BUCK CONVERTER

DES I G N
s
Calculation

Simulations
 PART 1A: Open-Loop – Calculations
Outline
1. Buck Converter Circuit
 PART 3: Component Selection
2. Specifications
3. Component Values  PART 4: PCB Design in Altium
4. Component Ratings
 PART 5: Software for Controller
 PART 1B: Open-Loop – Simulations
1. Simulations  PART 6: Mounting & Soldering
a. TINA-TI Spice
b. MATLAB/Simulink  PART 7: Testing & Verification
2. Fine Tuning

 PART 2A: Controller Design – Calculations

1. Stable Loop Transfer
2. Selecting Phase Margin
3. Controller Circuit Design

 PART 2A: Controller Design – Simulations

1. Simulations
a. TINA-TI Spice
b. MATLAB/Simulink
2. Fine Tuning
 PART 1A:
Calculations
3
 1. Introduction
 Linear Voltage Regulator
 Output voltage regulated by adjusting the transistor base current
 Power absorbed by the load
 Power dissipates by the transistor
 Inefficient  Transistor dissipates too much power.

 Switching Voltage Regulator

𝑡 𝑜𝑛 𝑡 𝑜𝑛
 Duty Cycle: 𝐷 = ¿
𝑡 𝑜𝑛 +𝑡 𝑜𝑓𝑓 𝑇
 Average Output Voltage:
𝑇
1
𝑉 𝑜= ∫ 𝑣 𝑜 ( 𝑡 ) 𝑑𝑡
𝑇 0 ¿0
(∫ )
𝐷𝑇 𝑇
1
𝑉 𝑜= 𝑣 𝑜 (𝑡 ) 𝑑𝑡 + ∫ 𝑣 𝑜 ( 𝑡 ) 𝑑𝑡
𝑇 0 𝐷𝑇

𝐷𝑇 𝐷𝑇
1 1
𝑉 𝑜= ∫ 𝑣 𝑜 ( 𝑡 ) 𝑑𝑡¿
𝑇 0 𝑇
∫ 𝑉𝑠𝑡 𝑉 𝑜= 𝐷𝑉 𝑠
0
 2. Buck Converter
 Voltage-Current Relationship
 Inductor Current: 𝑖 𝐿 (𝑡 +𝑇 )=𝑖 𝐿 (𝑡 )
𝑡 +𝑇

 Average Inductor Voltage: 𝑉 𝐿 =0⇒ 𝑉 𝐿 = 1 ∫ 𝑣 𝐿 ( 𝜏 ) 𝑑 𝜏 =0

𝑇 𝑡
𝑡 +𝑇
1
 Average Capacitor Current: 𝐼 𝐶 =0⇒ 𝐼 𝐶 =
𝑇
∫ 𝑖𝐶 (𝜏 ) 𝑑 𝜏= 0
CLOSED
𝑡

 Switching Analysis
𝑑 𝑖 𝐿 𝑑 𝑖 𝐿 𝑉 𝑠 −𝑉 𝑜 ∆ 𝑖 𝐿 ∆ 𝑖𝐿 𝑉 𝑠 − 𝑉 𝑜
 Switch CLOSED: 𝑣 𝐿 =𝑉 𝑠 −𝑉 𝑜= 𝐿 𝑑𝑡
⇒
𝑑𝑡
=
𝐿
⇒ =
∆ 𝑡 𝐷𝑇
=
𝐿
𝑉 𝑠− 𝑉 𝑜
∆ 𝑖 𝐿 ,𝑐𝑙𝑜𝑠𝑒𝑑 = 𝐷𝑇
𝐿
OPEN
𝑑 𝑖 𝐿 𝑑 𝑖 𝐿 −𝑉 𝑜 ∆ 𝑖 𝐿 ∆ 𝑖𝐿 −𝑉 𝑜
 Switch OPEN: 𝑣 𝐿 =−𝑉 𝑜= 𝐿 ⇒ = ⇒ = =
𝑑𝑡 𝑑𝑡 𝐿 ∆ 𝑡 (1 − 𝐷 )𝑇 𝐿
−𝑉 𝑜
∆ 𝑖 𝐿 ,𝑜𝑝𝑒𝑛= ( 1− 𝐷 ) 𝑇
𝐿
 2. Buck Converter
Inductor Voltage
 Switching Analysis
 Switch CLOSED:
𝑉 𝑠− 𝑉 𝑜
∆ 𝑖 𝐿 ,𝑐𝑙𝑜𝑠𝑒𝑑 = 𝐷𝑇
𝐿
 Switch OPEN: CLOSED
Inductor Current
−𝑉 𝑜
∆ 𝑖 𝐿 ,𝑜𝑝𝑒𝑛= ( 1− 𝐷 ) 𝑇
𝐿
At steady-state:
∆ 𝑖 𝐿 ,𝑐𝑙𝑜𝑠𝑒𝑑 +∆ 𝑖 𝐿, 𝑜𝑝𝑒𝑛=0
𝑉 𝑠 −𝑉 𝑜 −𝑉 𝑜 OPEN
𝐷𝑇 + (1 − 𝐷 ) 𝑇=0 Capacitor Current
𝐿 𝐿
( 𝑉 𝑠 − 𝑉 𝑜 ) 𝐷− 𝑉 𝑜 (1− 𝐷)=0
𝑉 𝑜= 𝐷𝑉 𝑠
 2. Buck Converter
𝐼 𝐶 =0 Inductor Voltage
 Circuit Equations
𝑉𝑜 1
𝑡+ 𝑇

 Load Current at Steady-State:𝐼 𝐿 =𝐼 𝑜=

𝑅
𝐼 𝐶=
𝑇
∫ 𝑖 𝐶 ( 𝜏 ) 𝑑 𝜏 =0
𝑡
 Peak-Peak Inductor Current:
𝑉 𝑜(1 − 𝐷 )𝑇 𝑉 𝑜 (1 − 𝐷) 𝑉 𝑠− 𝑉 𝑜
∆ 𝑖 𝐿= = ∆ 𝑖 𝐿 ,𝑐𝑙𝑜𝑠𝑒𝑑 = 𝐷𝑇
𝐿 𝐿𝑓𝑠 𝐿
Inductor Current
 Maximum Inductor Current: −𝑉 𝑜
∆ 𝑖𝐿 𝑉 𝑜 𝑉 𝑜 ( 1 − 𝐷 ) 1 ∆ 𝑖 𝐿 ,𝑜𝑝𝑒𝑛= ( 1− 𝐷 ) 𝑇
𝐼 𝑚𝑎𝑥 =𝐼 𝐿 + = + 𝑓 𝑠= 𝐿
2 𝑅 2𝐿𝑓𝑠 𝑇
 Minimum Inductor Current:
∆ 𝑖 𝐿 𝑉 𝑜 𝑉 𝑜 ( 1− 𝐷 )
𝐼 𝑚𝑖𝑛 =𝐼 𝐿 − = −
2 𝑅 2𝐿𝑓 𝑠 Continuous
Current Mode Capacitor Current
 Conduction Mode
𝑉 𝑜 𝑉 𝑜(1 − 𝐷 ) (1 − 𝐷 ) 𝑅 (1 − 𝐷 ) 𝑅
𝐼 𝑚𝑖𝑛 =0 ⇒ − ⇒
=0 𝐿= ≡ 𝐿𝑚𝑖𝑛 𝑚𝑖𝑛
𝐿 =
𝑅 2𝐿𝑓𝑠 2𝑓 𝑠 2𝑓 𝑠
 2. Buck Converter
Capacitor Current

 Output Voltage Ripple

 Capacitor Current:𝑖𝐶 =𝑖𝐿 − 𝑖𝑜
 Capacitor Charge: 𝑄=𝐶 𝑉 𝑜

 Change in the Capacitor Charge:

1 𝑇 ∆ 𝑖 𝐿∆ 𝑖 𝐿 𝑇 ∆ 𝑖 𝐿
∆ 𝑄=𝐶 ∆𝑉 𝑜 ∆ 𝑄= ⋅ ⋅ ¿ ¿ Output Voltage
2 2 2 8 8𝑓𝑠

 Change in the Output Voltage:

∆ 𝑖𝐿
∆ 𝑄 8 𝑓 𝑠 ∆ 𝑖𝐿 𝑉 𝑜(1 − 𝐷 )
∆ 𝑉 𝑜= ¿ ¿ ∆ 𝑖 𝐿=
𝐶 𝐶 8𝐶 𝑓 𝑠 𝐿𝑓𝑠
𝑉 𝑜 (1 − 𝐷 )
𝐿 𝑓 𝑠 𝑉 𝑜(1 − 𝐷 ) ∆𝑉𝑜 1− 𝐷 1− 𝐷
∆ 𝑉 𝑜= ¿ = 𝐶=
8 𝐶 𝑓 𝑠 8 𝐿𝐶 𝑓 𝑠
2
𝑉 𝑜 8 𝐿𝐶 𝑓 2𝑠 ∆𝑉𝑜 2
8𝐿 𝑓𝑠
𝑉𝑜
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage
Solution:  Calculations
𝑉 𝑜 15
 Duty Cycle:𝐷= = =0.25  Switching Frequency:𝑓 𝑠=100 kHz(selected)
𝑉 𝑆 60
 Peak-Peak Inductor Current:∆ 𝑖 𝐿 =0.2 ⋅ 𝐼 𝑜=0.4 A (selected inductor ripple current
is 20% of the output current)
𝑉 𝑜 ( 1 − 𝐷 ) 15 ⋅ (1 − 0.25 )
 Inductor: 𝐿= = =281 μH Select:
∆ 𝑖𝐿 𝑓 𝑠 0.4 ⋅ 10 5
Inductor Voltage
𝑉 𝑜 ( 1 − 𝐷 ) 15 ⋅ (1 − 0.25 )
Recalculate the new peak-peak inductor current:∆ 𝑖 𝐿 = = =0.375 A
𝐿𝑓𝑠 300 ⋅ 10 −6 ⋅ 105
∆ 𝑖𝐿 0.375
 Maximum inductor current: 𝐼 𝐿 ,𝑚𝑎𝑥 =𝐼 𝐿 + =2+ =2.188 A
2 2
∆ 𝑖𝐿 0.375
 Minimum inductor current: 𝐼 𝐿 ,𝑚𝑖𝑛 =𝐼 𝐿 − =2 − =1. 81¿30AA Continuous
2 2 Current

√ ( ) √
2 Mode

( )
2 ∆𝑖 𝐿 /2 0.375/2
2
2
 RMS inductor current:𝐼 𝐿 , 𝑅𝑀𝑆 = 𝐼 + = 2+ =2.003 A Inductor Current
𝐿
√3 √3
1− 𝐷 1 − 0.25 Select:
𝐶
 Capacitor: = = =3.125 μF
¿ 𝐶 𝑚𝑖𝑛
( )
5 2
∆ 𝑉𝑜 8 ⋅ 300 ⋅ 10 ⋅ 0.01 ⋅ ( 10 )
−6
2
8𝐿 𝑓𝑠
𝑉𝑜
 Maximum allowed ESR: ∆ 𝑉 𝑜 =0.01 𝑉 𝑜=0.01 ⋅15=0.15 V∆ 𝑉 𝑜 =𝑟 𝐶 ∆ 𝑖𝐶 =𝑟 𝐶 ∆ 𝑖𝐿
 RMS capacitor current:
∆ 𝑉 𝑜 ∆ 𝑉 𝑜 0.15

√ √
𝑟𝐶= = = =0.4 Ω
( )
2

( )
2 ∆ 𝑖 𝐿 /2 2 0.375/2
2
∆ 𝑖𝐶 ∆ 𝑖𝐿 0.375 Capacitor Current
𝐼 𝐶 , 𝑅𝑀𝑆= 𝐼 𝐶 + = 0+ =0.1083 A
√3 √3
𝑉 𝑜 15
 Load Resistor:𝑅= = =7.5 Ω Minimum Allowed Load Resistor
𝐼𝑜 2
 PART 1B:
Simulations
MATLAB/Simulink
10
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage

Solution:  Simulations – Simulink Circuit

Inductor Voltage

Inductor Current

Capacitor Current

𝑓 𝑠=100 kHz ∆ 𝑉 𝑜 =0.15 V

𝐿=300 μH 𝐼𝐼𝐿 ,𝑚𝑎𝑥 =2.188 A
=1.813 A
𝐶=3.125 μF 𝐿∆,𝑚𝑖𝑛 𝑖 𝐿 =0.375 A
𝑅=7.5 Ω 𝐼 =2.003 A
𝑟 𝐶 =0.4 Ω 𝐿 , 𝑅𝑀𝑆
𝐼 𝐶 , 𝑅𝑀𝑆=0. 1083 A
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage

Solution:  Simulations – Steady-State Values for Output Voltage & Output Current

Inductor Voltage

Inductor Current

𝐼 𝑜=2.001 A Capacitor Current

𝑓 𝑠=100 kHz ∆ 𝑉 𝑜 =0.15 V

𝑉 𝑜=15.04 V 𝐿=300 μH 𝐼𝐼𝐿 ,𝑚𝑎𝑥 =2.188 A
=1.813 A
𝐶=3.125 μF 𝐿∆,𝑚𝑖𝑛 𝑖 𝐿 =0.375 A
𝑅=7.5 Ω 𝐼 =2.003 A
𝑟 𝐶 =0.4 Ω 𝐿 , 𝑅𝑀𝑆
𝐼 𝐶 , 𝑅𝑀𝑆=0. 1083 A
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage

Solution:  Simulations – Peak-Peak Inductor Current

𝐼 𝐿 ,𝑚𝑎𝑥 =2.193 A
Inductor Voltage
∆ 𝑖 𝐿 =0.3737 A

𝐼 𝐿 ,𝑚𝑖𝑛 =1.819 A
Inductor Current

Capacitor Current

𝑓 𝑠=100 kHz ∆ 𝑉 𝑜 =0.15 V

𝐿=300 μH 𝐼𝐼𝐿 ,𝑚𝑎𝑥 =2.188 A
=1.813 A
𝐶=3.125 μF 𝐿∆,𝑚𝑖𝑛 𝑖 𝐿 =0.375 A
𝑅=7.5 Ω 𝐼 =2.003 A
𝑟 𝐶 =0.4 Ω 𝐿 , 𝑅𝑀𝑆
𝐼 𝐶 , 𝑅𝑀𝑆=0. 1083 A
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage
𝑉 𝐿 ,𝑚𝑎𝑥 =𝑉 𝑠 − 𝑉 𝑜=60 − 15=45 V
Solution:  Simulations – Peak-Peak Inductor Voltage
𝑉 𝐿 ,𝑚𝑖𝑛 =− 𝑉 𝑜=−15V

Inductor Voltage

𝑉 𝐿 ,𝑚𝑎𝑥 =45.04 V
Inductor Current

𝑉 𝐿 ,𝑚𝑖𝑛 =− 15.10 V
Capacitor Current

𝑓 𝑠=100 kHz ∆ 𝑉 𝑜 =0.15 V

𝐿=300 μH 𝐼𝐼𝐿 ,𝑚𝑎𝑥 =2.188 A
=1.813 A
𝐶=3.125 μF 𝐿∆,𝑚𝑖𝑛 𝑖 𝐿 =0.375 A
𝑅=7.5 Ω 𝐼 =2.003 A
𝑟 𝐶 =0.4 Ω 𝐿 , 𝑅𝑀𝑆
𝐼 𝐶 , 𝑅𝑀𝑆=0. 1083 A
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage

Solution:  Simulations – Peak-Peak Load Voltage

Inductor Voltage

Inductor Current

Capacitor Current

𝑉 𝑜 ,𝑚𝑎𝑥 =15.11V ∆ 𝑉 𝑜 =0.15 V

𝑓 𝑠=100 kHz
∆ 𝑉 𝑜 =0.1498 V 𝐿=300 μH 𝐼𝐼𝐿 ,𝑚𝑎𝑥 =2.188 A
=1.813 A
𝐶=3.125 μF 𝐿∆,𝑚𝑖𝑛 𝑖 𝐿 =0.375 A
𝑉 𝑜 ,𝑚𝑖𝑛 =14.96 V 𝑅=7.5 Ω 𝐼 =2.003 A
𝑟 𝐶 =0.4 Ω 𝐿 , 𝑅𝑀𝑆
𝐼 𝐶 , 𝑅𝑀𝑆=0. 1083 A
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage

Solution:  Simulations – Peak-Peak Load Current

Inductor Voltage

Inductor Current

𝐼 𝑜 ,𝑚𝑎𝑥 =2.014 A
Capacitor Current
∆ 𝐼 𝑜 =0.01997 A

𝐼 𝑜 ,𝑚𝑖𝑛 =1.994 A
𝑓 𝑠=100 kHz ∆ 𝑉 𝑜 =0.15 V
𝐿=300 μH 𝐼𝐼𝐿 ,𝑚𝑎𝑥 =2.188 A
=1.813 A
𝐶=3.125 μF 𝐿∆,𝑚𝑖𝑛 𝑖 𝐿 =0.375 A
𝑅=7.5 Ω 𝐼 =2.003 A
𝑟 𝐶 =0.4 Ω 𝐿 , 𝑅𝑀𝑆
𝐼 𝐶 , 𝑅𝑀𝑆=0. 1083 A
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage

Solution:  Simulations – Peak-Peak Capacitor Current

Inductor Voltage

Inductor Current

Capacitor Current

𝑓 𝑠=100 kHz ∆ 𝑉 𝑜 =0.15 V

𝐿=300 μH 𝐼𝐼𝐿 ,𝑚𝑎𝑥 =2.188 A
=1.813 A
𝐶=3.125 μF 𝐿∆,𝑚𝑖𝑛 𝑖 𝐿 =0.375 A
𝐼 𝐶 ,𝑚𝑎𝑥 =0.1934 A 𝑅=7.5 Ω 𝐼 =2.003 A
𝑟 𝐶 =0.4 Ω 𝐿 , 𝑅𝑀𝑆
𝐼 𝐶 , 𝑅𝑀𝑆=0. 1083 A
∆ 𝑖 𝐶 =0.3725 A
𝐼 𝐶 ,𝑚𝑖𝑛 =− 0.1791 A
 PART 1B:
Simulations
TINA-TI Spice
18
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage

Solution:  Simulations – Steady-State Values for Output Voltage & Output Current

Inductor Voltage

Inductor Current

Capacitor Current

𝑓 𝑠=100 kHz ∆ 𝑉 𝑜 =0.15 V

𝐿=300 μH 𝐼𝐼𝐿 ,𝑚𝑎𝑥 =2.188 A
=1.813 A
𝐶=3.125 μF 𝐿∆,𝑚𝑖𝑛 𝑖 𝐿 =0.375 A
𝑅=7.5 Ω 𝐼 =2.003 A
𝑟 𝐶 =0.4 Ω 𝐿 , 𝑅𝑀𝑆
𝐼 𝐶 , 𝑅𝑀𝑆=0. 1083 A
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage

Solution:  Simulations – Original Design: Peak-Peak Output Voltage

Inductor Voltage

Inductor Current

Capacitor Current

𝑓 𝑠=100 kHz ∆ 𝑉 𝑜 =0.15 V

∆ 𝑉 𝑜 =610 m V 𝐿=300 μH 𝐼𝐼𝐿 ,𝑚𝑎𝑥 =2.188 A
=1.813 A
𝐶=3.125 μF 𝐿∆,𝑚𝑖𝑛 𝑖 𝐿 =0.375 A
𝑅=7.5 Ω 𝐼 =2.003 A
𝑟 𝐶 =0.4 Ω 𝐿 , 𝑅𝑀𝑆
𝐼 𝐶 , 𝑅𝑀𝑆=0. 1083 A
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage

Solution:  Simulations – Tuning Attempt 1  C = 10 μF: Peak-Peak Output Voltage

Inductor Voltage

Inductor Current

Capacitor Current

𝑓 𝑠=100 kHz ∆ 𝑉 𝑜 =0.15 V

∆ 𝑉 𝑜 =215 m V 𝐿=300 μH 𝐼𝐼𝐿 ,𝑚𝑎𝑥 =2.188 A
=1.813 A
𝐶=3.125 μF 𝐿∆,𝑚𝑖𝑛 𝑖 𝐿 =0.375 A
𝑅=7.5 Ω 𝐼 =2.003 A
𝑟 𝐶 =0.4 Ω 𝐿 , 𝑅𝑀𝑆
𝐼 𝐶 , 𝑅𝑀𝑆=0. 1083 A
Objective: Design the buck converter circuit such that:
 Output voltage  DC input voltage
 Output current
 Maximum percentage peak-peak output ripple voltage

Solution:  Simulations – Tuning Attempt 2  C = 20 μF: Peak-Peak Output Voltage

Inductor Voltage

Inductor Current

Capacitor Current

𝑓 𝑠=100 kHz ∆ 𝑉 𝑜 =0.15 V

∆ 𝑉 𝑜 =99 m V
𝐿=300 μH 𝐼𝐼𝐿 ,𝑚𝑎𝑥 =2.188 A
=1.813 A
𝐶=3.125 μF 𝐿∆,𝑚𝑖𝑛 𝑖 𝐿 =0.375 A
𝑅=7.5 Ω 𝐼 =2.003 A
𝑟 𝐶 =0.4 Ω 𝐿 , 𝑅𝑀𝑆
𝐼 𝐶 , 𝑅𝑀𝑆=0. 1083 A
 PART 2A:
CONTROLLER
DESIGN
23
 PART 2B:
SIMULATIONS
24