light loads

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Boost Converter Design Example

Boost Converter: Effect of Parasitics

The duty-ratio D is generally limited before the parasitic effects become significant

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Boost Converter Design Example

Boost Converter Output Ripple

ESR is assumed to be zero Assume that all the ripple component of diode current flows through capacitor; DC component flows through resistor

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Boost Converter Design Example

Boost Converter 1st-Cut Design --- Inductor

D = 0.5 What is minimum inductor value to keep this converter in continuous conduction mode ? (I.e. this converter operates at the continuous/discontinuous conduction boundary) Average diode current: 0.5Ipk(1-D) = Io = 1A Ipk = 4A Lmin =(Vo Vi)(1-D)T/i = (24-12)(0.5)(10-5)/4 = 15 H For the diode, ID,rms = I pk

1 = 2.3A 3

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Boost Converter Design Example

Inductor Datasheet
Use 22 H (ESR = 0.085 Ohms) Note that series resonant frequency (SRF) is much higher than operating frequency Note that IRMS rating of this inductor is 2.7A

M. T. Thompson, 2008

Boost Converter Design Example

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Boost Converter Current Waveforms

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Boost Converter Design Example

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Boost Converter 1st-Cut Design --- Capacitor

What is minimum capacitor value ?

Vo pp

Vo D R f swC

C m in

Vo D ( 24 )( 0.5) 5 100 F f sw RVo pp 10 ( 24 )( 0.05 )

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Boost Converter Design Example

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Capacitor Datasheet
Use 3 47 F caps in parallel (35V, ESR = 0.9 Ohms)

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Boost Converter Design Example

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MOSFET Datasheet
This device is over-sized, but lets use it anyway

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Boost Converter Design Example

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1st Cut Design

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Boost Converter Design Example

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Simulation Result --- Inductor Current

Note that inductor ripple is about 3A peak to peak

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Boost Converter Design Example

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Simulation Result --- Output Ripple

Why is output voltage ripple so large ?

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Simulation Result --- Analysis

The culprit is capacitor ESR. Ripple current is 3A pp, divided into 3 capacitors. Ripple voltage = ripple current x ESR This is a problem with the boost converter --- large output ripple current makes sizing capacitor difficult

Ripple 1 V pp

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Mitigating Strategies
Parallel up more capacitors, or find capacitors with even lower ESR Alternative strategy: use lower ESR caps with a post-filter

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2nd Cut Design

Lower ESR capacitors and an LC post filter added

Lower ESR caps

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2nd Cut Design --- Simulation Results

Ripple 20 mV pp

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Boost Converter Design Example

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2nd Cut Design --- Efficiency Estimate

Losses due to: Inductor loss Switch conduction loss Switch switching loss Diode loss Capacitor ESR loss Gate drive loss

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2nd Cut Design --- Efficiency Estimate

Boost converter lecture example MTT 10-9-03 fsw 1.00E+05 L 2.20E-05 Vi 12 Vo 24 Rinductor 0.085 D 0.5 Rsw 0.0825 IL,avg 2 IL,max 3.36E+00 IL,min 6.36E-01 tsw 1.50E-07 IL,rms 2.15E+00 Isw,RMS 1.52E+00 Vd 0.8 Diode voltage Io 1 Output current Qg 1.00E-07 LOSSES CALCULATION Pdiode Pinductor Pswitch, conduction Pswitch, switching Gate drive loss Capacitor ESR loss

0.80 0.39 0.19 0.61 0.12 0.12

Total losses Output power Efficiency

2.23 24 91.5%

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Boost Converter Design Example

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2nd Cut Design --- Evaluation

FATAL DESIGN FLAW Note that ISAT rating of this inductor is 2.6A Peak current in inductor is 3.4A Therefore, this design will blow up

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3rd Cut Design --- Replace Inductor

Using next-size up Coilcraft inductor, Isat rating of 22 H inductor is 7.0A, RMS rating is 3.5A, so this should be OK Inductor loss will be lower due to lower DC resistance This comes at the cost of a more expensive inductor, and more PC board space needed
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Boost Converter Design Example