ElectronicDesign 28749促销图甲板电压喂半桥检查图

巧妙的电压喂养的半桥转换器体系结构

2019年9月19日
If push (or push-pull) comes to shove, you can put the buck regulator on the bottom of a cascaded converter design.

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Design engineers often turn to push-pull, half-bridge, and full-bridge power-converter designs for higher power output.These architectures从200 W到500 W及以后出现。当空间或重量是约束时,使用也可能有意义a cascaded converter,如果降压器调节器将电压施加到这些架构进行调节的情况下。这意味着您将功率变压器设置为使用50%的占空比 - 这是一个简单的DC-DC变压器,没有脉冲宽度调制(PWM)。

由于变压器以50%的占空比工作,因此您可以最大程度地减少其重量和尺寸。宽敞的占空比可能使您可以使用开关频率和磁性材料,这些频率和磁性材料也可以减轻体重,尺寸和成本。在减少变压器的大小方面,推扣架构没有太大的意义。它缺乏半和全桥设计的绕组效率,有时称为铜效率。采用推拉设计,您只在任何给定时间都使用一半的主要绕组。两个线圈用于逆转芯中的磁通量,而不是通过逆转施加的电压来逆转单个线圈中的电流。

半桥与全桥

使用半或全桥设计之间存在权衡。半桥可能具有更高的计算可靠性,因为电容器的评分比主动设备的额定值更好。它也将具有更简单的控制方案,因为您只需要驱动两个晶体管即可。这两个电容器将比全桥设计中的两个晶体管便宜。对于军事规格(MIL-SPEC)设计,成本差异可能很大。

您可以设置一个全桥以进行电流喂养。这意味着BUCD预调节器没有输出电容器。这意味着您需要确保桥梁激发周期中没有死时间。实际上,您必须确保重叠,以便从雄鹿调节器中的电流可以在切换周期中始终出现。

当前喂养的全桥驱动波形中的重叠使您可以从转换器的输出中删除任何过滤器感应器。这意味着多输出设计中将有很好的交叉调节。它还给出输出非常好的瞬态响应,因为缺乏输出电感器意味着所有输出上的所有电容器都将有助于抵消任何一个输出上的瞬态事件。

对于低功率输出,您可能侥幸no output inductors on a half-bridge design. You have to examine the ripple currents you will get in the output capacitors, and the subsequent ripple voltage that appears in the regulated voltage. Because one leg in a half-bridge is formed by two capacitors, it’s always a voltage-fed design. The capacitors that form the half-bridge will also be output capacitors for the buck pre-regulator(Fig. 1)

1.您可以用雄鹿调节器喂食半桥转换器,以制造电压喂养的半桥转换器。(由鲍勃Belland Texas Instruments)

半桥的优势

半桥的一个优点是,与推扣设计相比,主要侧晶体管仅暴露于一半的电压。这意味着您可以使用较低的抗抗性的较便宜的晶体管。形成桥梁一条腿的电容器意味着没有直流电流可以将核心中的磁通插入直至饱和。电容器还意味着只有太多的能量以至于FET必须承受。这可以使半桥比全桥更强大。

一个现实世界的示例

I was exposed to the voltage-fed half-bridge cascaded converter when I worked on a power supply for the radar jamming pod in anF-16战斗机(Fig. 2)。这是1990年代的合格的零件清单,(QPL),但是设备的电压和当前评级不及今天的好。

2. This voltage-fed half-bridge puts the buck regulator on the bottom to simplify the control and grounding scheme. The transformers are drawn to simplify the schematic, with dotted lines indicating a shared core.

该设计的一个有趣的方面是,降压器的调节器位于级联的低端。这意味着降压器控制芯片被称为供应的公共导轨,并且可以直接驱动N通道FET。我不能声称我发明了这个;我继承了设计,尽管它无法正常工作。我认为无需更改架构。我只需要尺寸尺寸,添加一些功能,然后获得完善的循环的补偿。

The design did not have to drop the incoming 265-V dc bus to start up. The startup was made easier by an external 15-V supply that came into the circuit board. It powered a simple oscillator that drove a transformer coil at 50% duty cycle. The secondary of that transformer, T1, would provide isolated drive to the gates of the half-bridge. It also had a startup coil that would power the control logic for the buck regulator. Once the supply came up, the startup power was overridden by power from the secondary of the main transformer, T2.

The startup power signal was also used to synchronize the buck section with the half-bridge. The running power from the main transformer T2 was used as the feedback to the buck-regulator chip. Since the outputs cross-regulate well, it was acceptable to just regulate the supply based on this sense coil output. The output of the supply was a two-phase, 90-V ac power rail, as well as ±15 V ac, ±15 V dc, and linear post regulators for a precise ±5 V dc.

如三个原理图符号所示,降压调节器的共同是从传入的265-V DC共同分离为265-V DC公共,而电源的输出则引用了底盘接地。“跑步能力”辅助线圈被引用为降压调节器公共。请注意,雄鹿调节器的自由向二极管正在返回高方向电源轨。这意味着开关节点上的晶体管必须承受总线电压。

示意图

I regret to say I did the schematics in PADS, but the 1993 version I used will not open in the freeMentor Graphics PADS viewer。我确实发现DWG格式画的示意图(图3),但不能保证是正确的,因为它不是推动板设计的垫子文档。因为这是MIL规格的设计,所以所有组件都是密封的。设计的一个非常好的功能是,雄鹿和半桥部分都使用相同的控制芯片UC1526A, the Unitrode chip now made byTexas Instruments。Not only did the control chip have to be in a hermetic ceramic DIP package, it also had to be available in mil-spec screening.

3.详细的示意图揭示了设计可以为雄鹿和半桥部分使用相同的控制芯片和晶体管。请注意,输入功率,控制功率和底盘的独特地面符号。

次级进料的反馈是由R5,R6和R7形成的电压分隔器,因此技术人员可以调整输出以提供精确的输出电压。由于这种设计是针对外国政府拥有的战斗机,因此该硬件没有被分类。但是,这些规格已分类,因此我觉得我可以说出输出电流等,即使我可以在某个地方找到这些规格。您可以从降压器上的两个FET中推断出功率。控制IC并行驱动两个,因此每个FET上的功率都减半。

如您所料,2N6802 FET具有500-V的分解额定值。这为切换265-V总线提供了足够的利润和提高的可靠性。FET的评分为2.5-A,因此告诉我供应的功能很容易超过200W。就像将相同的控制ICS用于Buck和Half-Bridge一样,设计也使用相同的FET。

There are 22-Ω resistors in the gate feeds of each transistor to prevent oscillations and add damping. This slows down the turn-on and turn-off, so it will increase switching losses. It will also reduce electromagnetic interference (EMI), although there are no FCC standards required for military electronics.

小尺寸和低体重

The design ended up fitting on a 3.3- by 3.6-in. circuit card(图4)。因为这是飞行硬件必须达到70,000英尺的高度,所以所有组件下都有一个铝制热框到达最大65°C的液冷冷板。这使得组件相当间隔,这导致了与希望进行热框架图纸变得简单的机械工程师的战斗,而不是将组件放置在最高电感的位置。

4.电压喂养的半桥转换器适合3.3 x 3.5英寸。电路卡组件(CCA)。

执行MIL-SPEC文档是学习正确方法来记录设计的好方法。这个数字是组装图的一部分,其中包含所有符合飞行准备硬件所需的符号和修订控制。

Military contractors were also pioneering the use of 3D design back in 1993(图5)。我们使用了我在AutoCAD中制作的3D图纸来确保所有电路板都正确地融合在一起。您可以看到主变压器的大小,以了解该板可以提供的功率。它看起来有点超过一英寸。半桥转换器的好处在于,它们可以完全利用主要绕组,这与在任何给定时间只能使用一半的推扣不同。推扣也使桥晶体管上的压力增加了一倍。推扣就像一个摇摇欲坠。当一个晶体管将其主要腿向下拉下来时,另一只主要腿的波动在动力导轨上方一样高。

5. A 3D view of the voltage-fed half-bridge converter helps integrate it into the mechanical design, as well as allowing you to see the compact size and low weight needed in an F-16 fighter jet. The blue component is an aluminum heat frame that carries heat to the gray side clamps on the board assembly.

You could improve a modern design with much smaller surface-mount components. TheTO-39金属罐晶体管可以在陶瓷豆。If you don’t need hermaticity, then you have even more choices. The clever “upside-down” architecture might not be as clever these days, since there are so many gate-driver chips and isolation chips available(图1,再次)。不过,如果这些新零件不可用,那么这种聪明的设计可能会使您摆脱困境。

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