Texas Instruments Brazil Tech Day Digital Power

Adrian Harris Product Marketing Engineer High Performance Analog

Overview

What is Digital Power? UCD911x + UCD7230 Solution UCD92xx + Power Train Solution Application Examples Cost Analysis Phase Management Summary

What is Digital Power?

Generic Power System Block Diagram

Vin

Rectifier

Controller
(Compensator)

PWM

Switches
(FETs)

LC Network

Vout

The controller block is what differentiates between a digital power system and a conventional analog power system

What is Digital Power?

Analog Controller (s-domain)

Vout

Error Amplifier

Analog Controller
(s-domain)

Analog PWM

PWM

Vout C3 R1 R4 R3 R2

C1 C2 R5

Vref

+ R6

Vc

What is Digital Power?

Digital Controller (z-domain)

Vout

ADC
(Hi-speed)

Digital Controller
(z-domain)

Digital PWM

PWM

Data Bus
PMBus GPIO watchdog
5

ADC

CPU Flash

Analog vs. Digital Solution Tradeoffs

Strengths Weaknesses

Continuous operation (infinite sample rate) Low power consumption Single chip solutions available (integrated driver)

Hardwired design Separate signal lines for every converter No communication with controllers Need separate system manager

ANALOG DIGITAL

GUI, programmable parameters Adaptive and nonlinear compensation Flexibility, easier board development Features integration Multiphase reliability Phase shedding N+1 redundancy Easier PWM synchronization Fault logging Up to 32 devices on single PMBus

Higher quiescent current Dual chip solution (controller + driver)

What does a digital solution provide?

High levels of integration Multiple outputs and phases with one controller Integrated sequencing, margining, management General purpose microcontroller for housekeeping Advanced functionality Real time power system diagnostics data logging and failure prediction Adaptive control for varying operation modes and load characteristics Calibration in manufacturing System optimization Dead band control for improved efficiency Enhanced phase management
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Digital Power Ready End Equipment

Computer Servers Storage UPS Communications Rectifiers Base stations Routers Industrial, Test and Measurement Semiconductor Test Equipment Lighting Medical equipment
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TIs UCD 9k Digital Power Controller Family

FUTURE

UCD9240

4 ind outputs 64 & 80 pin

UCD92xx

UCD9230

Outputs
UCD9220

3 ind outputs 48 pin 2 ind outputs 40 pin

UCD9112

1 output, 2 phase 32 pin

UCD91xx
UCD9111

1 output, 1 phase 32 pin

Performance
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Digital Power Conversion

UCD91K Family Products

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UCD911x Single Loop Controller

Single and dual phase synchronous buck controllers
High speed Fusion Power Peripheral (FPP) 175ps PWM resolution to support wide Vin to Vout ratios Switching frequency up to 1 MHz Feature rich solutions:
Soft start, soft stop, margining, tracking, sequencing, fan control Dual phase solution supports phase shedding for improved light load efficiency Reconfigurable via PMBus

32pin QFN package

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UCD9112 Dual Phase Synch Buck Controller

Fusion Power Peripheral
Differential Sense Inputs

Feedback Analog Conditioning Digital Error Converter Digital Compensator

Compensator Configuration 1

0.5% 800mV Reference PMBusTM 32MHz Oscillator Watchdog

Compensator Configuration 2

PWM Outputs

2 x 175ps DPWMs

Internal Data Bus

6 User Configurable Channels for Monitoring Voltage Current Temperature

CPU Core

Data Flash
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UCD911x Fusion Power Peripheral

33MHz System Clock

8 bit Frequency Generator

Vref

V Sense G Sense

Differential Amp With Programmable Attenuator

Error ADC 10bit, 50ns LSB=+/-2mV LSB=+/-

PID CoCoprocessor

175ps PWM Resolution 20kHz 2MHz

PWM A PWM B

Loop Config A

Loop Config B

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UCD7230 Digital Power Driver

For digitally controlled power supplies using UCD9K or F28x controllers High performance
Thermal management, power stage reliability/safety, high efficiency
50x

Unique features:
Low-offset differential current sense amplifier High side FET protection 3.3-V, 10-mA internal regulator

Significantly reduces number of external components 4.75V to 15.5V supply voltage

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UCD7230 Implementation
Digital Controller Digital Driver

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Digital Power Conversion

UCD92K Family Products

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High-Density Digital Power Controller

A

DC/DC1
B

Reference

Oscillator
A

DC/DC2
B

uController for Housekeeping

DC/DC3
B

NV Memory

DC/DC4
B

Sequencing & Tracking

Margining

Fan Control
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UCD92xx Multiple Loop Controller

Up to four Outputs and up to eight phases
High speed Fusion Power Peripheral (FPP) 250ps PWM resolution to support wide Vin to Vout ratios Switching frequency up to 2 MHz Feature rich solutions:
Soft start, soft stop, margining, tracking, and sequencing Multi-phase solution supports phase shedding for improved light load efficiency Reconfigurable via PMBus

64 and 80 pin QFN package

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UCD9240 Controller Overview

Diff Input 1

Fusion Power Peripheral

PWM1 Outputs

Diff Input 2

Linear Regulator Fusion Power Peripheral +/- 0.5% 800mV Reference Fusion Power Peripheral 33MHz Oscillator Fusion Power Peripheral

PMBusTM

PWM2 Outputs

Diff Input 3 PWM3 Outputs

Watchdog 2 Counters / Timers

Diff Input 4 PWM4 Outputs

Internal Data Bus

Data Flash w/ECC 33MHz ARM7 CPU Core

Up to 16 x 12bit 200kHz Channels & 4 Comparators for Monitoring Voltage Current Temperature
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Digital Power Train Modules

Driver
Sampling Today Digital Configurability

FET

Output Voltage Current limit Frequency Inductor UVLO Over-temp Monitoring of Vin, Vout, Iout, Temperature

FET

Convenience of Modules

Designed and tested 10A and 20A PowerTrains PTD08A010W and PTD08A020W Current Sense

Temp Sense
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Power Train Efficiency

PTD08A020W Efficiency
VO = 1.2 V

PTD08A020W Efficiency
VO = 3.3 V

100 95 90 85 E ffi c i e n c y - % 75 70 65 60 55 50 45 40 0 5 10 Iout()-Amps 15 20 5.0V 8.0V 10.0V 12.0V 14.0V

E ffi c i e n c y - %

100 95 90 85

80

4.75V

80 75 70 65 60 55 50 45 40 0 5 10 Iout()-Amps 15 20

4.75V 5.0V 8.0V 10.0V 12.0V 14.0V

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Power Train Thermal Performance

PTD08A020W Safe Operating Area VI = 12 V, VO = 1.2 V, FS = 350kHz

90.0

PTD08A020W Safe Operating Area VI = 12 V, VO = 3.3 V, FS = 350kHz

90.0

80.0

80.0

70.0 400LFM 200LFM 50.0 100LFM Nat conv

70.0 400LFM 200LFM 50.0 100LFM Nat conv

Ta - C

40.0

Ta - C

60.0

60.0

40.0

30.0

30.0

20.0 0.0 5.0 10.0 15.0 20.0

20.0 0.0 5.0 10.0 15.0 20.0

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Power Train Thermal Performance

PTD08A010WAD Safe Operating Area VI = 12 V, VO = 3.3 V, FS = 350kHz

90.0
90.0

PTD08A010WAD Safe Operating Area VI = 12 V, VO = 1.2 V, FS = 350kHz

80.0

80.0

70.0 400LFM
Ta - C

70.0 400LFM 200LFM 100LFM 50.0 Nat conv

Ta - C

60.0

60.0

200LFM 50.0 100LFM Nat conv

40.0

40.0

30.0

30.0

20.0 0.0 2.0 4.0 6.0 8.0 10.0

20.0 0.0 2.0 4.0 6.0 8.0 10.0

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UCD9240 + Power Train Modules Typical System Architecture

4.75 14 VI

Control Lines

Vout1 @ 10A

Vout2 @ 10A

PMBus

Vout3 @ 20A

Vout4 @ 40A

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Power Stage Options

ET er/F Driv d

te gra Inte

Power Stage

UCD7230 Based Discrete

Po we rT

rai nM

od ule

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Maximize Efficiency with Integrated Driver/FET

UCD9240 + Integrated Driver/FET Technology 1.1-V, 150-A Efficiency

100 95 90 85 80 75 70 65 60 55 50 45 40 0 20 40 60 80 Iout()-Amps 100 120 140

Efficiency - %

10.0V 12.0V 14.0V

Plots of various input voltages with output voltage set to 1.1V Switching frequency at 300kHz, UCD9240 six phase with Renesas DrMos (8V gate drive)
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UCD9240EVM - Four-Output EVM

Digital Control Dynamic configuration Full feature

Margining Soft start/stop Tracking Sequencing Selectable fault response

GUI Configurable

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Power + Designer Graphical User Interface

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Digital Power Conversion

UCD9xxx Applications

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Multi-Processor, Multi-Supply Rail Systems

Media Interface 1.5V

1.5 V

3.3 V

3.3V

PMBus
1.8 V

1.8V Multiple DSP's PLL 1. 8 V 1.2V

1.2 V
Rapid I/O 1.2V

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High Current Application

1.0 V @ 80 A
A digital control stacking alternative to analog solutions TPS40140 and PTH08T250W

PMBus

Very cost competitive with an analog control solution. Stacked 10 amp Power Trains
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Cost Analysis

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UCD9240 Cost Effectiveness - 4-Rail Systems

PMBus

+
4x UCD7230 Driver
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UCD9240 Controller

Cost Analysis UCD9240 Controller -vs- Analog

Got 4 rails? Need to sequence and monitor those rails? Need multiphase or load sharing operation?

Controller MOSFET Driver Supply Voltage Sequencer Bias Power Total

UCD9240RGC Digital Controller # of Estimated devices Cost 1 $4.50 4 $2.20

Analog Based Controller # of Estimated devices Cost 4 $7.20 0 $0.00

0 1 6

$0.00 $0.40 $7.10

1 0 5

$1.50 $0.00 $8.70

Estimated cost figures are based on typical 1k unit pricing. The output current requirement is estimated to be at least 8-A/rail. The analog based controller is assumed to have a MOSFET driver built-in. Analysis is based on TPS40180 analog solution. Power stage cost estimates are not included, and are assumed to be identical for both analog and digital. 34

Digital Power Conversion

Phase Management

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Multi-Phase Buck Converter

Lp1

RLp1 Lp2

vin +
s1p2 s1p3 s2p2
UCD7230

eslp1 CRLp2 p1 Resrp1 eslp2 Cp2 Resrp2

Rp

iou

vo
eslo

Co Resro

Ro io

pwm1

pwm2

s1p4 s2p3

UCD7230

s2p4

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Phase Management
Advantages of Multi-Phase Conversion
Smaller input and output ripple Less capacitance Fast dynamic response Smaller PCB board Better Thermal Performance Low cost profile

+ advantages of Digital Control Technology

Higher efficiency at both light load and heavy load Ripple voltage minimization across the entire load range Optimized dynamic response across the entire load range
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Power Dissipation and Efficiency

Power Losses Versus Load
40 35 30 L o sses (W)
Effi(%) 90 80 70 60

Effi versu Load

25 20 15 10 5 0 0 10 One Phase 20 30 40 50 60 70 80 Iout (A) Tw o Phase Three Phase Four Phase 90

50 40 30 20 10 0 0 10 One phase 20 30 Tw o phase 40 50 Three phase 60 70 Four phase 80 Iout(A) 90

Using a single phase converter, power losses increase dramatically at heavy load Multi-phase converters have slightly higher power losses at light load Multi-phase converters has higher conversion efficiency at heavy load
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Phase Shedding Efficiency Optimization

Light Load Efficiency
90 80 70 60
Effi (%)

One Phase Two Phase Three Phase Four Phase

50 40 30 20 10 0 0 5 10
Load (A)

15

20

25

Efficiency has optimum point at different phase and load conditions 30% efficiency increase at 1-A load for single phase compared with 4 phases

Phase Shedding Benefits

Selectable # of phases for a given load condition Optimized efficiency across the entire load range for enhanced performance
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Phase Management Control Loop Design

Bode Diagram Gm= 6.95 dB (at 1.57e+006 rad/sec) , P = 70.2 deg (at 3.09e+005 rad/sec) m 80 60 Magnitude (dB)
Magnitude (dB) 80 60 40 20 0 -20 -45 -90 Phase (deg) -135 -180 -225
2

Bode Diagram Gm= 18.9 dB (at 1.57e+006 rad/sec) , P = 42 deg (at 1.02e+005 rad/sec) m

40 20 0 -20 0 -45

Phase (deg)

-90 -135 -180 -225 10 10

3

10

10

10

10

10

10

10

10

10

10

Frequency (rad/sec)

Frequency (rad/sec)

At heavy load (30A) and 4-phase, PM = 70.2 deg at Fcr = 50kHz

At light load (1A) and 1-phase with the same controller PM=42 deg at Fcr =13 kHz 40

Control Loop Design Stability and Dynamic Response

The PM decreases when shedding phases for light load operation; this may affect stability. The bandwidth also decreases during phase shedding. This will affect the dynamic response. After compensator redesign, the loop will have improved performance characteristics.
Bode Diagram Gm = 6.87 dB (at 1.57e+006 rad/sec) , Pm = 67.6 deg (at 3.09e+005 rad/sec) 80 60 Magnitude (dB) 40 20 0 -20 -45 -90 Phase (deg) -135 -180 -225 10
2

At light load (1A) and 1-phase with redesigned controller. PM=68 deg at Fcr=50KHz

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10

10

10

10

Frequency (rad/sec)

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Dynamic Phase Adjustment

4 Phase, Io= 40A, Vo=1V 90 interval, Vp-p = 4mV
11 10 9 1 0.5 0 1.002 1 0.998 0.996 1 3 2 Time ( s) 4 5 Vout (V) Iph1, Iph2, Iph3, Iph4 (A)

Shedding from 4 to 3 phases without interval adjustment, Vp-p=10mV

Iph1, Iph2, Iph3 (A) 11 10 9 1

pwm1, pwm2, pwm3, pwm4

pwm1, pwm2, pwm3

0 1.005 1 0.995 0.990 1 2 3 Time ( s) 4 5

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Vout (V)

Phase Adjustment Ripple Voltage Reduction

Shedding from 4 to 3 phases with adjustment to 120 gives 5mVp-p

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Fusion Digital Power Controller UCD9240

Bringing Intelligence to the Point-of-Load
Digital power management capabilities include voltage tracking, margining, sequencing, and monitoring. Maximize over the entire load range through phase management and integrated driver/FET technology.

Eliminate the need for external filters and improve EMI performance.

Configure your POL system to cost effectively meet any power requirement using a single device.

Reduce the number of design components.

Meet 3% IC Supply Voltage Tolerance for up to 20-A load step with minimum capacitance. 44

Contacts
Product Marketing Broad Market - Adrian Harris (214) 567-2207 - aharris@ti.com

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