Power Esim FACT sheets Prepared by Franki Poon

Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 1

Hardware Prototype Implementation Topology: AC/DC Flyback Dual-output Converter Input range: 85 -264 VAC/50 Hz Outputs: O/P 1 – 5 V/6 A; O/P 2 – 12 V/2. 5 A Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 2

Drain Voltage Waveform Analysis Critical waveforms Input voltage at 85 VAC Simulation peak voltage from Powere. Sim = 300 V Actual peak voltage approx. = 285 V Primary MOSFET switching waveform Ch 1 – M 1 drain source voltage waveform; Ch 2 – M 1 drain current waveform Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 3

Bulk Capacitor Voltage Waveform Analysis Critical waveforms Input voltage and bulk capacitor voltage waveforms Measurement Simulation Similar intersection point Ch 1 - Input AC voltage waveform Ch 2 - Rectified bulk capacitor voltage Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 4

Input Current Waveform Analysis Critical waveforms Input voltage and current Measurement Simulation Ch 1 - Input AC voltage waveform Ch 2 - Input current waveform Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 5

Line Regulation Output at full load Measurement Simulation Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 6

Load Regulation Input voltage at 85 VAC Simulation Measurement Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 7

Power Loss Analysis Efficiency comparison at full load Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 8

Closed-loop Analysis (Bode plot) Cut-off freq Input voltage at 115 VAC full load Measurement Simulation Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 9

Closed-loop Analysis (Transient Response) Measurement CH 1: Load current CH 2: Output voltage of O/P 1 Simulation Conditions: Input voltage at 162 VDC O/P 1: 5 V @ 0. 2 A-6 A O/P 2: 12 V at 1 A Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 10

Input Current Harmonics Analysis Input voltage at 230 VAC/50 Hz Measurement Simulated bar charts showed in good agreement with measurement. Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 11

Thermal Analysis Measurement 123. 1 103 70 Simulation 65 78 62 94 68 52 93 52 94 66 Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 12

Transformer Design Leakage inductance: Measurement = 2. 787 u. H Simulation = 2. 982 u. H Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 13

DVT Report – SMPS from other factory Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 14

DVT Report – 100 times faster to know the design fault Measurement Simulation Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 15

DVT Report – Every component checked include Xformer Measurement Saturation current observed in experimental measurement Simulation Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 16

DVT Report – MOSFET Stress Measurement Simulation A simulated drain voltage of 75 W flyback converter with 3 outputs – result = ~580 V Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 17

Evaluation Design Measurement Simulation Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 18

After ALL Traditional Engineer Daily Work Power. Esim Engineer Daily Work • Day 1 – start paper calculation • Day 2 – collect data sheets • Day 3 – collect data sheets • Day 4 – find equations • Day 5 – understand equations • Day 6 – start calculation • Day 14 – finish calculation • Day 15 – Bench Work • Day 21 – fs changed • Day 22 – re-calculate design • Day 25 – finish re-calculation • Day 26 – redesign Xformer • Day 27 – MOSFET overstress • Day 28 – redesign Xformer • Day 29 – OP diode overstress : • Day 60 - FINISH • Day 1 – Power. Esim calculation • Day 2 – Bench Work : : Day x – Power. Esim recalculation : : • Day 30 - FINISH Power. Esim FACT sheets Prepared by Franki Poon Power. ELab Limited www. power. Esim. com 19