Full Digitally Controlled Power Supply Design
Full Digitally Controlled Power Supply Design
Full Digitally Controlled Power Supply Design
Supply design
Olivier Monnier
TI Business Development Manager, C2000 DSP Controllers
Agenda
The Digital Vision: Why DSP?
Software Strategy
Implementation
Next Steps
Agenda
The Digital Vision: Why DSP?
Software Strategy
Next Steps
The Digital Vision
V I V V I V I
Filter V I
PFC DC/DC
Bridge
Output
8 4
5 1
Multi-mode
Interface optional Power control
circuit
Monitor Supervisory
MCU House
(MCU ?) Keeping
Circuits
UART
Aux P/S To Host
Digital approach with Single Device example for AC/DC Rectifier
1000W / 48 V
F2810 DSP based
2 Phase PFC-IL
Phase shifted ZVS-FB
200 KHz PWM (DC/DC)
100 KHz PWM (PFC)
Typical Control System On A Chip
i.e. Buck
Converter
PWM
(DAC function)
Comms
CAN CPU
UART (DSP/uC/RISC)
RX SPI + Control Loop
TX IIC Memory (i.e. PID/IIR)
IIS (FLASH/ROM,
FlexRay RAM)
USB
EMAC
ADC i.e. V
+
High bandwidth Insensitive to environment (temp, drift,)
High resolution High reliability
Easy to understand / use S/w programmable / flexible solution
relatively low cost ?? Precise / predictable behaviour
Advanced control possible (non-linear, multi-
variable)
Can perform multiple loops and other
functions
Component drift and aging / Bandwidth limitations (sampling loop)
unstable PWM frequency and resolution limits
Component tolerances Numerical problems (quantisation,
Hardwired / not flexible
Limited to classical control theory
only
rounding,)
AD / DA boundary (resolution, speed, cost)
CPU performance limitations
?
Large parts count for complex System cost
systems
DSP Controllers value-Proposition
Integration
Flexibility
Ease of differentiation
System cost optimization
Software Strategy
Next Steps
Controller Considerations for Digital
Power Supplies
Ease of Use to r !
r f a c
SW F ea
Reliability
CPU Performance
PWM resolution
Low Interrupt Latency
Fast Sample Rate
Numeric Considerations
Cost
Technical Support
Fully Digital System
Outputs
280x DSP
"DAC"
Buck / Boost
Half bridge
PWM Full bridge / PS
Multi phase IL
Clock speed (MIPs)
Word size (dynamic range)
"A D C "
MAC size (16x16 / 32x32)
Inputs
Large on-chip SRAMs ADC
C / C++ Current
Voltage
Temperature
Resolution
Continually Linearity / Accuracy
Sampling rate (speed)
Improving HV isolation
specs !
Processor capability
# Inst. vs Algorithm
S/W algorithm clks
Controller 26
(2 pole / 2
zero)
Controller 36
(3 pole / 3
zero)
# Instructions vs PWM
PFC current 30
PWM freq. PWM per. Processor MIPS command
(KHz) (uS) 40 100 150
50 20.0 800 2000 3000 PFC OVP 25
100 10.0 400 1000 1500 BiQuad Filter 46
200 5.0 200 500 750
ZVSFB PWM 14
250 4.0 160 400 600
driver
300 3.3 133 333 500
500 2.0 80 200 300 PFC2PHIL PWM 26
750 1.3 53 133 200 driver
1000 1.0 40 100 150
MIPS = Million Instruction Per Second
Typical Power Stage Switching Frequencies
Software Strategy
Next Steps
Digital approach with Single Device example for AC/DC Rectifier
1000W / 48 V
F2810 DSP based
2 Phase PFC-IL
Phase shifted ZVS-FB
200 KHz PWM (DC/DC)
100 KHz PWM (PFC)
Digital Control Design Steps
Choose the topology for each power stage.
Choose the location for the microprocessor: primary side or
secondary side.
Define the gate drive circuits.
Define the ADC signal conditioning circuits.
Choose the configuration of the timing hardware that implements
the PWM signals, ADC strobe and interrupt service routine (ISR)
timing.
Architect the firmware: time critical interrupts versus background
Implement the SW
Closing the loop digitally offers several advantages when bringing
up a system for debug.
Each stage can be enabled separately.
Loops can easily be run open-loop, usually by commenting out a
line of code.
Compensation parameters are quickly changed with a few
keystrokes.
Sophisticated diagnostics are possible, such as a circular buffers or
complex event triggers.
Digital Control Design Steps
Choose the topology for each power stage.
Choose the location for the microprocessor: primary side or
secondary side.
Define the gate drive circuits.
Define the ADC signal conditioning circuits.
Choose the configuration of the timing hardware that implements
the PWM signals, ADC strobe and interrupt service routine (ISR)
timing.
Architect the firmware: time critical interrupts versus background
Implement the SW
Closing the loop digitally offers several advantages when bringing
up a system for debug.
Each stage can be enabled separately.
Loops can easily be run open-loop, usually by commenting out a
line of code.
Compensation parameters are quickly changed with a few
keystrokes.
Sophisticated diagnostics are possible, such as a circular buffers or
complex event triggers.
Agenda
The Digital Vision: Why DSP?
Software Strategy
Next Steps
Software
Modularity, re-use
efficiency
Software - is key in Digital Power !
Module example 1
f(x) = Sin (x)
Single In / Single out
Non-configurable
No History
Multiple Instantiation
Out = Sin (In)
2 of 2
Exploring Modularity
Module example 2
f(x) = mx + b
Single In / Single out
Configurable
m, b, Constant ?
or Variable ?
No History Out = m.In + b
Multiple Instantiation
Module example 3
Single In / Single out
Non-Configurable f(x) = ( xn + xn-1+ xn-2 + xn-3 ) / 4
History
Multiple Instantiation BoxCarAvg
In Out
X(n)
X(n-1)
X(n-2)
X(n-3)
Module Types
Application Indep. / Application Config. / Application Config. /
Peripheral Indep. Peripheral Indep. Peripheral Depend.
(Peripheral Driver)
CNTL
2P2Z
Ref
Out
Fdbk
SinGen
T1
Freq
Out
Gain
Offset
1 of 2
Peripheral Drivers
Depends on:
PWM frequency
System clock frequency
Good choice for addressing many power systems (even complex ones)
Simple to use and understand
Efficient (incurs only 1 ISR context save/restore)
Deterministic (all events synchronous and submultiples of ISR freq.)
High degree of visibility during debug and development
Back-ground loop (BG)
C / C++, large code, complex, feature rich, key customer differentiator
System intelligence / personality, heavy in if then else
Interrupt Service Routine (ISR) Main control loop
lean and mean in-line assembly (ASM) results in a very small footprint.
Typically Math function type code (very few if then else branches or loops)
Once developed, changes very little. Low maintenance burden.
2 of 4
Exploring Ideas / Methods
Number of Instructions / cycles (words)
2. In-line assembly ISR r!
ct o PWM MIPS
fa (KHz) 100 150
How complex ? e ar
F 200 500 750
250 400 600
How much code development ? 300 333 500
How much maintenance burden ? 350 286 429
400 250 375
How wasteful on memory ? 500 200 300
In1A
f1 Out3 = f3( In3A, In3B )
move ? , In1B (2)
call f1 (8)
In1B
Out1
In3A
f3 move ? , In2A
call f2
(2)
(8)
f2 In3B
Out3 move Out1 , In3A (2)
move Out2 , In3B (2)
In2A Out2
call f3 (8)
move Out3 , ? (2)
Pointer based approach
Pseudo code (without macros)
Mem? *In1A
call f1 (8)
*Out1 Mem1
call f2 (8)
Mem? *In1B call f3 (8)
*In3A
*Out3 Mem?
Pseudo code (with macros)
Mem2 *In3B
call f1 (zero)
Mem? *In2A *Out1 call f2 (zero)
call f3 (zero)
4 of 4
Exploring Ideas / Methods
5. Signal Net based module connectivity
PWM1 PWM7
F
I
L
T1 T2
T PWM PWM
E
R PWM2 PWM8
Diode Diode A
IPFC clamp clamp VOUT(P)
IphA IphB
Phase A Phase B
current current
Input Current,
Po = 860W
Input Current,
Po = 580W
DSP Controlled PFC Controller
PFC MOSFETs
Drain-Source Voltages
DC Bus Voltage
Transient Response,
Step load = 250W
DC/DC Stage Transient Response
Software Strategy
Next Steps
2 of 2
Real-Time debug
Software Strategy
Implementation
Next Steps
C2000TM Roadmap
Device
Higher
Production F2812 Performance
Sampling F2811
F2810 C/R2812 C281xTM
Development C/R2811 150 MIPS
C2810 128-256 KB
Future
12.5 MSPS ADC
Performance
F2809 C280xTM
F2808 100 MIPS
F2806 DPS 32-256 KB
F2802 150ps PWM
F2801
C2801
C2802 7 pin-compatible
Lower
Cost devices
C240xTM
10 Devices 40 MIPS
LF/C240xA 16-64 KB
10-bit ADC F = Flash
C = Custom ROM
R = RAM only
Integration
How to get Started today?
High-
Numerous data converter and power management
Performance
Analog products designed for motor control
Third Party
Development boards and emulation tools
Large consultant network
Network Increasing range of application software
TI Provides the Systems Expertise, Silicon, Software and
Support for Control Applications
Systems Expertise
Silicon Software
Digital Software Library
EV
Web casts (PWM) Peripheral
CAN SCI-A/B IQmath Drivers
Workshops
DSP/BIOS
KnowledgeBase
TI Power
Application notes Management
Foundation Software
PC Test
CAN Equipment
Network
Modular Software Development for Digital
Control Systems
Reduces time
Application Specific Systems (ACI, BLDC, PID cntl) to market
Hardware Tools
Modular Libraries (DMC, FFT, Math, Filtersetc)
reuseable
Third Parties
QEP Serial CAP PWM software
PWM ADC04 Speed
Position EEPROM DAC
drv drv drv drv drv drv
Gets you
Real-Time Monitor RealTime +DSP/BIOS there
quickly
C24xTM C28xTM
http://www.ti.com/c2000appsw
http://www.ti.com/c2000sigproclib
The Foundation: Software Libraries
PFC
2PHIL E T2PWM
DRV V
Net1 Duty H
W T4PWM
Net2 Adj
Digital Power Supplies: collaterals
First version of the Digital Power Supply Library has been
released
Pure simulation plus DSP-in-loop simulation and block level monitoring gives
rapid feedback of controller response
VisSim on PC
Peripheral
Input Blocks
C2000TM Peripheral
DSP Output Blocks
External
Hardware (I/O
Only)
VisSim block diagram
28x has the right set of peripherals for Digital Power Supply
Visit us
Stand 134, Hall 12