CN111478590A - 一种磁隔离型超薄dc-dc变换器 - Google Patents

一种磁隔离型超薄dc-dc变换器 Download PDF

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CN111478590A
CN111478590A CN202010285965.5A CN202010285965A CN111478590A CN 111478590 A CN111478590 A CN 111478590A CN 202010285965 A CN202010285965 A CN 202010285965A CN 111478590 A CN111478590 A CN 111478590A
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unit
converter
power supply
control unit
magnetic core
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王宇琦
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CETC 58 Research Institute
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/22—Conversion of dc power input into dc power output with intermediate conversion into ac
    • H02M3/24—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters
    • H02M3/28—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
    • H02M3/325—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal
    • H02M3/335—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/33507—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of the output voltage or current, e.g. flyback converters
    • H02M3/33523—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of the output voltage or current, e.g. flyback converters with galvanic isolation between input and output of both the power stage and the feedback loop
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
    • H01F27/266—Fastening or mounting the core on casing or support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2804—Printed windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/08—Circuits specially adapted for the generation of control voltages for semiconductor devices incorporated in static converters
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/32—Means for protecting converters other than automatic disconnection
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/22—Conversion of dc power input into dc power output with intermediate conversion into ac
    • H02M3/24—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters
    • H02M3/28—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
    • H02M3/325—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal
    • H02M3/335—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/33569—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only having several active switching elements
    • H02M3/33576—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only having several active switching elements having at least one active switching element at the secondary side of an isolation transformer
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2804—Printed windings
    • H01F2027/2819—Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Dc-Dc Converters (AREA)

Abstract

本申请涉及一种磁隔离型超薄dc‑dc变换器，属于变压器技术领域，所述变换器包括：脉冲宽度调制PWM控制单元，输出过压保护单元，过流过功率保护单元，欠压保护单元，反馈控制单元，供电单元，过应力保护单元，平面变压器单元；所述PWM控制单元内置有低压差线性稳压器IDO；降低了变换器的复杂度，提高了变压器电源的稳定性。

Description

一种磁隔离型超薄dc-dc变换器
技术领域
本申请涉及一种磁隔离型超薄dc-dc变换器，属于变压器技术领域。
背景技术
随着集成变换器制造技术和开关电源技术的发展，小体积，高功率密度，散热好，低EMI(电磁干扰),平面化等越来越成为电源的追求目标和发展方向，作为电源设计最重要的一项指标，效率为电源设计最为关切优化的，这里着重针对电源的超薄化，高效化提出一种设计实例和方法。
发明内容
本申请提供了一种磁隔离型超薄dc-dc变换器，可以解决现有方案中的问题。本申请提供如下技术方案：
第一方面，提供了一种磁隔离型超薄dc-dc变换器，所述变换器包括：
脉冲宽度调制PWM控制单元，输出过压保护单元，过流过功率保护单元，欠压保护单元，反馈控制单元，供电单元，过应力保护单元，平面变压器单元；
所述PWM控制单元内置有低压差线性稳压器IDO。
进一步的，所述反馈控制单元由adum4130ep和外围环路补偿阻容结合供电储能滤波电容和上拉电阻进行输出电压的反馈。
进一步的，所述供电单元通过变压器的辅助供电绕组和外围分离元器件构成的低压差线性稳压器IDO进行小电压范围的稳定电压供电。
进一步的，所述欠压保护单元包括3个欠压设定电阻。
进一步的，所述平面变压器单元包括磁心和绕组，所述绕组包括原边绕组、副边绕组和辅助供电绕组；所述磁心嵌入安装在印制电路PCB板的开槽中，所述磁心的磁心柱穿过所述PCB板。
本申请的有益效果在于：
通过设置一种磁隔离型超薄dc-dc变换器，该变换器包括脉冲宽度调制PWM控制单元，输出过压保护单元，过流过功率保护单元，欠压保护单元，反馈控制单元，供电单元，过应力保护单元，平面变压器单元；所述PWM控制单元内置有低压差线性稳压器IDO。降低了变换器的复杂度，提高了变压器电源的稳定性。
上述说明仅是本申请技术方案的概述，为了能够更清楚了解本申请的技术手段，并可依照说明书的内容予以实施，以下以本申请的较佳实施例并配合附图详细说明如后。
附图说明
图1本发明所述的磁隔离型超薄dc-dc变换器的变换器图；
图2本发明实施例所述的原边绕组的示意图；
图3本发明实施例所述的副边绕组的示意图；
图4本发明实施例所述的原边绕组和辅助供电绕组的示意图；
图5本发明所述的变压器应用的小功率反激式电源的原理图。
具体实施方式
下面结合附图和实施例，对本申请的具体实施方式作进一步详细描述。以下实施例用于说明本申请，但不用来限制本申请的范围。
请参考图1，其示出了本申请一个实施例提供的一种磁隔离型超薄dc-dc变换器，如图1所示，所述变换器包括：脉冲宽度调制PWM(Pulse Width Modulation，脉冲宽度调制)控制单元，输出过压保护单元，过流过功率保护单元，欠压保护单元，反馈控制单元，供电单元，过应力保护单元，平面变压器单元。
其中，所述PWM控制单元与所述欠压保护单元、所述过流过功率保护单元和所述平面变压器单元相连，所述过流过功率还与所述过应力保护单元连接，所述供电单元与所述平面变压器单元连接，用于为所述平面变压器单元供电，所述反馈控制单元与所述输出过压保护单元和所述输出电压设定单元和所述输出过压保护单元相连。
所述PWM控制单元内置有低压差线性稳压器IDO。
所述反馈控制单元由adum4130ep和外围环路补偿阻容结合供电储能滤波电容和上拉电阻进行输出电压的反馈。
所述供电单元通过变压器的辅助供电绕组和外围分离元器件构成的低压差线性稳压器IDO进行小电压范围的稳定电压供电。
所述欠压保护单元包括3个欠压设定电阻。
上述仅以变换器中包括上述功能单元来举例说明，实际实现时，还可以包括更多或者更少的功能单元，下述将给出一种可能的变换器，并详细说明变换器中各个功能单元的具体实现。具体的，请结合图1：
1.储能滤波单元
储能滤波单元分为输入部分和输出部分。且均为CLC型滤波，这里输入电容不必太小，否则储能不足，同时增加滤波电感和小滤波电容进行纹波滤除。对于输出储能滤波部分通过两个小esr钽电容和一个mlcc电容进行纹波滤除。
2.PWM控制单元
PWM控制单元可以为内置有IDO的NCP12700控制芯片和外围变换器进行搭建，内置有IDO的控制芯片可以为NCP12700芯片。NCP12700是高度集成的PWM控制芯片，满足宽范围电压输入，轻载跳周期，过功率限制，斜坡补偿，这里采用2R2，二极管和10R电阻进行mosfet的驱动控制，mosfet选用低Qg(导通栅极所需的电荷量),低导通电阻器件，使得开关损耗和导通损耗大大降低。
3.反馈控制单元
反馈控制单元采用磁反馈模块adum4130ep和外围环路补偿阻容结合供电储能滤波电容和上拉电阻进行输出电压的反馈，反馈连接到NCP 12700的片内误差放大器的输出comp脚，当外部输出电压偏高或偏低时进行对占空比的控制，达到输出稳压隔离的作用。由于adum4130ep为超低功耗芯片，达到了降功耗和提高稳压功能的效果。
4.供电单元
通过变压器辅助绕组加外围分离元器件构成的ldo进行小电压范围的稳定电压对芯片供电，其中R9为限流电阻，C23为储能电容，通过稳压管D7稳定10V电压，结合10k基极电阻和处于线性工作的三极管对芯片进行供电，使芯片稳定工作在正常电压工作范围。
平面变压器单元包括磁心和绕组，所述绕组包括原边绕组、副边绕组和辅助供电绕组；所述磁心嵌入安装在PCB板的开槽中，所述磁心的磁心柱穿过所述PCB板。
可选的，磁心可以采用ER型磁心，选用ER型平面磁心的好处在于磁心相对耦合度好，漏感小。比如，可以为ER18型磁心，其Ae为30.2mm2,Ve为667mm3,其大致功率传输能力为15W/300KHZ；30W/600KHZ。通过专用的磁心粘合胶水粘合。这样磁心耦合度好，漏感低。在磁心的中心圆处可以留出一定气息，避免变压器的磁饱和，同时可以根据变换器所需变压器原边电感量控制粘合紧密程度进一步控制气息。磁心为Mn-Zn铁氧体材质，当承受电流越大，铜皮宽度和厚度就要求越大。同时pcb材料最好采用耐热散热的材料。
磁心有两个，磁心的磁心柱通过手工打磨控制气息，进而通过变压器黏结胶水，相互扣合在PCB板上。可选的，本实施例所说的PCB板为6层PCB板，PCB板根据磁心柱尺寸进行挖槽。
原边绕组和所述副边绕组的材质为铜，作为大电流的电流路径，组成功率回路。辅助供电绕组的材质为普通布线，提供小电流给芯片。其中，原边绕组和所述副边绕组可以为2OZ铜厚。所述原边绕组和所述副边绕组分布在所述PCB板的不同层，同一绕组分布在所述PCB板的至少两层，并且围绕同一磁心的不同绕组线圈交错排列。并且，实际实现时，请参考图2，各绕组的导电线圈通过过孔互联，形成闭合的通路。
所述PCB板的不同层之间的间距较小，也即层与层之间的间距小于预设阈值，达到了漏感小的效果。
实际实现时，所述原边绕组为6圈，所述PCB板为6层，所述PCB板的顶层和底层各绕2圈，通过内径过孔串联；所述PCB板的第2层和第5层通过铜皮对称绕有1圈。请参考图3，所述副边绕组为4圈，所述副边绕组在所述PCB板的中间两层各绕两圈，并通过过孔串联。请参考图4，所述辅助供电绕组为4圈，在所述PCB板的顶层和底层各绕2圈，并且所述辅助供电绕组与所述原边绕组交错排列。通过执行上述设置，进一步减小漏感。另外，实际实现时，原边绕组、副边绕组、辅助供电绕组在端口上采用0402的0欧姆电阻进行网络区分，也可用于分辨同名端。
请参考图5，其示出了该平面变压器的原理图，如图5所示，该平面变压器可以为反激式变压器结构，1，4，6号绕组互为同名端，2，3，5号绕组互为同名端，原边绕组和副边绕组交替工作，副边绕组与辅助绕组互为正激结构，原边绕组与副边绕组均为主功率回路，辅助绕组为信号回路。
5.过流过功率控制单元
通过R16，R12两个mos管下面的电流检测电阻和NCP 12700芯片cs引脚的R10，C22前沿消隐滤波单元对原边峰值电流进行控制，若输出电流超过一定电流将导致过功率触发，进而对应原边过功率触发，形成输出过流保护功能。
6.输出电压设定单元
通过adum4190ep内置的基准电压结合外部输出电压调节电阻R32和R8电阻进行输出电压的精准电压调控。
7.输出过压保护单元
通过与副边变压器绕组等匝比的辅助绕组进行输出电压的等比例转化，进而在限流电阻R9后连接稳压二极管进行输出过压保护。
8.欠压保护单元。
通过NCP 12700芯片uvlo引脚与外部欠压分压电阻网络进行输入欠压保护功能的调控，R11,R13,R19三个欠压设定电阻分别为64.5k，10k，7.5k设定输入欠压保护点大致为7.3v。
9.使能，频率控制单元
通过NCP 12700芯片频率引脚和NCP 12700芯片频率设定电阻37k设定震荡频率为270khz,通过NCP 12700芯片使能控制引脚单独引出，接高电平或悬空正常输出，接低电平控制输出。
10.过应力保护单元
通过NCP 12700芯片内部软启动单元和外部软启动电容C8对PWM占空比进行逐渐调控，避免上电初期的过冲和浪涌电流。通过RCD嵌位保护网络将漏感能量吸收到嵌位电容，再转移到电阻将多余能量消耗掉，避免mosfet的过应力，副边通过rc网络对二极管进行电压应力的保护，优化了器件选型的范围。
通过设置一种磁隔离型超薄dc-dc变换器，该变换器包括脉冲宽度调制PWM控制单元，输出过压保护单元，过流过功率保护单元，欠压保护单元，反馈控制单元，供电单元，过应力保护单元，平面变压器单元；所述PWM控制单元内置有低压差线性稳压器IDO。降低了变换器的复杂度，提高了变压器电源的稳定性。
另外，通过设置包括磁心和绕组的开关电源用平面变压器，其中绕组包括原边绕组、副边绕组和辅助供电绕组；所述磁心嵌入安装在PCB板的开槽中，所述磁心的磁心柱穿过所述PCB板；也即通过将磁心形成在PCB板中，磁心柱穿过PCB板；解决了现有技术中变压器体积大的问题，达到了变压器平面化，小型化，超薄化的效果。多层PCB上的铜皮作为变压器的原边和副边，增加电流传输能力同时提供散热。
以上所述实施例的各技术特征可以进行任意的组合，为使描述简洁，未对上述实施例中的各个技术特征所有可能的组合都进行描述，然而，只要这些技术特征的组合不存在矛盾，都应当认为是本说明书记载的范围。
以上所述实施例仅表达了本申请的几种实施方式，其描述较为具体和详细，但并不能因此而理解为对发明专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本申请构思的前提下，还可以做出若干变形和改进，这些都属于本申请的保护范围。因此，本申请专利的保护范围应以所附权利要求为准。

Claims (5)

1.一种磁隔离型超薄dc-dc变换器，其特征在于，所述变换器包括：脉冲宽度调制PWM控制单元，输出过压保护单元，过流过功率保护单元，欠压保护单元，反馈控制单元，供电单元，过应力保护单元，平面变压器单元；
所述PWM控制单元内置有低压差线性稳压器IDO。
2.根据权利要求1所述的变换器，其特征在于，所述反馈控制单元由adum4130ep和外围环路补偿阻容结合供电储能滤波电容和上拉电阻进行输出电压的反馈。
3.根据权利要求1所述的变换器，其特征在于，所述供电单元通过变压器的辅助供电绕组和外围分离元器件构成的低压差线性稳压器IDO进行小电压范围的稳定电压供电。
4.根据权利要求1所述的变换器，其特征在于，所述欠压保护单元包括3个欠压设定电阻。
5.根据权利要求1所述的变换器，其特征在于，所述平面变压器单元包括磁心和绕组，所述绕组包括原边绕组、副边绕组和辅助供电绕组；所述磁心嵌入安装在印制电路PCB板的开槽中，所述磁心的磁心柱穿过所述PCB板。
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