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  • 300W, 12V Output ZVS Full-Bridge Converter Reference Design for 100kRad Applications

    • TIDT424 March   2025

       

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  • 300W, 12V Output ZVS Full-Bridge Converter Reference Design for 100kRad Applications
  1.   1
  2.   Description
  3.   Features
  4.   Applications
  5. 1Test Prerequisites
    1. 1.1 Voltage and Current Requirements
    2. 1.2 Considerations
    3. 1.3 Dimensions
    4. 1.4 Test Setup
  6. 2Testing and Results
    1. 2.1 Efficiency Graphs
    2. 2.2 Efficiency Data
    3. 2.3 Thermal Images
    4. 2.4 Bode Plots
  7. 3Waveforms
    1. 3.1 Switching
    2. 3.2 Output Voltage Ripple
    3. 3.3 Load Transients
    4. 3.4 Start-up Sequence
  8. IMPORTANT NOTICE
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Test Report

300W, 12V Output ZVS Full-Bridge Converter Reference Design for 100kRad Applications

Description

This reference design is a full-bridge topology that is comprised of a TPS7H5005-SEP referenced on secondary ground that controls three TPS7H6005-SEP half-bridge gate drivers. The two drivers referenced to the primary side operate in PWM mode which allows for the design to achieve zero-voltage switching (ZVS) at higher loading conditions. On the secondary side the other driver controls a pair of secondary rectifiers to further improve the conversion efficiency. In this design the controller, half-bridge drivers and GaN field-effect transistors (FET) are chosen to meet radiation for geostationary orbit (GEO). These components can be swapped out to meet other mission specifications.

Features

  • GEO class radiation performance
  • GaN FETs on primary and secondary side to increase efficiency
  • Secondary-side controller for faster control loop
  • < 1% voltage ripple on output
  • Single-side assembly, two-layer, 3.25 in × 5.5 in PCB

Applications

  • Command and data handling (C and DH)
  • Optical imaging payload
  • Radar imaging payload
PMP23391 Top of BoardTop of Board
PMP23391 Angled ImageAngled Image
PMP23391 Bottom of BoardBottom of Board

1 Test Prerequisites

1.1 Voltage and Current Requirements

Table 1-1 Voltage and Current Requirements
Parameter Specifications
Input voltage 22V to 36V
Output voltage 12V
Maximum output current 25V
Switching frequency 500kHz (primary side)

1.2 Considerations

  • Unless noted, all tests were conducted with 25A loading on the output
  • Local airflow used
  • External 12V bias applied to primary and secondary sides

1.3 Dimensions

Board size: 3.25in × 5.5in, tallest component = 0.67in (bridge transformer).

1.4 Test Setup

Air flow is recommended to test at full load conditions. Thermal image shows relative temperature rise across the PCBA.

PMP23391 Test Setup Figure 1-1 Test Setup

2 Testing and Results

2.1 Efficiency Graphs

PMP23391 Efficiency and Power Loss
                        With Nominal Input (28V) Figure 2-1 Efficiency and Power Loss With Nominal Input (28V)
PMP23391 Efficiency Across Input
                        Range Figure 2-2 Efficiency Across Input Range

2.2 Efficiency Data

Table 2-1 Efficiency Data With 28V Input
Input Output Total

Voltage (V)

Current (A)

Power (W)

Voltage (V)

Current (A)

Power (W)

Loss (W)

Efficiency (%)

27.994

0.572

16.012

12.01

0.993

11.926

4.086

74.481

27.991

1.0557

29.551

12.009

1.998

23.994

5.557

81.195

27.99

1.9498

54.57

12.006

3.99

47.904

6.666

87.784

27.988

2.8657

80.21

12.004

5.997

71.988

8.222

89.749

27.985

3.791

106.1

12.001

7.99

95.888

10.212

90.375

27.983

4.727

132.26

11.999

9.983

119.786

12.474

90.569

27.979

5.68

158.91

11.996

11.991

143.844

15.066

90.519

27.979

6.636

185.68

11.993

13.985

167.722

17.958

90.329

27.984

7.588

212.34

11.991

15.979

191.604

20.736

90.235

27.986

8.564

239.66

11.988

17.988

215.640

24.020

89.978

27.985

9.544

267.11

11.986

19.981

239.492

27.618

89.661

27.983

10.555

295.36

11.983

21.976

263.338

32.022

89.158

27.976

11.582

324.01

11.98

23.984

287.328

36.682

88.679

27.978

12.095

338.38

11.979

24.974

299.164

39.216

88.411

Table 2-2 Efficiency Data With 32V Input

Input

Output

Total

Voltage (V)

Current (A)

Power (W)

Voltage (V)

Current (A)

Power (W)

Loss (W)

Efficiency (%)

31.946

0.5264

16.816

12.009

0.993

11.925

4.891

70.914

31.942

0.9616

30.714

12.008

1.998

23.992

6.722

78.114

31.941

1.7566

56.106

12.005

3.99

47.900

8.206

85.374

31.939

2.5581

81.703

12.003

5.998

71.994

9.709

88.117

31.937

3.3671

107.53

12.001

7.991

95.900

11.630

89.184

31.935

4.1841

133.62

11.998

9.984

119.788

13.832

89.648

31.932

5.0176

160.22

11.996

11.992

143.856

16.364

89.787

31.929

5.8563

186.99

11.993

13.987

167.746

19.244

89.709

31.928

6.706

214.1

11.991

15.98

191.616

22.484

89.498

31.931

7.557

241.3

11.988

17.988

215.640

25.660

89.366

31.934

8.408

268.51

11.986

19.982

239.504

29.006

89.198

31.935

9.274

296.16

11.983

21.976

263.338

32.822

88.918

31.933

10.167

324.67

11.981

23.984

287.352

37.318

88.506

31.932

10.618

339.05

11.979

24.974

299.164

39.886

88.236

Table 2-3 Efficiency Data With 36V Input

Input

Output

Total

Voltage (V)

Current (A)

Power (W)

Voltage (V)

Current (A)

Power (W)

Loss (W)

Efficiency (%)

35.947

0.4923

17.696

12.009

0.99

11.889

5.807

67.184

35.944

0.8883

31.928

12.008

1.994

23.944

7.984

74.994

35.942

1.6079

57.79

12.006

3.987

47.868

9.922

82.831

35.941

2.3199

83.378

12.003

5.994

71.946

11.432

86.289

35.941

3.0358

109.11

12.001

7.987

95.852

13.258

87.849

35.938

3.7726

135.58

11.998

9.98

119.740

15.840

88.317

35.937

4.519

162.4

11.996

11.989

143.820

18.580

88.559

35.934

5.2639

189.15

11.993

13.983

167.698

21.452

88.659

35.932

6.0207

216.33

11.991

15.977

191.580

24.750

88.559

35.931

6.791

244

11.988

17.985

215.604

28.396

88.362

35.933

7.559

271.42

11.986

19.978

239.456

31.964

88.224

35.935

8.322

299.06

11.983

21.971

263.278

35.782

88.035

35.936

9.111

327.43

11.98

23.98

287.280

40.150

87.738

35.936

9.508

341.69

11.979

24.97

299.116

42.574

87.540

 

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