开关电源设计指南：Power Supply Cookbook第二版

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"power supply cookbook, Second Edition, Marty Brown" 《电源供应手册》（第二版）是Marty Brown撰写的一本专业书籍，专注于开关电源技术，尤其是脉宽调制（PWM）技术的应用。这本书是电子工程师和相关专业人士的重要参考资料，旨在帮助读者深入理解并掌握开关电源的工作原理和设计技巧。开关电源是一种高效能的电力转换设备，它通过快速切换半导体开关元件（如晶体管）的状态来控制输出电压。脉宽调制是开关电源中常用的一种控制方法，通过改变开关元件的导通时间比例（即脉冲宽度），来调节输出电压的平均值。这种方法具有效率高、响应速度快等优点，广泛应用于各种电子设备和系统中。书中可能涵盖了以下关键知识点： 1. 开关电源的基本工作原理：包括交流到直流（AC-DC）转换、直流到直流（DC-DC）转换的拓扑结构，如 Buck、Boost、Buck-Boost、Flyback 和 Forward 转换器等。 2. PWM 控制技术：详细解释了PWM的工作机制，如何通过PWM控制器产生调制信号，以及如何调整占空比来控制输出电压。 3. 半导体开关元件的选择与应用：涉及MOSFET、IGBT等功率器件的特性、选择标准及驱动电路设计。 4. 电源滤波和电磁兼容性（EMC）：介绍如何设计有效的滤波网络以降低纹波和噪声，同时满足电磁兼容标准。 5. 安全与保护电路：讨论过电压、过电流、短路保护以及热管理等关键安全措施。 6. 效率优化与功率因数校正（PFC）：讲述如何提高电源效率，以及在前级加入PFC电路以改善电网负荷特性。 7. 设计实例与故障排查：提供真实的设计案例分析，帮助读者将理论知识应用于实践，并学习如何诊断和解决电源系统中的问题。 8. 可充电电池的应用：对于电源系统中涉及电池的部分，可能会讲解电池的特性和应用，以及电池管理系统（BMS）的设计。 9. 其他相关组件：如电感器、电容器、变压器等被动元件的选择与设计，它们在开关电源中的作用及其对整体性能的影响。 10. 电路设计和标准：介绍电子电路设计的一般原则和行业标准，为工程师提供设计指导。这本书不仅涵盖了开关电源的理论知识，还强调了实践经验和个人风格，是电源设计工程师和爱好者的宝贵资源。通过阅读和学习，读者可以提升自己的设计技能，更好地应对实际工程中的挑战。

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The three major power supply technologies that can be considered within a

power supply system are:

1. Linear regulators.

2. Pulsewidth modulated (PWM) switching power supplies.

3. High efﬁciency resonant technology switching power supplies.

Each of these technologies excels in one or more of the system considera-

tions mentioned above and must be weighed against the other considerations

to determine the optimum mixture of technologies that meet the needs of

the ﬁnal product. The power supply industry has chosen to utilize each of the

technologies within certain areas of product applications as detailed in the

following.

Linear

Linear regulators are used predominantly in ground-based equipments where

the generation of heat and low efﬁciency are not of major concern and also where

low cost and a short design period are desired. They are very popular as board-

level regulators in distributed power systems where the distributed voltage is less

than 40VDC. For off-line (plug into the wall) products, a power supply stage

ahead of the linear regulator must be provided for safety in order to produce

dielectric isolation from the ac power line. Linear regulators can only produce

output voltages lower than their input voltages and each linear regulator can

produce only one output voltage. Each linear regulator has an average efﬁciency

of between 35 and 50 percent. The losses are dissipated as heat.

PWM switching power supplies

PWM switching power supplies are much more efﬁcient and ﬂexible in their

use than linear regulators. One commonly ﬁnds them used within port-

able products, aircraft and automotive products, small instruments, off-line

applications, and generally those applications where high efﬁciency and

multiple output voltages are required. Their weight is much less than that of

linear regulators since they require less heatsinking for the same output ratings.

They do, however, cost more to produce and require more engineering

development time.

High efﬁciency resonant technology switching power supplies

This variation on the basic PWM switching power supply ﬁnds its place in appli-

cations where still lighter weight and smaller size are desired, and most impor-

tantly, where a reduced amount of radiated noise (interference) is desired. The

common products where these power supplies are utilized are aircraft avionics,

spacecraft electronics, and lightweight portable equipment and modules. The

drawbacks are that this power supply technology requires the greatest

amount of engineering design time and usually costs more than the other two

technologies.

The trends within the industry are away from linear regulators (except for

board-level regulators) towards PWM switching power supplies. Resonant

and quasi-resonant switching power supplies are emerging slowly as the

technology matures and their designs are made easier. To help in the selec-

tion, Table 1–1 summarizes some of the trade-offs made during the selection

process.

4 Role of the Power Supply within the System and Design Program

1.4 Developing the Power System Design Speciﬁcation

Before actually designing the power system, the designer should develop the

power system design speciﬁcation. The design speciﬁcation acts as the perfor-

mance goal that the ultimate power supply must meet in order for the entire

product to meet its overall performance speciﬁcation. Once developed, it should

be viewed as a semi-ﬁrm document and should only be changed after the needs

of the product formally change.

When developing the design speciﬁcation, the power supply designer must

keep in mind what is a reasonable requirement and what is an idealistic require-

ment. Engineers not experienced in power supply design often will produce

requirements on the power supply that either will cost an unnecessary fortune

and take up too much space or will be impossible to meet with the present state

of the technology. Here the power supply designer should press the other engi-

neers, managers, and marketers for compromises that will prompt them to

review their requirements to decide what they can actually live with.

The power system speciﬁcation will be based upon the questions that should

previously have been asked of the other departments involved in deﬁning and

designing the product. Some of the requirements can be anticipated to grow,

such as the current needed by various subsystems within the product. Always

add 25 to 50 percent to the output current capabilities of the power supply

during the design process to accommodate this inevitable event. Also, the space

allocated to the power system and its cost will almost always be less than what

will be ﬁnally required. Some negotiations will be in order. Since the power

system is a support function within the product, its design will always be modi-

ﬁed in reaction to design issues within the other sections of the product. This

will always make the power supply design the last circuit to be released for pro-

duction. Recognizing and addressing these potential trouble areas early in the

design period will help avoid delays later in the program.

To develop a good design speciﬁcation, the designer should understand the

meaning of the terms used within the power supply ﬁeld. These are measurable

1.4 Developing the Power System Design Speciﬁcation 5

Table 1–1 Comparison of the Four Power Supply Technologies

Resonant

Transition Quasi-Resonant

Linear PWM Switching Switching Switching

Regulator Regulator Regulator Regulator

Cost Low High High Highest

Mass High Low-medium Low-medium Low-medium

RF Noise None High Medium Medium

Efﬁciency 35–50% 70–85% 78–92% 78–92%

Multiple outputs No Yes Yes Yes

Development time 1 week 8 person-months

10 person- 10 person-months

to production months

5 person-months

8 person- 8 person-months

months

Based upon a reasonable level of experience and facilities.

With the use of this book.

power supply parameters with a common set of test conditions that the actual

design affects. These parameters are the following.

Input voltage

in(nom)

The input voltage at which the product expects to

operate for >99 percent of its life.

in(low)

The lowest anticipated operational input voltage

(brown-out).

in(hi)

The highest anticipated operational average input

voltage.

Line Frequency(s) dc, 50, 60, or 400Hz, etc.

Include any adverse operating conditions that may require the supply to operate

outside the conventional speciﬁcations such as:

Dropout A period of time over which the input line voltage

completely disappears (the speciﬁcation is typically

8mS for 60Hz ac off-line applications).

Surge A deﬁned period of time where the input voltage will

exceed the V

in(hi)

speciﬁcation that the unit must

survive and during which it may need to operate.

Transients These are very high voltage “spikes” (+/-) that are

characteristic of the input power system.

Emergency operation Any operation required of the product during any

adverse operating periods. This may be because the

product’s function is so critical for the survival of the

operator of the unit, that it must operate to just short

of its own destruction.

Input current

in(max)

This is the maximum average input current. Its maximum limit may

be speciﬁed by a safety regulatory agency.

Output voltage(s)

out(rated)

The nominal output voltage (ideal).

out(min)

The output voltage below which the load should be inhibited or

turned off.

out(max)

The maximum output voltage under which normal operation of the

load circuits can operate.

out(abs)

The voltage at which the loads reach their destructive limits.

Ripple voltage (switching power supplies) This is measured in peak-to-peak

volts, and its frequency and level should be acceptable to the load circuits.

Output current

out(rated)

The maximum average current that will be drawn from an

output.

out(min)

The minimum current that will be drawn from the output during

normal operation.

The maximum current limit that should be delivered into a short-

circuited load.

6 Role of the Power Supply within the System and Design Program

Describe any unusual load demand characteristics related to any output. These

consist of intermittent loads such as motors, CRTs, etc., and also any loads

that may be removed from or added to the system as part of an overall system

architecture, such as probes, handsets, and the like.

Dynamic load response time: This is the amount of time it requires the power

supply to recover to within load regulation limits in response to a step

change in the load.

Line regulation: Percentage change in the output voltage(s) in response to a

change in the input voltage.

(1.0)

Load regulation: Percentage change in the output voltage(s) in response to a

change in load current from one-half rated to rated load current.

(1.1)

Overall efﬁciency: This will determine how much heat will be generated within

the product and whether any heatsinking will be needed in the physical

design.

(1.3)

Protections



Input fusing limits.



Overcurrent foldback on the outputs.



Overvoltage trip protection limits.



Undervoltage lockout on the input power line.



Any graceful degradation features and repair philosophy after system

failure.

Operating and Storage Ambient Temperature Ranges Outside the Product

Safety regulatory agency issues



Dielectric withstanding voltage (hipot).



Insulation resistance.



Enclosure considerations (interlocks, insulation class, shock, marking,

etc.).

RFI/EMI (Radiofrequency and electromagnetic interference) which regulatory

agency speciﬁcations the product must meet.



Conducted EMI: line ﬁltering.



Radiated RFI: physical layout and enclosures.

Special functionalities required of the power supply. These include any power-on

resets and power-fail signals needed by any microcomputers in the system,

remote turn-off, output voltage or current programming, power sequencing,

status signals, etc.

Efﬁc.

out

=◊

()

100 %

Load Reg.

o full-load o half-load

o rated-load

◊

()

()( )

()

100 %

Line Reg.

o hi-in o lo-in

o nom-in

◊

()

() ()

()

100 %

1.4 Developing the Power System Design Speciﬁcation 7

This now forms a very good basis from which to begin a power supply design.

This speciﬁcation is now at a point that it can dictate which design paths must

be pursued in order to meet the above speciﬁcations and will help to guide the

designer during the design process.

1.5 A Generalized Design Approach to Power Supplies:

Introducing the Building-block Approach to Power

Supply Design

All power supply engineers follow a general pattern of steps in the design of

power supplies. If the pattern is followed, each step actually sets the foundation

for subsequent design steps and will guide the designer through a path of least

resistance to the desired result. This text presents an approach that consists

of two facets: ﬁrst it breaks the power supply into distinct blocks that can be

designed in a modular fashion; secondly, it prescribes the order in which the

blocks are to be designed in order to ease their “pasting” together. The reader

is further helped by the inclusion of typical industry design approaches for each

block of various applications used by power supply designers in the ﬁeld. Each

block includes the associated design equations from which the component

values can be quickly calculated. The result is a coherent, logical design ﬂow in

which the unknowns are minimized. The approach is organized such that the

typical inexperienced designer can produce a “professional” grade power supply

schematic in under 8 working hours, which is about 40 percent of the entire

design process. The physical design, such as breadboarding techniques, low-

noise printed circuit board (PCB) layouts, transformer winding techniques, etc.,

are shown through example. The physical factors always present a problem, not

only to the inexperienced designer, but to the experienced designer as well. It

is hoped that these practical examples will keep the problems to a minimum.

All power supplies, regardless of whether they are linear or switching, follow a

general design ﬂow. The linear power supplies, though, because of the maturity

of the technology and the level of integration offered by the semiconductor

manufacturers, will be presented mainly via examples. The design ﬂow of the

switching power supplies, which are much more complicated, will be covered in

more detail in the respective chapters dealing with the selected power supply

technology. The generalized approach is as follows.

1. Select the appropriate technology and topology for your application.

2. Perform “black box” approximations knowing only the design speciﬁcation

requirements. This results in estimates of semiconductor power losses,

peak currents and voltages. It may also indicate to the designer that the

chosen topology is inappropriate and a different choice is necessary. It also

allows the designer to order any semiconductor samples that may be

required during the breadboarding phase of the program.

3. Design the power supply schematically, guided by the design ﬂowcharts.

4. Build the breadboard using the techniques outlined in the physical layout

and construction sections in the text.

5. TEST, TEST, TEST! Test the power supply against the requirements stated

in the design speciﬁcation. If they do not meet the requirements, some

design modiﬁcations may be necessary. Make “baseline” measurements so

8 Role of the Power Supply within the System and Design Program

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