Integrated circuit control of resonant and hard switched dc/dc converters for industrial and educational applications

Abstract

This thesis presents an integrated secondary side synchronous rectification controller, designed on a modern industrial silicon IC process, for use in the LLC resonant converter topology. The controller is intended to function in systems with output power levels up to 500 W and switching frequencies up to 1 MHz. Simulation data for this controller indicates high degrees of performance over a input voltage range of 12-48 V and an operating temperature range of -50° C to 150° C. Significant improvement over existing synchronous rectication controllers is observed. In addition, a simulation and written exercise framework, intended to couple with circuits in a pre-existing discrete hardware kit, has been developed for a proposed class on power IC design. SPICE schematics of important circuit modules as well as relevant coursework is presented and explained. The course itself is motivated by the challenges of the industrial design process, and goals include teaching students about practical power IC design techniques and developing their intuition for high level circuit function. The end result is student construction of a working controller for a traditional hard-switched dc/dc converter.