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PowerEsim FACT sheet

PowerEsim FACT sheet. Hardware Prototype Implementation. Topology: AC/DC Flyback Dual-output Converter Input range: 85-264VAC/50Hz Outputs: O/P1 – 5V/6A; O/P2 – 12V/2.5A. Drain Voltage Waveform Analysis. Critical waveforms Input voltage at 85VAC. Simulation peak voltage from

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PowerEsim FACT sheet

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  1. PowerEsim FACT sheet

  2. Hardware Prototype Implementation • Topology: AC/DC Flyback Dual-output Converter • Input range: 85-264VAC/50Hz • Outputs: O/P1 – 5V/6A; O/P2 – 12V/2.5A

  3. Drain Voltage Waveform Analysis • Critical waveforms • Input voltage at 85VAC • Simulation peak voltage from • PowereSim = 300V • Actual peak voltage approx. = 285V • Primary MOSFET switching waveform • Ch1 – M1 drain source voltage waveform; Ch2 – M1 drain current waveform

  4. Bulk Capacitor Voltage Waveform Analysis • Critical waveforms • Input voltage and bulk capacitor voltage waveforms Measurement Simulation • Similar intersection point • Ch1 - Input AC voltage waveform  • Ch2 - Rectified bulk capacitor voltage

  5. Input Current Waveform Analysis • Critical waveforms • Input voltage and current Measurement Simulation • Ch1 - Input AC voltage waveform  • Ch2 - Input current waveform

  6. Line Regulation Output at full load Measurement Simulation

  7. Load Regulation Input voltage at 85VAC Simulation Measurement

  8. Power Loss Analysis • Efficiency comparison at full load

  9. Closed-loop Analysis (Bode plot) Input voltage at 115VAC full load Measurement Simulation Cut-off freq Cut-off freq

  10. Closed-loop Analysis (Transient Response) Measurement Simulation Conditions: Input voltage at 162VDC O/P1: 5V @ 0.2A-6A O/P2: 12V at 1A CH1: Load current CH2: Output voltage of O/P1

  11. Input Current Harmonics Analysis Input voltage at 230VAC/50Hz Measurement Simulated bar charts showed in good agreement with measurement.

  12. Thermal Analysis Measurement Simulation 123.1 103 65 70 78 62 94 68 52 93 94 52 66

  13. Transformer Design Leakage inductance: Measurement = 2.787uH Simulation = 2.982uH

  14. DVT Report – SMPS from other factory

  15. DVT Report – 100 times faster to know the design fault Measurement Simulation

  16. DVT Report – Every component checked include Xformer Measurement Saturation current observed in experimental measurement Simulation

  17. DVT Report – MOSFET Stress Measurement Simulation A simulated drain voltage of 75W flyback converter with 3 outputs – result = ~580V

  18. Evaluation Design Measurement Simulation

  19. After ALL Traditional Engineer Daily Work PowerEsim 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 • : • Day60 - FINISH • Day 1 – PowerEsim calculation • Day 2 – Bench Work : : Day x – PowerEsim recalculation • : • : • : • : • Day30 - FINISH

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