Switched-mode power supply

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For other uses, see Switch (disambiguation).
Interior view of an ATX switched-mode power supply:
A - bridge rectifier
B - Input filter capacitors
C - Transformer
D - output filter coil
E - output filter capacitors
A switching-mode power supply for laboratory use

A switched-mode power supply (also switching-mode power supply and SMPS) is an electronic power supply unit (PSU) that incorporates a switching regulator. While a linear regulator maintains the desired output voltage by dissipating excess power in a pass power transistor, the switched-mode power supply switches a power transistor between saturation (full on) and cutoff (completely off) with a variable duty cycle whose average is the desired output voltage. It switches at a much-higher frequency (tens to hundreds of kHz) than that of the AC line (mains), which means that the transformer that it feeds can be much smaller than one connected directly to the line/mains. Switching creates a rectangular waveform that typically goes to the primary of the transformer; typically several secondaries feed rectifiers, series inductors, and filter capacitors to provide various DC outputs with low ripple.

The main advantage of this method is greater efficiency because the switching transistor dissipates little power in the saturated state and the off state compared to the semiconducting state (active region). Other advantages include smaller size and lighter weight (from the elimination of low frequency transformers which have a high weight) and lower heat generation due to higher efficiency. Disadvantages include greater complexity, the generation of high amplitude, high frequency energy that the low-pass filter must block to avoid electromagnetic interference (EMI), and a ripple voltage at the switching frequency and the harmonic frequencies thereof.

Contents

[edit] A note about terminology

Although the term "power supply" has been in use since radios were first powered from the line/mains, that does not mean that it is a source of power, in the sense that a battery provides power. It is simply a device that (usually) accepts commercial AC power and provides one or more DC outputs. It would be more correctly referred to as a power converter, but long usage has established the term.

[edit] Classification

SMPS can be classified into four types according to the input and output waveforms:

[edit] SMPS and linear power supply comparison

There are two main types of regulated power supplies available: SMPS and linear. The reasons for choosing one type or the other can be summarized as:

Comparison of a Linear power supply and a switched-mode power supply
Linear power supply Switching power supply Notes
Size and weight If a transformer is used, large due to low operating frequency (mains power frequency is at 50 or 60 Hz). Small if transformerless. Smaller due to higher operating frequency (typically 50 kHz - 1 MHz) A transformer's power handling capacity of given size and weight increases with frequency provided that hysteresis losses can be kept down. Therefore, higher operating frequency means either higher capacity or smaller transformer.
Output voltage With transformer used, any voltages available; if transformerless, not exceeding input. If unregulated, voltage varies significantly with load. Any voltages available. Voltage varies little with load. A SMPS can usually cope with wider variation of input before the output voltage changes.
Efficiency, heat, and power dissipation If regulated, output voltage is regulated by dissipating excess power as heat resulting in a typical efficiency of 30-40%[1]; if unregulated, transformer iron and copper losses significant. Output is regulated using duty cycle control, which draws only the power required by the load. In all SMPS topologies, the transistors are always switched fully on or fully off. The only heat generated is in the non-ideal aspects of the components. Switching losses in the transistors, on-resistance of the switching transistors, equivalent series resistance in the inductor and capacitors, and rectifier voltage drop contribute to a typical efficiency of 60-70%. However, by optimizing SMPS design, the amount of power loss and heat can be minimized; a good design can have an efficiency of 95%.
Complexity Unregulated may be diode and capacitor; regulated has a voltage regulating IC or discrete circuit and a noise filtering capacitor. Consists of a controller IC, one or several power transistors and diodes as well as a power transformer, inductors, and filter capacitors. Multiple voltages can be generated by one transformer core. For this SMPSs have to use duty cycle control. Both need a careful selection of their transformers. Due to the high operating frequencies in SMPSs, the stray inductance and capacitance of the printed circuit board traces become important.
Radio frequency interference No high-frequency interference. Some mains hum induction into unshielded cables, problematical for low-signal audio. EMI/RFI produced due to the current being switched on and off sharply. Therefore, EMI filters and RF shielding are needed to reduce the disruptive interference. Long wires between the components may reduce the high frequency filter efficiency provided by the capacitors at the inlet and outlet.
Electronic noise at the output terminals Unregulated PSUs may have a little AC ripple superimposed upon the DC component at twice mains frequency (100-120 Hz). Can cause audible mains hum in audio equipment or brightness ripples or banded distortions in analog security cameras. Noisier due to the switching frequency of the SMPS. An unfiltered output may cause glitches in digital circuits or noise in audio circuits. This can be suppressed with capacitors and other filtering circuitry in the output stage. With a switched mode PSU the switching frequency can be chosen to keep the noise out of the circuits working frequency band (e.g. for audio systems above the range of human hearing)
Electronic noise at the input terminals Causes harmonic distortion to the input AC, but no high frequency noise. Very low cost SMPS may couple electrical switching noise back onto the mains power line, causing interference with A/V equipment connected to the same phase. Non power-factor-corrected SMPSs also cause harmonic distortion. This can be prevented if a (properly earthed) EMI/RFI filter is connected between the input terminals and the bridge rectifier.
Acoustic noise Faint, usually inaudible mains hum, usually due to vibration of windings in the transformer and/or magnetostriction. Inaudible to humans, unless they have a fan or are unloaded/malfunctioning. The operating frequency of an unloaded SMPS is sometimes in the audible human range.
Power factor Low for a regulated supply because current is drawn from the mains at the peaks of the voltage sinusoid. Ranging from low to medium since a simple SMPS without PFC draws current spikes at the peaks of the AC sinusoid. Active/Passive power factor correction in the SMPS can offset this problem and are even required by some electric regulation authorities, particularly in Europe.
Risk of electric shock Supplies with transformers allow metalwork to be grounded, safely. Dangerous if primary/secondary insulation breaks down, unlikely with reasonable design. Transformerless mains-operated supply dangerous. In both linear and SM the mains, and possibly the output voltages, are hazardous and must be well-isolated. Common rail of equipment (including casing) is energised to half mains voltage, but at high impedance, unless equipment is earthed/grounded or doesn't contain EMI/RFI filtering at the input terminals. Due to regulations concerning EMI/RFI radiation, many SMPS contain EMI/RFI filtering at the input stage before the bridge rectifier consisting of capacitors and inductors. Two capacitors are connected in series with the Live and Neutral rails with the Earth connection in between the two capacitors. This forms a capacitive divider that energises the common rail at half mains voltage. Its high impedance current source can provide a tingling or a 'bite' to the operator or can be exploited to light an Earth Fault LED. However, this current may cause nuisance tripping on the most sensitive residual-current devices.
Risk of equipment damage Very low, unless a short occurs between the primary and secondary windings or the regulator fails by shorting internally. Can fail so as to make output voltage very high. Can in some cases destroy input stages in amplifiers if floating voltage exceeds transistor base-emitter breakdown voltage, causing the transistor's gain to drop and noise levels to increase. [2] Mitigated by good failsafe design. Failure of a component in the SMPS itself can cause further damage to other PSU components; can be difficult to troubleshoot. The floating voltage is caused by capacitors bridging the primary and secondary sides of the power supply. A connection to an earthed equipment will cause a momentary (and potentially destructive) spike in current at the connector as the voltage at the secondary side of the capacitor equalises to earth potential.

[edit] Theory of operation

Block diagram of a mains operated AC-DC SMPS with output voltage regulation

[edit] Input rectifier stage

AC, half-wave and full wave rectified signals

If the SMPS has an AC input, then the first stage is to convert the input to DC. This is called rectification. The rectifier circuit can be configured as a voltage doubler by the addition of a switch operated either manually or automatically. This is a feature of larger supplies to permit operation from nominally 120 volt or 240 volt supplies. The rectifier produces an unregulated DC voltage which is then sent to a large filter capacitor. The current drawn from the mains supply by this rectifier circuit occurs in short pulses around the AC voltage peaks. These pulses have significant high frequency energy which reduces the power factor. Special control techniques can be employed by the following SMPS to force the average input current to follow the sinusoidal shape of the AC input voltage thus the designer should try correcting the power factor. An SMPS with a DC input does not require this stage. An SMPS designed for AC input can often be run from a DC supply (for 230V AC this would be 330V DC), as the DC passes through the rectifier stage unchanged. It's however advisable to consult the manual before trying this, though most supplies are quite capable of such operation even though nothing is mentioned in the documentation. However, this type of use may be harmful to the rectifier stage as it will only utilize half of diodes in the rectifier for the full load. This may result in overheating of these components, and cause them to fail prematurely. [3]

If an input range switch is used, the rectifier stage is usually configured to operate as a voltage doubler when operating on the low voltage (~120 VAC) range and as a straight rectifier when operating on the high voltage (~240 VAC) range. If an input range switch is not used, then a full-wave rectifier is usually used and the downstream inverter stage is simply designed to be flexible enough to accept the wide range of dc voltages that will be produced by the rectifier stage. In higher-power SMPSs, some form of automatic range switching may be used.

[edit] Inverter stage

The inverter stage converts DC, whether directly from the input or from the rectifier stage described above, to AC by running it through a power oscillator, whose output transformer is very small with few windings at a frequency of tens or hundreds of kilohertz (kHz). The frequency is usually chosen to be above 20 kHz, to make it inaudible to humans. The output voltage is optically coupled to the input and thus very tightly controlled. The switching is implemented as a multistage (to achieve high gain) MOSFET amplifier. MOSFETs are a type of transistor with a low on-resistance and a high current-handling capacity. Since only the last stage has a large duty cycle, previous stages can be implemented by bipolar transistors leading to roughly the same efficiency. The second last stage needs to be of a complementary design, where one transistor charges the last MOSFET and another one discharges the MOSFET. A design using a resistor would run idle most of the time and reduce efficiency. All earlier stages do not weight into efficiency because power decreases by a factor of 10 for every stage (going backwards) and thus the earlier stages are responsible for at most 1% of the efficiency. This section refers to the block marked Chopper in the block diagram.

[edit] Voltage converter and output rectifier

If the output is required to be isolated from the input, as is usually the case in mains power supplies, the inverted AC is used to drive the primary winding of a high-frequency transformer. This converts the voltage up or down to the required output level on its secondary winding. The output transformer in the block diagram serves this purpose.

If a DC output is required, the AC output from the transformer is rectified. For output voltages above ten volts or so, ordinary silicon diodes are commonly used. For lower voltages, Schottky diodes are commonly used as the rectifier elements; they have the advantages of faster recovery times than silicon diodes (allowing low-loss operation at higher frequencies) and a lower voltage drop when conducting. For even lower output voltages, MOSFETs may be used as synchronous rectifiers; compared to Schottky diodes, these have even lower conducting state voltage drops.

The rectified output is then smoothed by a filter consisting of inductors and capacitors. For higher switching frequencies, components with lower capacitance and inductance are needed.

Simpler, non-isolated power supplies contain an inductor instead of a transformer. This type includes boost converters, buck converters, and the so called buck-boost converters. These belong to the simplest class of single input, single output converters which utilize one inductor and one active switch. The buck converter reduces the input voltage in direct proportion to the ratio of conductive time to the total switching period, called the duty cycle. For example an ideal buck converter with a 10 V input operating at a 50% duty cycle will produce an average output voltage of 5 V. A feedback control loop is employed to regulate the output voltage by varying the duty cycle to compensate for variations in input voltage. The output voltage of a boost converter is always greater than the input voltage and the buck-boost output voltage is inverted but can be greater than, equal to, or less than the magnitude of its input voltage. There are many variations and extensions to this class of converters but these three form the basis of almost all isolated and non-isolated DC to DC converters. By adding a second inductor the Ćuk and SEPIC converters can be implemented, or, by adding additional active switches, various bridge converters can be realised.

Other types of SMPSs use a capacitor-diode voltage multiplier instead of inductors and transformers. These are mostly used for generating high voltages at low currents (Cockcroft-Walton generator). The low voltage variant is called charge pump.

[edit] Regulation

A feedback circuit monitors the output voltage and compares it with a reference voltage, which is set manually or electronically to the desired output. If there is an error in the output voltage, the feedback circuit compensates by adjusting the timing with which the MOSFETs are switched on and off. This part of the power supply is called the switching regulator. The Chopper controller shown in the block diagram serves this purpose. Depending on design/safety requirements, the controller may or may not contain an isolation mechanism (such as opto-couplers) to isolate it from the DC output. Switching supplies in computers, TVs and VCRs have these opto-couplers to tightly control the output voltage.

Open-loop regulators do not have a feedback circuit. Instead, they rely on feeding a constant voltage to the input of the transformer or inductor, and assume that the output will be correct. Regulated designs work against the parasitic capacity of the transformer or coil, monopolar designs also against the magnetic hysteresis of the core.

The feedback circuit needs power to run before it can generate power, so an additional non-switching power-supply for stand-by is added.

[edit] Transformer design

SMPS transformers run at high frequency. Most of the cost savings (and space savings) in off-line power supplies come from the fact that a high frequency transformer is a lot smaller than the 50/60 Hz transformers used before SMPS.

There are several differences in the design of transformers for 50 Hz vs 500 kHz. Firstly a low frequency transformer usually transfers energy through its core (soft iron), while the (usually ferrite) core of a high frequency transformer limits leakage. Since the waveforms in a SMPS are generally high speed (PWM square waves), the wiring must be capable of supporting high harmonics of the base frequency due to the skin effect, which is a major source of power loss.

[edit] Power factor

Simple off-line switched mode power supplies incorporate a simple full wave rectifier connected to a large energy storing capacitor. Such SMPSs draw current from the AC line in short pulses when the mains instantaneous voltage exceeds the voltage across this capacitor. During the remaining portion of the AC cycle the capacitor provides energy to the power supply.

As a result, the input current of such basic switched mode power supplies has high harmonic content and relatively low power factor. This creates extra load on utility lines, increases heating of the utility transformers and standard AC electric motors, and may cause stability problems in some applications such as in emergency generator systems or aircraft generators. Harmonics can be removed through the use of filter banks but the filtering is expensive, and the power utility may require a business with a very low power factor to purchase and install the filtering onsite.

In 2001 the European Union put into effect the standard IEC/EN61000-3-2 to set limits on the harmonics of the AC input current up to the 40th harmonic for equipment above 75 W. The standard defines four classes of equipment depending on its type and current waveform. The most rigorous limits (class D) are established for personal computers, computer monitors, and TV receivers. In order to comply with these requirements modern switched-mode power supplies normally include an additional power factor correction (PFC) stage.

Putting a current regulated boost chopper stage after the off-line rectifier (to charge the storage capacitor) can help correct the power factor, but increases the complexity (and cost).

[edit] Types

Switched-mode power supplies can be classified according to the circuit topology.

Type[4] Power [Watts] Typical Efficiency Relative cost Input range [Volts] Isolation Energy storage Voltage relation Features
Buck 0–1000 75% 1.0 5–1000* N Single inductor Out < In
Boost 0–150 78% 1.0 5–600* N Single inductor Out > In
Buck-boost 0–150 78% 1.0 5–600* N Single inductor Any inverted Inverted output voltage. Voltage ratio depend on duty cycle.
Split-Pi (Boost-Buck) 0-2000 95% >2.0 10-100 N Two inductors + three capacitors Up or down Bidirectional power control In or Out
Flyback 0–150 78% 1.0 5–600 Y Transformer Up or down Multiple outputs
Half-Forward 0–250 75% 1.2 5-500 Y Transformer + inductor
Forward 78% 60-200 Y Transformer + inductor Any fixed [5] [6] Multiple outputs
Push-Pull 100–1000 72% 1.75 50–1000 Y
Half Bridge 0–500 72% 1.9 50–1000 Y
Full-Bridge 400–2000 69% >2.0 50–1000 Y
Resonant, zero voltage switched >1000 >2.0
Ćuk N Capacitor + two inductors Any inverted Negative voltage for positive input.
Ćuk isolated Y One (pure AC) transformer + two capacitors + two inductors Any Negative or positive voltage output.
Inverting charge-pump (Modified Ćuk) N Single inductor Output voltage negative and higher-magnitude than positive input voltage.
SEPIC N Two inductors Any
Charge pump N Capacitors only Charge pumps used to generate very high voltages are usually called voltage multipliers.
  • Only for non human accessible equipment, otherwise <42.5 V and 8.0 A limit apply for UL, CSA, VDE approval.

[edit] Quasiresonant ZCS/ZVS

A quasiresonant ZCS/ZVS switch (Zero Current/Zero Voltage) is a design where "each switch cycle delivers a quantized 'packet' of energy to the converter output, and switch turn-on and turn-off occurs at zero current and voltage, resulting in an essentially lossless switch." [7]

[edit] Applications

Switched mode mobile phone charger

Switched-mode PSUs in domestic products such as personal computers often have universal inputs, meaning that they can accept power from most mains supplies throughout the world, with rated frequencies from 50 Hz to 60 Hz and voltages from 100 V to 240 V (although a manual voltage range switch may be required). In practice they will operate from a much wider frequency range and often from a DC supply as well. In 2006, at an Intel Developers Forum, Google engineers proposed the use of a single 12 V supply inside PCs, due to the high efficiency of switch mode supplies directly on the PCB. [8]

Most modern desktop and laptop computers already have a DC-DC converter on the motherboard, to step down the voltage from the PSU or the battery to the CPU core voltage, as low as 0.8 V for a low voltage CPU to 1.2-1.5 V for a desktop CPU as of 2007. Most laptop computers also have a DC-AC inverter to step up the voltage from the battery to drive the backlight, typically around 1000 Vrms. [9]

Certain applications, such as in automobile industry and in some industrial settings, DC supply is chosen to avoid hum and interference and ease the integration of capacitors and batteries used to buffer the voltage. Most small aircraft use 28 V DC, but larger aircraft often use 120 V AC at 400 Hz, though they often have a DC bus as well. Some submarines like the Soviet Alfa class submarine utilized two synchronous generators providing a variable three-phase current, 2 x 1500 kW, 400 V, 400 Hz. [10]

In the case of TV sets, for example, one can test the excellent regulation of the power supply by using a variac. For example, in some models made by Philips, the power supply starts when the voltage reaches around 90 volts. From there, one can change the voltage with the variac, and go as low as 40 volts and as high as 260 (known such case that voltage was 360), and the image will show absolutely no alterations.[citation needed]

[edit] Terminology

The term switchmode was widely used until Motorola trademarked SWITCHMODE(TM), for products aimed at the switching-mode power supply market, and started to enforce their trademark.[11] Switching-mode power supply, switching power supply, and switching regulator refer to this type of power supply.[11]

[edit] See also

Energy portal

[edit] External links

[edit] Book references

 This section includes a list of references or external links, but its sources remain unclear because it lacks inline citations. Please improve this article by introducing more precise citations where appropriate. (January 2008)
  • AN19, Application Notes , LT1070 design Manual, an extensive introduction in Buck, Boost, CUK , Inverter application with Integrated circuit. Carl Nelson (download as PDF from http://www.linear.com/designtools/app_notes.jsp)
  • Abraham I. Pressman, Keith Billings, Taylor Morey (2009). Switching Power Supply Design, Third Edition. McGraw-Hill. ISBN 0-07-148272-5.
  • Ned Mohan, Tore M. Undeland, William P. Robbins (2002). Power Electronics : Converters, Applications, and Design. Wiley. ISBN 0-471-22693-9.
  • Muhammad H. Rashid (2003). Power Electronics : Circuits, Devices, and Applications. Prentice Hall. ISBN 0-13-122815-3.
  • Fang Lin Luo, Hong Ye (2004). Advanced DC/DC Converters. CRC Press. ISBN 0-8493-1956-0.
  • Mingliang Liu (2006). Demystifying Switched-Capacitor Circuits. Elsevier. ISBN 0-7506-7907-7.
  • Fang Lin Luo, Hong Ye, Muhammad H. Rashid (2005). Power Digital Power Electronics and Applications. Elsevier. ISBN 0-12-088757-6.
  • Robert W. Erickson & Dragan Maksimovic (2001). Fundamentals of Power Electronics. Second edition. ISBN 0-7923-7270-0.
  • Marty Brown, Power Supply Cookbook. Newnes. 2nd ed 2001. ISBN 0-7506-7329-X.
  • Christophe Basso (2008), Switch-Mode Power Supplies: SPICE Simulations and Practical Designs. McGraw-Hill. ISBN 0071508589.

[edit] References

  1. ^ "Energy Savings Opportunity by Increasing Power Supply Efficiency". http://www.efficientpowersupplies.org/efficiency_opportunities.html. 
  2. ^ "Ban Looms for External Transformers". http://sound.westhost.com/articles/external-psu.htm.  080224 sound.westhost.com
  3. ^ "DC Power Production, Delivery and Utilization, An EPRI White Paper" (PDF). http://mydocs.epri.com/docs/CorporateDocuments/WhitePapers/EPRI_DCpower_June2006.pdf.  Page 9 080317 mydocs.epri.com
  4. ^ ON Semiconductor (July 11, 2002). "SWITCHMODE Power Supplies—Reference Manual and Design Guide" (PDF). http://www.profesores.frc.utn.edu.ar/electronica/ElectronicaAplicadaII/pdfs/SMPSRM-D.pdf. Retrieved on 2008-11-11. 
  5. ^ "DC-DC Converter Basics". http://www.powerdesigners.com/InfoWeb/design_center/articles/DC-DC/converter.shtm.  090112 powerdesigners.com
  6. ^ "DC-DC CONVERTERS: A PRIMER". http://www.jaycar.com.au/images_uploaded/dcdcconv.pdf.  090112 jaycar.com.au Page 4
  7. ^ EDN: Comparing dc/dc converters' noise-related performance
  8. ^ "High-efficiency power supplies for home computers and servers". http://services.google.com/blog_resources/PSU_white_paper.pdf. 
  9. ^ "How to Backlight an LCD - 10/25/2004 - Design News". http://designnews.com/article/CA473494.html.  080224 designnews.com
  10. ^ "705 Alfa class". http://warfare.ru/?catid=306&linkid=1762.  080325 warfare.ru
  11. ^ a b Foutz, Jerrold. "Switching-Mode Power Supply Design Tutorial Introduction". http://www.smpstech.com/tutorial/t01int.htm. Retrieved on 2008-10-06. 
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