Pain points in different stages of direct power supply design
Time:2022-09-01
Views:1815
In the global environment of energy conservation and environmental protection and the renovation of intelligent Internet terminals, energy conservation, high frequency, high efficiency, miniaturization and intellectualization are the future development trends of the power industry. The wide application of new low-energy devices, the optimization of PMIC design and the emergence of the third generation semiconductor material SiC / GaN MOSFET technology are driving the power electronics industry to undergo subversive changes. These new devices improve the efficiency of the whole power conversion system by several percentage points.
The design and development of power supply is a technical work and a tiring one. The work is complicated and there are many challenges. The power supply design engineer selects the appropriate devices and topology according to the assignment, and designs the prototype version that conforms to the function. The optimization of power supply design is particularly important. To ensure the realization of functions, efficiency, cost and EMC shall be taken into consideration. The final product shall also be subject to the overall power quality evaluation and industry standard certification.
In the process of power testing, power testing engineers will go through four stages: power device selection, power prototype design, power quality analysis and final product certification. Each stage will face different pain.
What are the test difficulties that power test engineers are concerned about? After visiting hundreds of test engineers, Teck summed up the test pain points of the engineers and found that efficiency is the focus of power design engineers, and it is very important to determine the main power loss points. The traditional theoretical calculation method has many shortcomings, because the actual power supply is different, the design structure is different, and the loss during the period is very different. Therefore, engineers need tools and methods that can accurately test the main power loss switching devices and passive devices.
Stage 1: pain point of power device selection
Can‘t accurately grasp the characteristics of low-power ICs and power devices newly launched in the market? There is a lack of a simple and economic evaluation method to determine whether it really plays the largest role in its own power supply design.
For the design of power products, the selection of high-power switches is very critical and difficult. How to test the characteristics of IGBT modules before system commissioning, especially based on the bridge topology, and test the characteristics of IGBT and corresponding diodes under different load conditions? Becoming a headache for engineers.
Stage 2: pain points of prototype design
Test the input and output signals in the power function design, signal waveform and main parameter indexes. For the evaluation of the system, whether the test equipment can reliably and accurately reflect the real signal characteristics is a problem of great concern to the engineers, who are worried that a certain test will lead to misleading.
As the main devices of switching power supply, MOSFET and IGBT have become the most important factors affecting the overall efficiency of power supply. In different applications, the driving conditions are different and the power consumption varies greatly. How to evaluate the loss in real power supply with energy becomes a very important issue.
The emergence of the third generation wide band gap semiconductor devices Gan and SiC has promoted the subversive transformation of the power electronics industry. The new switching device can achieve low switching loss, and can handle ultra-high speed DV / dt conversion, and support ultra fast switching frequency. The test challenges brought by it have also become a nightmare for engineers.
How to evaluate the influence of magnetic devices on power supply stability and overall efficiency? How to test the inductance, magnetic loss, BH curve, magnetic properties and other indicators is a difficult problem for engineers.
Engineers need to spend more time and energy on the integrity of power supply (PDN). In addition to the switching loss, input power quality and output ripple test that we often mentioned, we also involve the loop response test. Through the loop response test, we can know how stable our feedback loop is?
The output quality of power supply is an important part of power supply evaluation. Especially for DC output, not only the voltage and current should be tested, but also the output ripple should be accurately tested. Especially for some special power supplies, the ripple needs to be controlled in a very small range. How to accurately test the small ripple signal is very difficult.
Stage 3: pain point of power quality analysis
When the product design is completed, the efficiency is the most important indicator. How to accurately evaluate the power quality? Active power, power factor, efficiency and other items?
In order to meet the standard of power industry, harmonic is a very important index. How to accurately evaluate the harmonic of power supply and how to pass the conformance test of iec61000-3-2 standard at one time?
It is very important for energy-saving certification of power supply products. How to accurately evaluate the pre consistency standard iec62301 v2.0 for standby power consumption of power supply?
Stage 4: pain point of final product certification
Before the power supply goes on the market, it needs to pass CE certification, among which EMC consistency certification is a very important one. Many engineers have to consider the challenges of EMC while realizing functional design. How can engineers understand the EMC status of power products and pass the certification at one time?
The last process of power products requires a long-time toaster test. How to improve the efficiency, especially for the scenario of mass production, it is very important to have an accurate and efficient test method.
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