Push-Pull Power Converter Topologies

This course is an introduction to a family of DC-DC power converters often referred to as "Push-Pull" topologies. We will explore some of the advantages and tradeoffs made as compared to the more common "Single-Ended" converters. Our main interest will be several topologies which apply to isolated DC to DC converters. You will see how a conventional Forward converter design is transformed into the Push-Pull converter and then get an introduction to the parts that National offers for these application. Push-Pull converters get their name from the fact that the transformer windings get used in a bi-directional manner (two quadrant operation), unlike Forward converters which operate in a single magnetic quadrant.

Course Map/Table of Contents

1. Course Navigation 1. 1.1 Course Navigation 2. Single-Ended Review 1. 2. 3. 4. 5. 6. 7. 2.1 Common One-Switch Power Converter Topologies 2.2 Buck Regulator Basics 2.3 Buck Converter Characteristics 2.4 Forward Converter 2.5 Forward Diode Currents 2.6 Forward Converter Characteristics 2.7 Common Two-Switch Power Converter Topologies

3. Push-Pull Topology 1. 2. 3. 4. 5. 3.1 Push-Pull Topology 3.2 Push-Pull Switching Waveforms 3.3 Push-Pull Diode Currents 3.4 Core Utilization: Forward & Push-Pull Converters 3.5 Push-Pull Characteristics

4. Push-Pull Controller 1. 2. 3. 4. 5. 4.1 LM5030 Push-Pull Controller 4.2 LM5030 Push-Pull Demo Board 4.3 LM5030 Push-Pull Demo Board Schematic 4.4 LM5030 3G Base Station RF Power Supply 4.5 LM5030 3G Base Station RF Supply Schematic

5. Cascaded Buck/Push-Pull 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 5.1 Cascaded Buck & Push-Pull 5.2 Cascaded Voltage-Fed Converter Benefits 5.3 Current-Fed Push-Pull Concept 5.4 Cascaded Current-Fed Converter Benefits 5.5 Current-Fed Switching Voltages 5.6 Current-Fed Push-Pull Switches 5.7 Current-Fed Switch Waveforms 5.8 Why is it important to reduce secondary rectification losses? 5.9 Comparison of Rectifier Stresses 5.10 Sync Rectifier Waveforms

6. Cascaded PWM Controller 1. 2. 3. 4. 6.1 LM5041 Cascaded PWM Controller 6.2 LM5041 Block Diagram 6.3 LM5041 Current-Fed Push-Pull Demo Board 6.4 LM5041 / LM5100 Demo Board Schematic

7. Half-Bridge Topology 1. 7.1 The Basic Half-Bridge 8. Half-Bridge Controller 1. 2. 3. 4. 8.1 LM5035 Half-Bridge Controller 8.2 LM5035 Demo Board Schematic 8.3 Cascaded Half-Bridge Concept 8.4 Cascaded Half-Bridge Characteristics

9. Full-Bridge

1. 2. 3. 4.

8.1 LM5035 Half-Bridge Controller 8.2 LM5035 Demo Board Schematic 8.3 Cascaded Half-Bridge Concept 8.4 Cascaded Half-Bridge Characteristics

9. Full-Bridge 1. 2. 3. 4. 9.1 Full-Bridge Concept 9.2 Full-Bridge Current Doubler 9.3 Cascaded Full-Bridge Concept 9.4 Cascaded Full-Bridge Characteristics

Course Navigation
1.1 Course Navigation

Course Navigation
This course is organized like a book with multiple chapters. Each chapter may have one or more pages. The previous and next arrows move you forward and back through the course page by page.

The left navigation bar takes you to any chapter. It also contains the bookmarking buttons, 'save' and 'go to.' To save your place in a course, press the 'save' button. The next time you open the course, clicking on 'go to' will take you to the page you saved or bookmarked. The 'Go to Final Test' button on the left navigation bar takes you back to the Analog University course listing, where you started. Take the course final test by clicking on 'Test Yourself.' The top services bar contains additional information such as glossary of terms, who to go to for help with this subject and an FAQ. Clicking home on this bar will take you back to the course beginning. Don't miss the hints, references, exercises and quizzes which appear at the bottom of some pages.

Single-Ended Review
We will start off with a brief review of common DC to DC power converter topologies. 2.1 Common One-Switch Power Converter Topologies 2.2 Buck Regulator Basics 2.3 Buck Converter Characteristics 2.4 Forward Converter 2.5 Forward Diode Currents 2.6 Forward Converter Characteristics 2.7 Common Two-Switch Power Converter Topologies

Common One-Switch Power Converter Topologies

Shown here are the power stage arrangements for several popular power converter topologies which use a single primary switching element. The Buck and Buck-Boost are among the simplest and apply to non-isolated power converters.

The Forward and Flyback topology are used in isolated converters where it is desirable to electrically isolate the Primary and Secondary grounds. A Forward converter is simply a Buck regulator with a transformer inserted between the buck switch and the load. The input to output transfer function is the same as a Buck regulator if the transformer's turns ratio is one.

The Flyback regulator is derived from the Buck-Boost regulator and the same logic applies with regards to transfer functions.

The advantage of the transformer coupled designs is that any output voltage can be produced from any input voltage with the proper choice of turns ratio.
The one-switch Forward and Flyback are both examples of single-ended converters.

Buck Regulator Basics

A more detailed look at the anatomy of a Buck regulator shows a switching section, comprised of Q1 and D1, and an output filter comprised of L1 and C1. The Buck regulator is used to efficiently step down voltages. The output voltage is given as VinD, where D is the duty cycle of the main switch Q1. All of the transfer functions we will show assume the inductor current does not return to zero during the switching cycle, this is called "Continuous Conduction Mode" or CCM operation. The rising inductor current is driven by Q1 during its on time, and then "freewheels" through the rectifier, D1 while Q1 is off.

For continuous conduction mode, the inductor current is always flowing.

For continuous conduction mode, the inductor current is always flowing.

Find the Output Voltage

A buck regulator operates at a duty cycle of 0.3 with 5V at the input. What is the output voltage? 1. 0.5V 2. 1.5V 3. 2.5V 4. 3V 1 Answer: Vo=VinD=5V0.3=1.5V

Buck Converter Characteristics

Non-Isolated Grounds Voltage Step-Down Only Single Output Only Very High Efficiency Low Output Ripple Current High Input Ripple Current High Side (Isolated) Gate Drive Required Large Achievable Duty Cycle Range Wide Regulation Range (due to above) We will be able to eliminate many of the drawbacks associated with non-isolated Buck regulators by adding a transformer in the power path. That result is what is classically known as the "Forward" converter. This addresses the need for isolation, allows step-up or step-down operation, allows a more favorable duty cycle for high step down ratios and allows the main switch to be ground referenced for simpler drive. All of this however, comes with a price.

Forward Converter
The first isolated topology we will look at is the Forward converter. A Forward converter is basically a transformer isolated Buck regulator. The output inductor current is still the composite of two alternating switch currents, in this case D1 and D2. D1's current is the secondary current from the transformer, which equals I(Q1) divided by the turns ratio (Ns/Np). The transfer function is the same as the Buck regulator with an additional transformer voltage gain term of Ns/Np. One problem with the Forward topology is that the primary switch voltage can rise essentially unconstrained. When the switch turns off, energy stored in the transformer primary wants to cause current to continue to flow toward the FET drain. Since the FET has been turned off, this causes the voltage on the drain to rise rapidly. The good news is this tends to help reset the transformer (more on this later). The bad news is it will radically increase the required breakdown voltage of the FET. The reset winding Nr helps keep this reset voltage under control.

Forward Diode Currents

Forward Diode Currents

This plot shows each of the rectifier diode currents which sum together to form the inductor current. The inductor current looks exactly the same as in an equivalent Buck regulator. The need to reset the transformer tends to limit the maximum duty cycle that a Forward converter can operate at. There is a requirement that in any inductor in steady state operation, the average DC voltage across the inductor must be zero. From this it's easy to conclude that the inductor's VoltSecond product must be equal during each half cycle. The transformer's primary winding is an inductor and so this principle applies to it as well. During the time the primary switch is on the voltage across the primary winding is Vin. So the VoltSecond product during the "on time" is VinTon. If the on time becomes large relative to the off time, the voltage Voff, must get large relative to Vin. Simply put, the larger the duty cycle, the higher the switch voltage during the off time must get. This need to reset the transformer is a serious limitation for the Forward topology.
To maintain VoltSecond balance, VinTon=VoffToff.

Forward Converter Characteristics

A Forward Converter is a Buck type converter with an added Isolation Transformer. Grounds are Isolated. Voltage Step-down or Step-up. Multiple Outputs Possible. Low Output Ripple Current. High Input Ripple Current. Simple Gate Drive. Limited Achievable Duty Cycle Range. Note that the transformer is only driven in one direction in a Forward converter. This means that the transformer core is not being utilized to its full capability. There is also the matter of resetting the core each cycle. These issues tend to limit the power level that a Forward converter is useful for. In general the topology is best used for power levels between 30W and 150W although they have been used successfully to over 1kW. Above the 150W level, it's usually more economical to look at Push-Pull topologies that better utilize the magnetic core's power handling ability.

Common Two-Switch Power Converter Topologies

Here are several popular isolated power converters which use two or more primary switches. The Push-Pull and Half-Bridge require two switches while the Full-Bridge requires four switches. Generally, the power capability increases from Push-Pull to Half-Bridge to Full-Bridge. Note that these are all derived from the basic Buck architecture and share the fundamental transfer function that the output voltage is equal to the input voltage multiplied by the switch duty cycle, assuming a 1:1 transformer turns ratio. So for the general case, the transfer function becomes: Vout=VinDNs/Np. In all cases the primary switches are driven in

transfer function that the output voltage is equal to the input voltage multiplied by the switch duty cycle, assuming a 1:1 transformer turns ratio. So for the general case, the transfer function becomes: Vout=VinDNs/Np. In all cases the primary switches are driven in such a sequence that the transformer windings get driven in alternate directions on each half cycle. In the case of the Push-Pull and Half-Bridge this means one switch at a time. For the Full-Bridge the transistors are driven in pairs across the diagonals, i.e. top right/bottom left followed by top left/bottom right.
The Push-Pull, Half-Bridge and Full-Bridge are all Buck derived topologies.

Push-Pull Topology
3.1 Push-Pull Topology 3.2 Push-Pull Switching Waveforms 3.3 Push-Pull Diode Currents 3.4 Core Utilization: Forward & Push-Pull Converters 3.5 Push-Pull Characteristics

Push-Pull Topology
The Push-Pull topology is basically a Forward converter with two primaries. The primary switches alternately power their respective windings. When Q1 is active current flows through D1. When Q2 is active current flows through D2. The secondary is arranged in a center tapped configuration as shown. The output filter sees twice the switching frequency of either Q1 or Q2. The transfer function is similar to the Forward converter, where "D" is the duty cycle of a given primary switch, that accounts for the "x 2" term. When neither Q1 nor Q2 are active the output inductor current splits between the two output diodes. A transformer reset winding shown on the Forward topology is not necessary, the topology is self-resetting. Keep in mind that with any transformer, the number of volts/turn is a constant across the entire structure, both primary and secondary windings. Therefore, when Q1 is on, Vin appears across of the primary winding. As such, Vin will also appear across the other half of the primary that connects to the drain of Q2. That forces the drain of Q2 to 2Vin.

Push-Pull Switching Waveforms

Shown here are oscilloscope waveforms for the drain voltages of the two primary switches and the output inductor current. You can see the off switch drain voltage being driven to twice the input as expected. When neither switch is active then both drain voltages are at the input voltage potential. Note that like the Forward converter, the drain voltage is inherently unconstrained. There's nothing related to the basic topology that acts to clamp the FET drains and limit the instantaneous voltage. As a result the FET's need to be over rated beyond the theoretical

Note that like the Forward converter, the drain voltage is inherently unconstrained. There's nothing related to the basic topology that acts to clamp the FET drains and limit the instantaneous voltage. As a result the FET's need to be over rated beyond the theoretical level that would be expected. It can be seen in the photo above that there can be significant overshoots beyond the expected 2Vin. These spikes are cause by the transformer's primary referenced leakage inductance. This inductance is cause by uncoupled flux linkages. This is magnetic field energy that does not get coupled into one of the windings of the transformer. This energy is released in the form of primary current continuing to flow for a time after the switch is turned off. The leakage energy in the form of LI /2 is transferred into the FET's output capacitance in the form CV /2. This can be limited with snubbers or Zener clamps, but there's the obvious cost of additional parts and board real estate, not to mention efficiency losses due to these efforts.
The uncoupled transformer leakage inductance contributes to drain voltage spikes.
2 2

Push-Pull Diode Currents

Shown here is the current for each of the two output diodes. These two currents sum to form the output inductor current shown on the previous page. Note that as discussed previously when neither of the primary switches are active, the output inductor current has a negative slope and flows half in each of the two secondary diodes. In theory, this current should split equally through the secondary windings and therefore the resulting magnetic fields should exactly cancel. In practice, due to slight differences in diode forward voltage, winding resistance, and layout related parasitics, it's possible to see small imbalances. There's also a chance for slight differences in primary voltsecond inputs to the two winding halves. If these offsets are systematic, a phenomenon know as "flux walk" can occur. Over time, the magnetic flux being developed in the transformer's core material will be biased slightly in one direction. After some number of switching cycles, the peak magnetic flux can increase beyond the core's saturation limit and cause the primary current to spike up rapidly. The use of current-mode control prevents this from ever getting out of hand and provides good, inherent flux balancing. Voltage-mode control can prove problematic if this issue isn't carefully addressed.
For the Push-Pull, current-mode control provides good flux balancing.

Core Utilization: Forward & Push-Pull Converters

Shown here are the transformer B-H curves for the Forward and the Push-Pull topology. The "X" axis represents Magnetic Field Intensity (Coercive Force) which is proportional to the AmpereTurns. The "Y" axis represents Flux Density which is proportional to the Core Area and the VoltSeconds applied to the primary winding when active. The lines are the core's complete B-H loop. In normal operation the converter operates through a minor loop as shown in red. Note that the area enclosed in the loop is proportional to the product of current, voltage and time and as such represents energy. This is the "Core Loss" of every switch cycle. The primary magnetizing inductance is

that the area enclosed in the loop is proportional to the product of current, voltage and time and as such represents energy. This is the "Core Loss" of every switch cycle. The primary magnetizing inductance is proportional to the slope of the curve. This slope is known as the permeability of the core material, . Note that when the flux density reaches B the slope decreases
SAT

drastically. This corresponds to a significant reduction in the transformer's primary inductance. The Forward converter operates in a single quadrant of the B-H curve, moving up the right side of curve when the switch is active and resetting during the OFF time. Since there is no active reset the Coercive Force falls to zero and the residual flux drops to the Remanent Flux, B .
R

The Push-Pull converter operates in two quadrants of the B-H curve, see-sawing back and forth as each primary is activated. This important fact allows the maximum power capability of a Push-Pull transformer to be more than twice that of a Forward transformer.

Core Utilization
Which of the following are true statements? 1. The B-H curve represents stored energy. 2. The forward converter operates in one quadrant of the B-H curve. 3. At saturation, the core has reached it's maximum magnetization point. 1 Answer: They are all true.

Push-Pull Characteristics
A Push-Pull Converter is a Buck type converter with a bi-directionally driven Isolation Transformer. Push-Pull transformers and filters are much smaller than comparable Forward converter filters. Voltage Stress on the Primary Switches is > Vin2. Voltage Step-down or Step-up. Multiple Outputs Possible. Low Output Ripple Current. Lower Input Ripple Current. Simple Gate Drive (dual) . Large Achievable Duty Cycle Range. The better core utilization and the lack of a realistic duty cycle limit in the Push-Pull architecture allows them to operate at significantly higher power levels. For moderate input voltages (Telecom, 36-72 for instance) Push-Pull converters are useful to 500W and beyond. Above that power level the unclamped FET drains become a significant problem and force the FET breakdown voltage rating to be much higher than would be desirable. At that point, things like the Half-Bridge and Full-Bridge converters start to look more attractive. Let's look at a National implementation of a Push-Pull controller and a few typical applications built on that design.

Push-Pull Controller
4.1 LM5030 Push-Pull Controller 4.2 LM5030 Push-Pull Demo Board 4.3 LM5030 Push-Pull Demo Board Schematic 4.4 LM5030 3G Base Station RF Power Supply 4.5 LM5030 3G Base Station RF Supply Schematic

LM5030 Push-Pull Controller

National Semiconductor has developed a controller designed specifically for the Push-Pull topology.

LM5030 Push-Pull Controller

National Semiconductor has developed a controller designed specifically for the Push-Pull topology. This controller is designed for current-mode control, so the flux walk issue discussed earlier is of no concern. The LM5030 controller has many innovative features. Although designed for the Push-Pull topology this versatile controller can be used for most common power converters.

100V Push-Pull Current Mode PWM Controller: Net Links

LM5030 Push-Pull Demo Board

Shown here is a demo board utilizing the LM5030 controller in a Push-Pull topology. The power level is on the low side for a Push-Pull implementation. The purpose is to demonstrate the operation of the controller. The waveforms shown earlier were taken from this board.

LM5030 Evaluation Board

LM5030 Push-Pull Demo Board Schematic

36V-75Vin to +3.3V @ 10A Shown here is the schematic for the 33W demo board. Note the controller connects directly to the input voltage to provide the initial bias power

36V-75Vin to +3.3V @ 10A Shown here is the schematic for the 33W demo board. Note the controller connects directly to the input voltage to provide the initial bias power on Vcc. Once operational, the winding on the output inductor provides the bias power. There are very few components needed around the actual controller. A significant level of complexity gets added to the design when input-output isolation is required. The voltage loop's feedback signal needs to get communicated across the isolation barrier and is usually done with an optocoupler as is shown here. A significant portion of the control circuitry is related to the opto driver and control.

Application Note 1305 LM5030 Evaluation Board

LM5030 3G Base Station RF Power Supply

Shown here is an actual application at the higher end of the Push-Pull power capability. This unit is designed to power a telecom Base Station RF Power Amplifier.

LM5030 3G Base Station RF Supply Schematic

-48Vin to +27V @ 30A Shown here is the schematic for the 810W design. The schematic although somewhat more complicated then the 33W design, still has all of the same basic functional blocks.

Cascaded Buck/Push-Pull
5.1 Cascaded Buck & Push-Pull 5.2 Cascaded Voltage-Fed Converter Benefits 5.3 Current-Fed Push-Pull Concept 5.4 Cascaded Current-Fed Converter Benefits 5.5 Current-Fed Switching Voltages 5.6 Current-Fed Push-Pull Switches 5.7 Current-Fed Switch Waveforms 5.8 Why is it important to reduce secondary rectification losses? 5.9 Comparison of Rectifier Stresses 5.10 Sync Rectifier Waveforms

Cascaded Buck & Push-Pull

Cascaded Buck & Push-Pull Power Converter (Voltage-Fed) Now let's combine a Buck Regulator stage and a Push-Pull stage. The first thing to note here is that each switch of the Push-Pull stage is set to operate alternating at 50% duty cycle. This essentially configures the Push-Pull stage as an ideal DC transformer. A voltage presented to the Vpp node will be transferred to the output divided by the transformer turns ratio. It is the Buck stage that is actually used to regulate the output. If we combine the Buck stage transfer function and the Push-Pull stage transfer function we get the overall transfer function as shown in the lower right corner. The Push-Pull stage is said to be "Voltage-Fed" since the Vpp node contains the output capacitor from the Buck stage. The Push-Pull switches actually operate slightly less than 50% duty cycle such that there is no overlap during the switching transitions. Since the dead-time is very short the rectified secondary voltage is almost continuous. Therefore, only a very small inductor is required on the secondary side to filter this output waveform.
A Cascaded converter consists of more than one power stage in series.

Cascaded Voltage-Fed Converter Benefits

A Voltage-Fed Push-Pull Converter is a Buck type converter consisting of a Buck Regulation Stage followed by (cascaded by) a Push-Pull Isolation Stage. The Push-Pull stage FET voltage stresses are reduced to VoutN2 over all line conditions.

A Voltage-Fed Push-Pull Converter is a Buck type converter consisting of a Buck Regulation Stage followed by (cascaded by) a Push-Pull Isolation Stage. The Push-Pull stage FET voltage stresses are reduced to VoutN2 over all line conditions. The output rectification can be easily optimized due to reduced and fixed voltage stresses. The output rectification is further optimized since the power is equally shared between the rectifiers over all load and line conditions. Favorable topology for wide input ranges. We will spend more time explaining the important features in blue on the following pages.

Current-Fed Push-Pull Concept

The Cascaded "Voltage-Fed" Buck and Push-Pull is a viable design approach, however there are several large components which can be removed, while still maintaining all of the performance benefits of the cascaded approach. On the previous Voltage-Fed page, note we had 2 complete L-C filters. The Buck stage capacitor and the Push-Pull stage inductor can be removed and actually provide several benefits. Shown here is a Current-Fed Cascaded Buck and Push-Pull stage. The Push-Pull stage is said to be Current-Fed since only the Buck inductor, which acts a current source feeds the Push-Pull. In this case the Push-Pull switches need to have a very small overlap at the switching transitions to maintain the inductor current path. In the Voltage-Fed a small dead-time is required.

An example which we will look at next is a 2.5 Volt output, which has been designed with an 8 to 1 transformer turns ratio. Working from the output back from right to left yields a voltage at the Push-Pull primary of 20 Volts.
Removing the output capacitor from the Buck stage changes the Push-Pull from voltage-fed to current-fed.

Cascaded Current-Fed Converter Benefits

A Current-Fed Push-Pull Converter is a Buck type converter consisting of a Buck Regulation Stage followed by (cascaded by) a Push-Pull Isolation Stage. There is no high current output inductor! Reduced switching loss in Push-Pull stage. Favorable topology for multiple outputs since all outputs are tightly coupled. Favorable topology for wide input ranges, since the Buck stage pre-regulates while the Push-Pull and secondary operate independently of the input voltage level.

Current-Fed Switching Voltages

Shown here are scope plots of the Push-Pull stage drain voltages and the voltage at the common junction of the Buck stage switches. Note that the Buck stage operates at twice the frequency of either the Push or Pull switch.

Shown here are scope plots of the Push-Pull stage drain voltages and the voltage at the common junction of the Buck stage switches. Note that the Buck stage operates at twice the frequency of either the Push or Pull switch. This ensures that the Push-Pull stage currents are symmetrical. Each half cycle sees the same input conditions this way. Also note the overlap of the of the Push-Pull stage. This is done to ensure that the buck inductor current always has a path to ground. If there was any dead time where both FETs were off, the drain voltage would fly to damaging levels.

Current-Fed Push-Pull Switches

Shown here are scope plots of the Push-Pull drain voltages and Push-Pull switch currents. The drain currents sum to form the inductor current. On the next page we will take a more detailed look at the switching transitions of these waveforms.

Current-Fed Switch Waveforms

Expanded Scale One of the many advantages of the cascaded approach is a reduction in switching losses in the Push-Pull stage switches. You can note during the overlap time when both switches are ON the Buck inductor current divides equally between the two switches. At the conclusion of the overlap time the drain voltage is already at zero and therefore the switching losses are cut in half. Also remember that the voltage stress on the Push-Pull stage switches are reduced by the Buck stage and held nearly constant.

Why is it important to reduce secondary rectification losses?

Why is it important to pick a topology which offers the best opportunities to reduce losses in the secondary synchronous rectifiers? A look at a typical power loss budget of a 3.3V power converter shows approximately 40% of

Why is it important to pick a topology which offers the best opportunities to reduce losses in the secondary synchronous rectifiers? A look at a typical power loss budget of a 3.3V power converter shows approximately 40% of the overall power conversion losses occur in the secondary rectification. The Cascaded topology provides for lower peak voltages and currents in the inductors. Since this area is the largest loss contributor, anything that can help reduce these losses will have a significant impact on the total system efficiency.

For low voltage outputs, the rectifier represents the largest loss element.

Comparison of Rectifier Stresses

This chart compares secondary rectifier stresses for three of the topologies we have seen so far. The comparison example is for a typical 3.3 Volt output with a 35 to 80 Volt input. On the top chart voltage stresses are compared. As you can see for the Forward and the Push-Pull the voltage stresses are proportional to the input voltage. At high line the calculated stresses are much higher than the Cascaded topology whose rectifier stresses are only proportional to Vout. All of the compared topologies have two secondary rectifiers. The lower chart compares the ratio of ON times for each topology. The Push-Pull and the Cascade have balanced loading on the two secondary rectifiers. The loading ratio on the rectifiers for a Forward topology vary in proportion to the input voltage. Optimized and reliable designs are more readily accomplished with balanced loading.

Sync Rectifier Waveforms

At low output voltages, the output rectifier' s forward drop becomes the biggest impediment to achieving high efficiency. A typical Schottky diode in a high current application will have a forward voltage drop of roughly 500mV to 700mV. When the output voltage is 3.3V, and since one diode is always in series with the output power path, the maximum achievable efficiency is 3.3V/3.8V= 87% (assuming a 500mV diode). And that assumes the rest of the circuit is 100% efficient, something we know to be unachievable. Of course as the output voltage is further reduced, this problem gets worse. One thing that can be done to radically improve efficiency with low output voltages is to replace the secondary rectifiers with low on-resistance MOSFETs. The forward drop can be made arbitrarily low by selecting the appropriate transistors. This scope plot shows the drain voltage waveforms of the two synchronous rectifiers in a 2.5 Volt output. Excluding the switching spikes, the voltage stress is as expected, 5 volts. Therefore, extremely low voltage MOSFETs can be used in these applications.

a 2.5 Volt output. Excluding the switching spikes, the voltage stress is as expected, 5 volts. Therefore, extremely low voltage MOSFETs can be used in these applications.

Cascaded PWM Controller

6.1 LM5041 Cascaded PWM Controller 6.2 LM5041 Block Diagram 6.3 LM5041 Current-Fed Push-Pull Demo Board 6.4 LM5041 / LM5100 Demo Board Schematic

LM5041 Cascaded PWM Controller

National Semiconductor has developed a controller designed specifically for Cascaded topologies. The LM5041 controller has many innovative features: Internal 100V Capable Start-up Bias Regulator. Programmable Line Under Voltage Lockout with Adjustable Hysteresis. Current-Mode Control. Internal Error Amplifier with Reference. Dual Mode Over-Current Protection. Internal Push-Pull Gate Drivers with Programmable Overlap or Dead-Time. Programmable Soft-Start. Programmable Oscillator with Sync Capability. Precision Reference. Thermal Shutdown (165C). Packages: TSSOP 16 LLP 16 (5 x 5 mm) LM5041 Cascaded PWM Controller: Net Links

LM5041 Block Diagram

Shown here is the block diagram for the LM5041 Cascaded Controller. Note that on the right are the 4 switch control outputs. Gate drivers are included within the device for the Push and Pull outputs. A resistor connected to the TIME pin is used to set either overlap or dead-time of the Push-Pull outputs. Connecting the TIME resistor to ground sets the overlap time. Connecting the time resistor to REF sets dead-time. The Buck stage outputs are logic level controls which work with the LM5100 family of Buck stage gate drivers. The bias, control and protection circuits used in this controller are very similar to the

dead-time. The Buck stage outputs are logic level controls which work with the LM5100 family of Buck stage gate drivers. The bias, control and protection circuits used in this controller are very similar to the LM5030 controller, which is current-mode control. A unique LM5041 feature is a line under voltage lockout (UVLO) with adjustable hysteresis.

LM5041 Current-Fed Push-Pull Demo Board

The demo board shown here is an example of a typical application of the LM5041: 4-Layer Board. Planar Magnetics. (Coilcraft standard products for Transformer and Inductor). 100V Chipset: LM5041 Cascaded Controller LM5101 Synchronous Buck Driver

LM5041 / LM5100 Demo Board Schematic

2.5V @ 50A Cascaded DC-DC Converter Shown here is the schematic for the LM5041 demo board. The right side of the schematic contains the secondary synchronous rectifiers and the output capacitors. The left side contains the primary circuits: the Buck stage, Push-Pull primary and the controller. The gate driver shown for the Buck stage is the LM5101.

Application Note 1299 LM5041 Evaluation Board

Half-Bridge Topology
7.1 The Basic Half-Bridge

The Basic Half-Bridge

This is a basic Half-Bridge architecture circuit. One advantage of the Half-Bridge compared to the Push-Pull is that the FET drain voltages are inherently limited to the input voltage. If the center tap of the input stage tries to pull above Vin or below ground, the FET body diodes act to clamp the switch node at the rails. So unlike the Push-Pull design, we can use FETs rated at slightly above the maximum input voltage as compared to significantly greater than twice Vin. The downside for this is the need to have a pair of relatively large input caps to act as the right side of the bridge and split the input supply in half. There is also a blocking capacitor shown in series with the power transformer primary to prevent the flux walk problem discussed for the Push-Pull from causing transformer saturation. In most designs this capacitor proves to be unnecessary. Note also that the transformer primary is now a single winding rather than a center tapped winding. It sees true 100% utilization since the entire winding is driven each half cycle. Historically, Half-Bridge circuits have used voltage-mode control. There's an inherent instability in the system if current-mode control is used that causes the capacitor center tap voltage to walk off to a rail. It takes active control of the center tap voltage to be able to use current-mode control.
For the Half-Bridge, voltage-mode control keeps the capacitor center tap voltage from walking off to a rail.

Half-Bridge Controller
8.1 LM5035 Half-Bridge Controller 8.2 LM5035 Demo Board Schematic 8.3 Cascaded Half-Bridge Concept 8.4 Cascaded Half-Bridge Characteristics

LM5035 Half-Bridge Controller

National has developed the LM3035 Half-Bridge Controller. This part uses voltage-mode control to avoid

LM5035 Half-Bridge Controller

National has developed the LM3035 Half-Bridge Controller. This part uses voltage-mode control to avoid the instabilities discussed above. It incorporates input voltage feed-forward to keep the loop gain under control as the input voltage varies and also provide good line voltage rejection. Another significant feature of the LM5035 is that it contains on board control for a pair of synchronous rectifiers. This feature greatly simplifies the overall circuit complexity. As output voltages continue to fall, the ability to drive synchronous rectifiers becomes critical. Be aware that the high-side driver of the LM5035 can easily be ground referenced to be used to drive a conventional Push-Pull design as well. Simply ground the HS pin and connect the HB pin to the VCC rail. LM5035 PWM Controller with Integrated Half-Bridge and SyncFET Drivers: Net Links

LM5035 Demo Board Schematic

The design shown here accepts an input of 36V to 72V and provides a 3.3V, 30A output. Note that in the example below, the primary side MOSFETs are only rated at 100V for a 72V input. Had this been a Push-Pull design, the switches would need to be rated at a minimum of 200V and possibly higher. Of course, since the transformer primary voltage is the input voltage the current is twice what would be seen in a Push-Pull design. As a general rule this is a beneficial trade-off since a FET's on-resistance will vary approximately to the 3/2 power of its rated breakdown voltage for a given area of silicon. The synchronous rectifier drivers simplify the implementation of the secondary side MOSFET drives. The correct timing relationship to the primary side switches is ensured without adding a great deal of discrete circuits to introduce needed time delays. Also, a unique optocoupler feedback interface is included to help speed up the loop response and minimize phase delays caused by the optocoupler.

Application Note 1435 LM5035 Evaluation Board

Cascaded Half-Bridge Concept

Cascaded Half-Bridge Concept

The Cascaded approach can be extended to many other configurations. Here a Buck stage is cascaded with a Half-Bridge stage. In this case the Half-Bridge is said to be voltage-fed, since the splitter capacitors are necessary for proper operation. This approach offers the benefit of further reduced voltage stresses on the primary side switches of VoutN, where N is the turns ratio, and a single primary winding.

Cascaded Half-Bridge Characteristics

A Cascaded Half-Bridge Converter is a Buck type converter consisting of a Buck Regulation Stage followed by (cascaded by) a Half-Bridge Isolation Stage. The Isolation Stage is Voltage-Fed. Voltage splitter capacitors and a small output stage inductor are required. Dead-time is required for Half-Bridge switches. The Half-Bridge Stage FET stresses are reduced, to VoutN. (2x less than the Push-Pull). Since the Half-Bridge stage operates at very nearly 50% duty cycle, the output inductor requirements are minimal. A very small inductor is all that's required to prevent large currents spikes from trying to drive the output capacitor at each switch transition. This helps improve overall efficiency. Probably the biggest drawback of this architecture is the need to be voltage-fed due to the rail splitter caps. This is slightly detrimental to overall loop stability since it is a two pole system and also provides a fairly large energy reservoir to drive a shorted output. Both of these issues can be resolved by using the current-fed, Cascaded Full-Bridge design. Before we discuss the cascaded bridge, let's look briefly at the basic bridge architecture and examine its behavior.

Full-Bridge
9.1 Full-Bridge Concept 9.2 Full-Bridge Current Doubler 9.3 Cascaded Full-Bridge Concept 9.4 Cascaded Full-Bridge Characteristics

Full-Bridge Concept
Here is a basic Full-Bridge concept. Note that the transformer primary is inserted across the mid points of both sides of a bridge-configured set of MOSFETs, hence the name of the architecture. The drives to Phase A and Phase B will be 180 degrees out of phase and driven alternately. The FETs are driven across the diagonals of the bridge; in other words, Q1 and Q4 driven together followed by Q2 and Q3. Transformer primary

name of the architecture. The drives to Phase A and Phase B will be 180 degrees out of phase and driven alternately. The FETs are driven across the diagonals of the bridge; in other words, Q1 and Q4 driven together followed by Q2 and Q3. Transformer primary current flows in alternate directions so the core is fully utilized. The drain voltages of all four FETs get clamped between Vin and ground by the FET's body diodes. The FET's breakdown voltage rating does need to be raised to handle spikes or overshoots. All turn-off transitions are clamped. Note also that the transformer primary is a single winding with no center tap. This topology is particularly well suited for very high output power levels and is most economical above about 1kW. The cost of 4 primary switches and drivers makes this design less desirable at low power levels, but it will still work quite well. There's also the issue of having two FETs in series. This doubles the conduction losses but since the breakdown rating of the switches can be relatively low, the on-resistance can be made proportionally lower than would be possible with a Push-Pull design. The output rectifiers are synchronously driven MOSFETs for low losses. Note that the cross coupled drive really only works well for a 3.3V output. For lower output voltages the drive voltage gets pretty limited and for much higher voltages the gates are overdriven at high input lines. One disadvantage of the Full-Bridge is the center tapped secondary winding. High currents are forced to flow through only of the winding at a time, so the transformer secondary isn't optimally utilized. One solution to this is what's know as the current doubler secondary which will be seen next.
For the Full-Bridge, the MOSFET drain voltage is approximately equal to Vin.

Full-Bridge Current Doubler

The current doubler configuration requires the use of a second inductor on the secondary side. However, each inductor only has to handle the total load current and can be quite low in value. The ripple currents through the two inductors are 180 degrees out of phase and so tend to cancel to a large degree, allowing a larger ripple in each side while still producing a relatively low net output ripple current. Operation is as follows: When the dotted end of T1 is positive, the Phase A switch is on and current ramps positive in the upper inductor. When the transformer voltage switches over the Phase B switch turns on and current ramps up in the lower inductor while the upper inductor's current freewheels though the Phase B switch. When a sync switch is carrying the transformer current it also carries the freewheeling current from the un-driven inductor. As such the FET sees the full load current during this condition. During the periods where all four primary switches are off, both of the sync rectifiers will be on, with each now carrying the total load current. This architecture is good for high current outputs but must have the secondary switches actively driven as opposed to being self driven by the secondary winding. The current doubler can be used with all of the double ended architectures discussed here.
The current doubler requires two output inductors.

Cascaded Full-Bridge Concept

Here's an example of a Buck stage cascaded with a Full-Bridge stage. The benefit here is: Reduced primary FET voltage stress of VoutN. Reduced switch current relative to the Half-Bridge. A single primary winding. One thing to note is that the bridge is no longer clamped by a large capacitor. So the bridge voltage is no longer absolutely constrained as in the voltage-fed design. Some care must be taken when using synchronous rectifiers on the secondary since the regulator is capable of sinking output current and trying to boost the primary voltage. This is only a potential issue at very light loads and should be of no concern as long as the output is heavily loaded.

Cascaded Full-Bridge Characteristics

A Cascaded Full-Bridge Converter is a Buck type converter consisting of a Buck Regulation Stage followed by (cascaded by) a Full-Bridge Isolation Stage. The Isolation Stage is Current-Fed. No voltage splitter capacitors or output stage inductor are required as in the Cascaded Half-Bridge. Overlap time is required for Isolation Stage switches. The Full-Bridge Stage voltage stresses are VoutN, similar to the half-bridge. Full-Bridge Stage current levels are half that of a Half-Bridge. This completes our course on Push-Pull switching regulators. As you have seen there are a number of possible variations on the basic theme, all of which carry advantages and disadvantages.

B-H
Characteristic curve for a magnetic material, representing Flux Density B on the y-axis and Magnetic Intensity H on the x-axis.

Remanent Flux

SAT

Saturation flux density.

Buck
A voltage regulator used to step down a higher input voltage to a lower output voltage.

Buck-Boost
A voltage regulator used to invert a voltage, such as positive input to negative output.

Cascaded

Buck-Boost
A voltage regulator used to invert a voltage, such as positive input to negative output.

Cascaded
Term used for a circuit that is made up of more than one circuit in series.

CCM
Continuous Conduction Mode, referring to an inductor where current is always flowing.

Coercive Force
The magnetizing force H which is required to reduce the remanent flux B to zero is called the coercive force.
R

Core Loss
Usually expressed in watts per pound or mW per cubic centimeter. The area enclosed by the B-H curve is proportional to the core loss.

Current-Fed
Circuit where the input is fed by a current source, usually with a inductor at the input.

Current-Mode
A dual loop control method with an inner loop that servos on the inductor current, and an outer voltage control loop.

D
Duty cycle. The ratio of on-time to period, t(on)/T.

DC-DC
A converter which accepts a DC input voltage and produces a DC output voltage.

Dead-Time
The time when actively driven switches are off.

FET
Field-Effect Transistor.

Flux Density
The flux density of a magnetic field B is expressed as voltsecond (weber) per square meter (tesla) or lines per square centimeter (gauss). There are 10,000 gauss per tesla.

Flyback
A transformer isolated Buck-Boost regulator. The transformer is also the energy storage inductor.

Forward
A transformer isolated Buck regulator.

Freewheel
Refers to the current in a rectifier which is allowed to "freewheel" when the rectifier is forward biased by the inductor voltage.

Full-Bridge
An isolated converter where the primary is diagonally driven between the input voltage and ground by four switches.

Half-Bridge

An isolated converter where the primary is diagonally driven between the input voltage and ground by four switches.

Half-Bridge
An isolated converter where one end of the primary is alternately driven to the input voltage and ground by two switches.

Magnetizing Inductance
Generally referenced to the transformer primary, which must be magnetized in order to transfer energy.

MOSFET
Metal-Oxide Semiconductor Field-Effect Transistor.

OV
Over-Voltage

Permeability
Permeance is an expression of the ease with which a magnetic field is conducted. Permeability is represented by , where =B/H.

Push-Pull
A Forward converter with two primary switches and transformer windings. The primary switches alternately power their respective windings.

PWM
Pulse Width Modulation

Remanent Flux
The residual flux left in the core when the magnetic intensity H is returned to zero. This is the residual magnetism of the core after being driven into saturation, or maximum magnetization.

RF
Radio Frequency

Single-Ended
A converter which only drives one end of the primary or energy storage inductor. The term is usually applied to transformer isolated converters.

Synchronous
Used to describe a converter which has active devices for the output rectifiers which are synchronously driven.

UVLO
Under-Voltage Lockout

Voltage-Fed
Circuit where the input is fed by a voltage source, usually with a capacitor at the input.

Voltage-Mode
A control method with a single control loop which regulates the output voltage.

VoltSecond
Proportional to the flux density of a magnetic field B which is expressed as voltsecond (weber) per square meter (tesla) or lines per square centimeter (gauss). There are 10,000 gauss per tesla.

Frequently Asked Questions

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Proportional to the flux density of a magnetic field B which is expressed as voltsecond (weber) per square meter (tesla) or lines per square centimeter (gauss). There are 10,000 gauss per tesla.

Frequently Asked Questions

Do you have a question? We may have already answered it. Check below to see if you can find the answer to your question.

Questions Answers Contact/Help Information

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Push-Pull Power Converter Topologies Copyright 2010 by National Semiconductor All rights reserved