As an application engineer, I know that the implementation of a buck regulator inevitably involves a trade-off between efficiency and size. Although this principle applies to a wide range of switch-mode DC/DC topologies, when the application requires low output voltages and high output currents (for example, 1V and 30A), this principle is not necessarily applicable because it needs to balance efficiency and size. The small power solution.
High efficiency is an important performance benchmark that not only reduces power loss and component temperature rise, but also brings more useful power at a given airflow and ambient temperature conditions. From this point of view, the low switching frequency is very tempting, but at the same time requires large filter components to meet the requirements of the target specifications such as output ripple and transient response, so the cost and size will increase.
The PCB area dedicated to power management is a huge constraint for system designers. For this issue, we first review the advantages of high switching frequency. First, the inductor and capacitor requirements decrease with increasing frequency, resulting in a more compact PCB layout and a smaller size profile. The lower inductance not only enables faster large signal current changes and higher control loop bandwidth, but also enables faster load transient response. As a rule of thumb, the maximum loop bandwidth is 20% of the switching frequency. Finally, there are some interesting options for component selection at higher frequencies.
For example, we can look at this regulator design that can achieve the best efficiency/size/cost by carefully selecting components. Click here to watch a video demonstration.
(1) Inductors—Although iron core inductors or composite core inductors provide good performance at low frequencies, higher core losses negate the value positioning at frequencies above about 500 kHz. In this regard, ultra-low DCR ferrite magnetic materials are more likely to achieve lower copper losses and core losses. Note that the core loss is relatively easy to measure and only the converter's no-load input current can be observed. Ferrite inductors with single-turn staple windings now offer a wide range of off-the-shelf options, and if only one winding turn is required, DCRs below 1mΩ can easily be achieved!
(2) PWM controller - Now, if the design specifically requires the hard-saturation characteristics of the ferrite core inductor, then the inductor saturation current must not be exceeded. This requires a PWM controller that can take full advantage of parasitic circuit resistances for accurate lossless current sensing (read my previous blog, “Implementing Accurate and Lossless Current Sensing in High-Current Converters†for more on this topic. More details). Other key features include high-efficiency gate drivers, remote BJT temperature sensing, and fast error amplifiers.
(3) MOSFET - Power semiconductor devices are the basis for improving efficiency and size. Taking the power block NexFETTM family as an example, its widely-recognized advantage lies in the innovative and innovative combination of high-side and low-side MOSFETs in a vertical stack. When frequency proportional loss is of concern, low QG, QRR, and QOSS charges are required. In addition, low RDS(ON), high current copper clips, Kelvin gate connections, and grounding tabs are also important.
(4) Capacitors - At higher frequencies, ceramic capacitors are preferred over electrolytic capacitors. A large amount of output energy storage has now become superfluous because the control loop responds quickly to transient demands. Ceramic products not only provide lower ESR, but also provide lower ESL, which can mitigate output ripple caused by inductor splitting and low filter inductance.
What other factors affect the regulator's efficiency and size? Recent popular themes include GaN MOSFETs, power system package (PSIP), and on-chip power system (PSOC). Please tell me what you think?
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