S. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snubl.1 PASSIVE LOSSLESS SNUBBERS FOR HIGH FREQUENCY PWM CONVERTERS Sam Ben-Yaakov and Gregory lvensky Power Electronics Laboratory Department of Electrical and Computer Engineering Ben-Gurion University of the Negev P. O. Box 653, Beer-Sheva 84105, ISRAEL Tel: +972-7-646-1561; Fax: +972-7-647-2949 Email: sby @ bguee.ee.bgu.ac.il PESC'97 June 19978. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.2 OUTLINE Introduction ‘Turn on' and ‘turn off' losses of power switches Diode reverse recovery The damaging effects of leakage inductance Simulation as an analysis and design tool 1.4.1 Cycle by cycle simulation 1.4.2 Average simulation Passive lossless snubbers perspective . Switch turn off lossless snubber 3.1 Survey of ‘turn off' lossless snubbers . Switch ‘turn on' lossless snubber 4.1 Survey of turn on snubbers . Switch 'turn on’ and ‘turn off’ lossless snubber 5.1 Survey of ‘turn on' & ‘turn off’ snubbers Snubbers in Phase Shifted PWM 6.1 Blocking the circulating current 6.2 Rectifiers’ diodes snubber8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.3 SEMINAR OBJECTIVES * To demonstrate the use and benefits of passive lossless snubbers in modern high frequency power electronics design. ¢ Relevant topologies * Soft switching * Parasitic effects ¢ Limitation - pros & cons8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.4 HARD VERSUS SOFT SWITCHING MOSFET ~ ching waveforms switching stage (simulation) ¢ Switching losses are proportional to switching frequency @ Modern simulators include switching behavior'S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.5 Diode switching characteristics [32] 50 MUR86 Rg D Cy 0.5nF Diode switching circuit - reverse recovery8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub1.6 Diode reverse recovery switching waveforms for different values of L Very high reverse currents A function of series inductance Detrimental effect in isolated and non- isolated converters Becomes very important in high switching frequency converters8. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub1.7 Rectifiers - Center Tap Rectifier ©” alg Likg, Likgy Leakage inductance at secondaryS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.8 ‘age at input filter inductor * Greatly influenced by transformer leakage ¢ Forces the use of high voltage diodes ==> higher losses8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub1.9 IGBT BEHAVIOR ue HARD SWITCHING 5 Current tail Current tail due to stored minority carriers Switching losses increase linearly with switching frequency Switching frequency limit is at about 25 kHz8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub1.10 Switch-Diode Interaction Hard switched boost stage8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.11 Basic waveforms (simulation) « Diode reverse current and parasitic oscillations « Natural ‘softening’ at ‘turn off ¢'Turn On' more troublesome in MOSFETs ¢'Turn On' & 'Turn off' problematic for IGBT ==> ZCS8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.12 SOFT SWITCHING Terminology X¥ ‘True’ soft switching calls for external active or resonant circuitry xe ‘Pseudo' soft switching by lossless snubbers8. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snubl.13, SIMULATION TOOLS [2, 16] v Modern device models account for switching behavior Old models DO NOT account for switching behavior Difficult to account for PCB parasitics Simulation of switching losses is still unreliable xx Cycle-by-Cycle simulation v Can faithfully describe the basic switching phenomena v Very useful tool to examine snubber operation x Average Simulation v Can account for snubber effect on dynamics v Can be used to design the feedback loopS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub1.14 MODEL MUR860 D (IS=783U RS=30M N=4.82 BV=600 IBV=10U + CJO=330P VJ=.75 M=.333 TT=79.2N) * Motorola 600 Volt 8 Amp 55M us Si Diode 02-24-1994 «MODEL DN5406 D (IS=2.68P RS=7.31M N=1.17 BV=900 ou 24P VJ=.6 M=.333 TT=14.4U) * Motorola 600 Volt 3 Amp 15 us Si Diode 11-23-1990 + Parameters can be changed to test various aspects, e.g. TT for reverse recoveryS. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snubl.15 ‘SUBCKT IRF150 10 20 30 + TERMINALS: D G S M1 1 2 3 3 DMOS L=1U W-1U RG 20 2 5.35 RD 10 1 43M RDS 1 3 635K CGD 4 1 2.75N RCG 4 1 10MEG MCG 4 5 2 2 SWL=1U W=1U Eco 522144 DGD 2 6 DcGD MDG 6711 EDG 71124 DDS 3 1 DSUB LS 30 3 7.5N MODEL DMOS NMOS (LEVEL=3 VMAX=1.6MEG THETA=265.6M VTO=3.3 + KP=9 RS=8.12M 18=2.01P CGSO=2.65M) -MODEL SW NMOS (LEVEL=3 VT 45) ‘MODEL DCGD D (CJO=2.75N M=.5 VJ=.41) ‘MODEL DSUB D (IS=2.01P RS=5.20M W=.8 M=.4 CJO=2.60N TT=720N) :ENDS +" IR 100 Volt 28 Amp 45M ohm N-Channel Power MOS-FET 11-20-1980S. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub1.16 DISSIPATIVE RC SNUBBERS [29, 32, 38, 45] Diode RC snubber Lr [¢ R D @ LOSSES - e.g. in center tap rectifier QV.) c Pd(min) = ={(— > ths ptr)” Li Packg) = {5} Fs Pd(min) = minimum losses Vo = output voltage C = snubber capacitor fs = switching frequency Ipkr = peak reverse current Likg= leakage inductance QResistor dissipation may reach tens of WattsS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.17 PASSIVE LOSSLESS SNUBBER APPROACHES 1. Snubbing in multiple switch PWM topologies (e.g. half bridge) [7] ¢ Most effective ¢ Few extra components => economical 2. Auxiliary (dual) switch snubbers [ 3, 8, 17, 40] ° Effective but costly ¢ Calls for extra switches and drivers ¢ Diminishing return 3. Snubbers in single switch configuration [to be detailed below] * Good compromise * Only passive elements needed ¢ Proven to increase efficiency * Potentially lowers EMI emission This seminar will concentrate on single switch and diode snubbers for PWM converters8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub1.18 BASIC SWITCHING CELL OF COMMON PWM CONVERTERS [2] us Cc Do Lo Ss B Topology Vin Vo Topology VAB VCB Buck Vee VCA Buck Vin-Vo Vin Boost VAB VcB Boost Vin Vo Buck-Boost VAB -VCA Buck-Boost Vin VintVoS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.19 Fundamental Principles 1. Controlling st at ‘Turn On' Do c A DoS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub1.20 cc OC«SA A Lo Cc Do iS ‘f BS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.21 Fundamental Principles @# The major objective: to circulate the trapped energy ¢ Ina lossless manner ¢ Without increasing the switch and diode stresses ¢ As quickly as possible (D..& Dor limitations) ¢ Without generating new parasitic effects (of extra components) * Inexpensive to implement iG Use the followings as check points for comparison: Ipx(Switch) Vinax(Switch) Vinax( diode)8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub1.22 SWITCH 'TURN OFF' LOSSLESS SNUBBER The 'One Way' Capac : Version 1 (SNB1)S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.23 The 'One Way' Capacitor : Version 1 (SNB1) [42] ‘Snubber Snubbing ¢ Snubber capacitor C,+C.‘S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.24 Snubber * Resonant reset (Cre8, Ben-Yaakov and G. Ivensky, Passive lossless snubbers snubl.25 488us 49bus 492us a4us | | ag6us D vGdrain) 4 mn Tine 2 tg Waveforms of SNB1 (simulation)S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub 1.26 Interval t,-t, Assuming: C,=C,=C i=tos=lnsin(2nq- ) is=latiy Vor=Ve1=0.5Vee[t-cos(2nq- )] Interval t,-t. is=l,_ ; ino=ini=ip2=ips=O Interval tots Vo1=Vo2=Vea- 2G(t-t2) Vei(ts)=Vca(ts)=0 . 2CVq from which: tot AL Ia dv. and hence (qt )s=26 Interval t,-(t.+T;) ipo=la ; is=in1=in2=ips=0S. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snubl.27 Typical Design Given: Veo, lay (HE Vote? Tw Ves 4 ton min i) Vey ty ¢ The diodes D, & D, must be very fast and have a very low storage charge.S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub1.28 Example: Assuming: f.= 100KhZ; ton min= 11S = 400V/uS ; Vcs= 400V rata = 0.78 v Check points 1,.(switch) ta-ts Vpx(switch) = Same as original V,x(diode) = Same as originalS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub1.29 SWITCH 'TURN OFF' LOSSLESS SNUBBER The ‘One Way' Capac : Version 2 (SNB2) 42] * Identical to Version 1 (normally drawn differently)S. Ben-Yaakou and G, Ivenshy, Passive lossless snubbers snub1.30 The ‘One Way' Capacitor : Version 2 (SNB2) 42 (drawn differently) Do Db 0 Snubber /\ D3 Co KX D2 VS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.1 SWITCH ‘TURN OFF' LOSSLESS SNUBBER (SNB3) [42] Reset to Input ¢ One of the oldest snubbersS. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.2 Snubbing8. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.3S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.4 8 v(drain) 8 icd1) 8 iCdout) oem lea steel 488us agus | dozus 494us asus! | 49gus @ vdrain)-v6 avetorms of SNB3 (simulation) Case Vce-Vas > Vas; i.e. Vea < 2VasS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.5 Interval t.-t; in=io=hasin(2ry-) where T,=2nVLC, s=lotie t Ver=(Vee-Vas)cos(2n7) t, is found from the condition: (Vei)y= - Vas ti=VLC, cos- wwe) Interval t,-t. it=ios=ioa=lpsin(2ny)- VAC =t1) , t,-t, is found from the condition: (i) =9 IxLsin(2nt') tte Vie is=honitS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.6 Interval t.-ts is=lo ; ino=in1=in2=0 Interval t.-t. is=ipo=in2=0 I Vo1=-Vastqe(tets) tts is found from the condition: (Vc1),4=Vce-Vas CiVce le te-ts= Interval t.-(t.+Ts) is=ip;=ip2=0 5 ipo=ho8. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.7 Typical Design Given: Ves; Ito & Dmin20.5, Dinax Toate leo 1. Cave dt Yeacta CiVce 1-Dimax , 2. tees 8. EST 3-4 “Ta, (assumption: i, has a sine waveform not only during interval t,-t; but also during t,-t2) 5. Ip oB max8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.8 v Check points DnoxVeslre Ipa(switch)=Io4— eee ton min( “dt esta V,x(switch) = Same as o1 Vpx(diode) = Same as ori. cB Limitation: Via< ¥g* ein eave Power Factor, hard switching when V2”8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.9 SWITCH 'TURN ON! AND DIODE ‘TURN OFF’ SNUBBER [42, 45] FLYBACK RESET SNUBBER (energy recovery via a catch winding) Version 1 (SNB4)8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.10 Version 2 (SNB5)S. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.11 SnubbingS. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2. 12S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2. 13 8 v(pulse) (ae ‘ToT ! | fe ov: 5 i(at) 488us asbud 492us asius | aobus 496us Bv(drain) | 1 toa to ty Time to ty Waveforms of SNB4 (simulation) s00usS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.14 Analysis: Version 1 (SNB4) Interval t.-t; is= oot t,-t.is found from the condition: i.(t:)=l, from eT trto=Woe Vb max=Vca(1+N) - Peak voltage across D Interval t,-ts i= - Nae(tt) tetris bore from the condition: ip(ts)=0 1 tetra 4yc, Vs moc Veo( 147) 1-Dinax fs max= torteS. Ben-Yaakov and G, Ivensky, Passive lossless snubbers snub2.15 v Check points 1 Vs max=Voa(1+pq) 3 Vo max=Voa(1+N) ¢ The lower N, the shorter is t;-t. and hence the higher is the upper limit of the switching frequency f. max. BUT, the lower N, the higher is Vsmax- The voltage across the secondary blocking diode D is high when N is high. ¢ A major disadvantage of the converter is the leakage inductance between primary and secondary of the coupled inductor : it will cause a large voltage spike across the switch. Beware of reverse recovery problems of the auxiliary diode D.S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.16 FLYBACK RESET SNUBBER Version 1 (SNB4) Typical Design dis, Given: Ves, las (ot ),.442 Dmins Dmnax Lila Vo es 3 2. o=Ven 1. Lis (4s) to-tt Vestas 5. N= ala 6. Ve m=Vea(144) 7. Vb max=Vce(1+N)8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.17 v Check points I(switch) = Vines(SWitch) = Veo (1-444) =Vce}1+ —h—- tot min( “at tos Vnex(diode) = Ves (1+4N) di tott min( pen =Vcs|1+ —i;S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.18 LOW STRESS ‘TURN ON' SNUBBER (SNB6) [17, 19] Q - Main switch Dout - Main diode D1,D2 - Auxiliary diodes Ls, Cs - Resonant network8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.19 Basic waveforms of lossless snubber Interval to-t18. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.20 Interval t1-t2 Dout Bas Time8, Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.21 Interval t2-t3 DoutS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.22 Interval t3-t4 Dout VoutS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.23 Interval t4-t58. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.24 Interval t5-t6 Dout VoutS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.25 Practical requirement of peak reverse recovery current = In If Im < lin To avoid the above undesired condition In > lin8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.26 The coupled inductor realization Do - Main diode D1, D2 - Auxiliary diodes Ls, Cs - Resonant network Lm, L1 - Coupled inductors n- turn ratioS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.27 Simplified equivalent circuits of the resonant elements with coupling inductor Vepl on= nVin VepIl off = n (Vout - Vin)S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2,28 Basic waveforms of the lossless snubber with coupling inductor Ves(ts) is larger and therefore t;, is smallerS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.29 Component stresses = gg Mest Iocan = om + F285 emer = IBY + BV on8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.30 An experimental 1kW Boost converter Pout Vout Q - IRF460 Dout - MUR860 ; trr = 60nsec. D1, D2 - MUR460 Ls - 3uHy Cs - 100nF n=1/7 Operational conditions Fs - 100KHz Pout - 1000W Vin - 200V Vout - 400V lin - 5.8A Don - 0.5S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.31 Typical waveforms of the experimental Boost converter Vertical scales: 10V/div, 5A/div Horizontal scale: 2uSec/div v Smaller reverse recovery current of DoS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.32 Power dissipation Puissipated (W) calibration estimated 6.75] i conduction i i i losses x 16 26 30 with no snubber snubber 0 DC calibration points Power dissipation dropped by 19.6WS. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.33 Additional Comments Vv The main advantages of the lossless snubber: ¢ ZCS in turn-on * Smaller reverse recovery current V The preferred embodiment is coupled inductors X The main disadvantage of the snubber is limitation of the duty cycle range Vv The overall efficiency of the experimental Boost converter was found to increase by 1%-2% * The snubber can be adopted to other PWM topologiesS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.34 Implementation in APFC ¢ Simple implementation @ Watch Donmin i Proven to increase efficiency by = 2%S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.35 Implementation in Buck converter i» Proven to increase efficiency by ~ 2%8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.36 TURN-ON AND TURN-OFF SINGLE SWITCH SNUBBERS MODIFIED TURN-ON SNUBBER (SNB7) [24, 39] S - main switch D, - main diode D,, D2, Ds - auxiliary diodesS. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.37S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.38S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.39S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.40S. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.41 Simulation avipuise) || 1 4qgus — 410uqS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.42 Interval t.-t i=“'t Zes! dis _ Vo dt ~L. ipo=lin-is tt. is found from the condition: ino(t:)=0 Vei=0 5 Vo2=VoS, Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.43 Interval t-t. is=lntirs ee Vo os ILs=Ic1=Ic2=1 VE Ci where 7-7 12=C,4+C,? One LCs VorsVog Set -cos[Orn(t-t:)]} Cc. c Voo= = Vor=Voe+ 6,4! +G,c0s[On2(t-t))]} t,-t, is found from the condition: Voi(t2)=0 1 Cc, C. tetas (eoss(-¢)) = L.C,.cos-(-¢') ino=ini=ins=0S. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.44 Interval t.-t; is=ln t)]+is(t2)cos[o,1(t-te)] where ; On TLC, ty-t, is found from the condition: in1(ts)=ipe(ts)=0 ; L, 1 i,.(te) on 1 Ci. weed ean eV = taney C2,C2))) Le Ve1=Ve1(te)COS[Mr(t-te)]+iis(te) E,Sinlon(t-t)}= VC2(C1-C2) ee , Sin[or(t-te)] =VoG2C08[0n(t-t)]}+Vo Voults)=Ver\ G2S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.45 verever(t)=Ver/ SF Vc2=0 Interval t.-ts in1=lin Vie Veoint) te zs! ne & Vo3s=Vc2tVc1-Vo _ ts-t, is found from the condition: Vpa(ts)=0 Tin Interval ts-te_ i=0; ipo=i ihe Cog; (G2 +008[oxn(t-t)]} Vo2=V.(1- af + SO) fona(t-te)+G! sinfora(t-ts)]}S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.46 . Two operating modes are possible. They depend on the condition at t, of the interval ts-te: Mode 1 will prevail if : (Vc2)tg = Vo (ini), > 0 Mode 2 will prevail if : (in:):5= 9 (Vc2)tg < Vo Necessary condition for Mode 1: Vv. = ot lroe Gry (ENS. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.47 Cy/Cz The dependence of kc on & ¢ For Mode 1: t te-t; is found from the condition: vp2(ts)=0; Voco(te)=VoS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.48 Interval t.-ty, Mode 1, i=0; v.=Vo;ips=lin in1=ip2=lin-its jae tM sinfeon(t-t)] c t-t. is found from the condition: ips (tr)=i2(t7)=0 L. L. tr- te5sin NE 1 = sin: ve, Interval t,-ts, Mode 1, i,=ipo=ipi=ip2=0; ips=lin tft =) Vc1=Ver(tz) - ts-t, is found from the condition: vc;(te)=0 —Ver(t) Cr tet Vs= VorVe1 Interval te-t., Mode 1, i.=ip1=ip2=ipa=0; ioo=lin Ver=0 5) Vea=VoS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.49 LOSSLESS TURN-ON AND TURN-OFF SNUBBER Mode 2. Time interval before the switch Q is turned on ¢ Three auxiliary diodes are conducting ¢ Hard switching ¢ Coupling will help to avoid Mode 2.8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.50 MODIFIED TURN-ON SNUBBER (SNB7) Typical Design dis, dvs Given: Vo, lin Cot iors? (at Mtgtg? Dminr Drax 1. Le qe? 2. C2 Ss: Cat so. oe , 7 3. Ke > 7 Z 4. Select C,/C, using the plot ke=9(G), 5. ton min te® + \L.Cac0s-(-62)+ L.C,tan-( ExCry 6. tott min ~ ViCatten) Eit-Wagill + VLCisin: ge,S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.51 7. Dyin = (ton min) fs} Dmax =(1 ~ tott min) fs 8. Current stress of the switch S leelntVo\) Gu 9. Voltage stress of the switch S spk = Vo * Apply iteration to approach desired design goals8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.52 Some Additional Recent Passive Lossless Snubbers Moving the connection point to main inductorS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.53 Looks familiar ? (SNB7)8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.54 Buck snubber (SNB39) [1, 43]S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers 2.0 ow snub2.55 5 v(pulse) 8 v(ver) 1 iCsmain) 488us 490us 498us = vCin)-v¢in2) : Waveforms of (SNB9) 500usS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.56 Boost coupled inductor (SNB10) [25]. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.57 ; : “Vgs oy LL pers sev : a —___ Ve, | a veer rein) es : ag Le Td) icin) 7.04 2.0 2 1clr2) OOo EO . i i TVs 8 vdrain) 7.04 0.04 ‘492us, 1 iCsmain) Basic waveforms of SNB10S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.58 Boost coupled inductor (SNB10) [25] Advantages 1. Soft switching at turn-on and turn-off in a wide load range without high current and voltage stresses. 2. Coupling decreases the minimal needed value of turn-off time of the switch. Disadvantages 1. The resonant circuit L,C, is fed from the input voltage Vj,. Hence, the peak of the capacitor's voltage cannot be higher 2V;,. Consequently, when V.>2Vi,=> hard switching. 2. The snubber cannot be used in buck and buck-boost converters.8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.59 SNB11 [24]S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.60 1 ice) Bic) 1 iCsmain) 1.0Kv wi i Vg “eau 00s DUE vcerain) Basic waveforms of SNB11 (simulation)S. Ben-Yaakov and G. Ivenshy, Passive lossless snubbers snub2.61 Advantages 1. Soft switching at turn-on and turn-off. 2. Simple topology. Disadvantages 1. ZVS by turn-off is only in the case lin 7 =Vo. In other cases will be hard switching. If Hii Ve Vo the peak voltage across Cr (VC pk) will be higher than Vo. But in the same moment when the diode D2 turns off the diode Dj turns on and closes the resonant network Lr-Cr-Ls-Do-Co. The capacitor Cr discharges through this network up to the voltage Vc pk'=2Vo-VC pk which is lower than Vo . During the first part of the conducting interval of the switch S the voltage across the capacitor Cr changes its polarity due to resonant process in the circuit Lr-Cr-S-D1, but the peak of the negative voltage across the capacitor Cr will be equal VC 'pk, i.e. it will be lower than Vo. Therefore the voltage across the switch S will rise with a jump (Vo- Vc 'pk) when the switch S turns off .S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.62 2. The voltage stress of the switch S VS pk= Vot+VC pk Only in the case: lin: a =Vo VC pk=Vo and therefore VS pk=2Vo. In the case lin’ i >Vo Vc pk>Vo and therefore VS pk>2Vo. See also snubbers with recovery transformers [11-14]S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.63 PHASE SHIFTED PWM (PSPWM) [15, 20, 21, 33] ZVS of main switches Lo, B © Rhy Basic Phase Shifted PWM Stage ¢ Leading and lagging legs (bridge non- symmetrical) ¢ Coupling capacitor C, needed to block current ¢ Asymmetry of control (+noise !) ¢ Can be eliminated by applying peak current mode control8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.64 Stage 1 - PoweringS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.65 Stage 2 - Power to to. transition - capacitor charge8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.66 Stage 3 - Power to t.. transition - Diode catch'S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.67 Stage 4-t. (circulating current)S. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.68 Stage 5 - tux to Power TransitionS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.69 Back to Power ModeS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.70 Thig ty ts gh tg Waveforms « Two rectifier diodes are conducting during toS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.71 PSPWM DESIGN OVERVIEW Basic Conventional Phase Shift PWM design equations 2. 2 Topp ly . CaVBus 2 2 Cx, = total leg capacitance or: L, lar fer >Vaus ==> logZ, > Veus where the characteristic impedance is defined as usual:S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.72 The transition time (need to be larger than 1/4 of the resonant period a 2nJL,Ca “4 @ _ In the conventional scheme, L,need to be relatively large to store sufficient energy at low load current . This can be somewhat improved by making the primary current larger (lower L,, transformers magnetization inductance) . R¥ If the short circuit ( two diodes conducting) during to is avoided (only one diode conducts ) L,can be small since the energy comes from the secondaryS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.73 Stage 5 - t. to Power Transition - two diodes conductingS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.74 Stage 5 - tus to Power Transition - one diode conducting RE if only one diode is conducing ==> L, id not needed8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.75 RESIDUAL ISSUES IN PSPWM 1. Circulating Current Circulating Current Losses Primary current ¢ Thermal design of power stage for duty cycle D ==>1 =>The circulating current at D < 1 nota major problem * Possible Solution Apply the 'One Way' capacitor to block primary current at tonS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.76 Lossless output snubber [20] *L, and C, form a resonant circuitS. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.77 Modified lossless output snubber [21] RE Resonant inductor can be moved to primary8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.78 101m Basic waveforms of SNB13 (Simulation) * Suitable for IGBT (zero current at tox. combats current tail)S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.79 RESIDUAL ISSUES IN PSPWM 2. Rectifier's diodes reverse recovery Lik, o” ie” Leakage inductance at secondaryS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.80 Neicems es age 4, 1907 Experimental waveforms ¢ Greatly influenced by transformer leakage8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.81 RESIDUAL ISSUES IN PSPWM 2. Rectifiers' diodes reverse recovery * Possible Remedy -> Saturable reactor (SR) A Operating B pointS. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.82 150 960 $F D Cc 0.5nF Simulation Circuit ¢ Using fast diode ¢ Current source establishes the forward current and abrupt change ¢L,,emulate "large" back inductanceS. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.83 ‘ecaa ‘Current source Diode current « fn is ho ee a Simulation waveforms (L;,= 50,,H)S. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.84 RESIDUAL ISSUES IN PSPW [9, 10, 15] 2. Rectifiers' diodes reverse recovery ° Design equations overview Magnetic flux swing (one sided) AB= an A. VT = volt-second across SR A.= core effective cross section area n= number of turns For Amorphous Alloy 2714AF (Allied): Core Losses : Pcore (W/Kg, mW/gr)) = 10+ (f.)1.77 (AB)1.2 B = Magnetic flux (T) f. = Switching frequency (Hz) AB=(Pcore/(10- (f,)1-73))(1/1.88)S. Ben-Yaakou and G. Ivensky, Passive lossless snubbers snub2.85 Amorphous Alloy 2714AF (Allied) CORE LOSS (W/Kg, mW/g) 1 (Tl @ Extrapolated from Allied's data (originally given up to 200KHz)S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.86 RESIDUAL ISSUES IN PSPWM 2. Rectifiers' diodes reverse recovery ¢ Implementation in PSPWM ——t-+ an VT=10VuS For Amorphous Alloy 2714AF (Allied): Pcore (W/Kg, mW/gr)) = 10+ f1.73 AB1.s8 Assume Pcore = 50 mW/gr;_ f = 270KHz Amba Alley TMAP (ed SS mente mie CORELOSS (Wike, mW)S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub2.93 From loss equation => AB = 0.125T From AB= roe => Ac=0.4cm2 Using MP1906P-4AF (Allied): OD = 21mm; ID = 10mm; Ac = 0.16 cm2; n=1; 6.1 gr i= Need at least 3 units per leg > Effective frequency is much higher than switching frequency i Being a small body (small surface area), might get very hot. ¢ 4 units per leg were used in experimental converter.8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub3.1 Experimental PSPWM Converter Transformer: Payton 3000W T250-12-4C Nominal Operating frequency = 350KHz Input Voltage = 360 -390 Volt Max. VT = 864 VuS Primary to half secondary 6:1 Primary Max rms current: 11 Amp Dielectric strength (primary to secondary): 2500 Vrms Dielectric strength ( secondary to core ) : 500 Vdc Estimated power loss 65W (@ 60°C base plate) Estimated hot spot 110°C Mechanical dimensions 88*65*30(h) mm8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub3.2 Q\- Q, : 2SK1S44 2x 2250uH | 9.047 WF | TI al a 3.6nH] Dt c T250DC-12-4C oa | 220uF| 02 ‘ol Ly » Lg 4 x MP1906P-4AF Do1 » Dog - BYV5S4V200 Experimental power stage with discrete transistors8. Ben-Yaakov and @. Ivensky, Passive lossless snubbers snub3.3 APT EUROPE, LMHOSO12 T250DC-12-4C Lg}, Ly - 4x MP1906P-4AF Do} »Do2 - BYV54V200 Experimental power stage with Power Module8, Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub3.4 i Module power section O. om i iia Module driver -isolator X48. Ben-Yaakov and G. Ivensky, Passive lossless snubbers LMHOSO12 MODULE FOR RESONANT CONVE The LMHOSOI2 isan Application Speciic Power ‘Mole (ASPM) tht iterates al he necessary power function 1 bu! tesonant converter upto SKY System design times are dramatically reduced ducto he ‘megration of fll H Bdge made of SOOV 0.1208 Single de Morfots apd four associated isoaed gate “TReuilization othe body dodo the Moses prevents APPLICATIONS + High fequerey power supply + Baty Charge + urs 1 Welder power stage 1 High ower lass D ampli + Upto 3KW output power 1 gh resonant frequency (upto 4SOKH2) 1 Avalanche ated Mose 1 gate driver crus ioated with optocoupler Toolaied package exinal lad power spplie are equi {oom sing this module in hard switching application The close proximity of the gate diver craitalong wth the we of sree printed copper crave subst allow rouble ee opto 4S0KHr operation witha SU ‘AC lation MD serewon temlaas ar provided for the poses onnection, the signals UO pars are eampatle si Printed cic board insertion oe 3 male conmscoe 3 24mm (0.1 raster her Kenedy Pare Cara Nord BABS F-33700 MERIGNAG FRANCE “Tel +33 (0) 58792 1815 -Fax +33 (0)5 56479761, snub3.5S. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub3.6 Abe cebnm a on 2 ten ashen | tt ian Ave plastic Bone frame Sinn Bick coppre bore Bk 3mm copper plate TR cvmoce BE vone El egme Me Bean gl evuny bid aed Silicone ge polyurethene resin Cross section of APT Europe Power Module8, Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub3.7 Experimental Results 31122142 mon Ape 7, 1987 Vavat=TS7 a VeRCTIBSS Primary current (upper) and leg voltages (lower)8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub3.8 19126:51 Non ABE 14, 1987 SR Voltage Pa In circuit SR Performance8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers Rectifier dioge wotage SR Voltage —_ Rectifier diode current Log voltage (10 visiDivy SR Voltage Leg voltage —> Experimental Results snub3.98. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub3.10 Nenteamm es age 4, 1907 Rectifier diode voltage (upper trace) and current (lower) with amorphous core ¢ Some overshoot due to energy stored in SR8. Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub3.11 CONCLUSIONS * Passive lossless snubbers can improve performance of switch mode systems: ¢ Controlled + and wv ¢ Increased efficiency at high switching frequency ¢ Reduction of voltage and current spikes ¢ Relatively low cost ¢ High reliability * The magnitude of the reverse recovery current of the diode may affect performance of the snubber ¢ Check points to watch: ¢ Exrtra stresses ¢ Duty cycle limitation ¢ Current limitation8, Ben-Yaakov and G. Ivensky, Passive lossless snubbers snub3.12 et) (2) [3] REFERENCES L, Barbosa, J. Vieira Jr., L. de Freitas, M. Vilela, V. Farias, "A buck quadratic PWM soft-switching converter using a single active switch", Proceedings PESC' 96, pp. 69-75. 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