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Switching Power Supply Circuit Diagram with Explanation

Author: Apogeeweb Date: 13 Jul 2019 20631

Catalog

Ⅰ Development History of Switching Power Supply

Ⅱ The Basic Principle of Switching Power Supply

2.1 The Basic Principle of PWM Switching Power Supply
2.2 Working Principle of Switching Power Supply

Ⅲ Circuit Composition of the Switching Power Supply

Ⅳ Principle of Input Circuit and Common Circuit

4.1 Principle of AC Input Rectification and Filtering Circuit
4.2 Principle of DC Input Filter Circuit

Ⅴ Power Conversion Circuit

5.1 Working Principle of MOS Transistor
5.2 Push-pull Power Conversion Circuit
5.3 Power Conversion Circuit with Drive Transformer

Ⅵ Output Rectifier and Filter Circuit

6.1 Forward Rectifier Circuit
6.2 Flyback Rectifier Circuit
6.3 Synchronous Rectifier Circuit

Ⅶ Principle of Voltage Regulation Loop

7.1 Schematic of Feedback Circuit
7.2 Working Principle

Ⅷ Short-circuit Protection Circuit

Ⅸ Output Current Limiting Protection Circuit

Ⅹ Principle of Output Overvoltage Protection Circuit

10.1 Thyristor Trigger Protection Circuit
10.2 Photoelectric Coupling Protection Circuit
10.3 Output Voltage Limiting Protection Circuit
 10.4 Output Overvoltage Lockout Circuit

Ⅺ Power Factor Correction Circuit (PFC)

XII Input Over/Under Voltage Protection Circuit

XIII Battery Management

13.1 Schematic of Battery Management
13.2 Start Principle of Battery
13.3 The Voltage Regulated Principle of Battery Charging
13.4 The Principle of Battery Charging Current Limiting
13.5 The Principle of Battery Undervoltage Shutdown

XIV Intelligent Fan Cooling

14.1 Intelligent Heat Dissipation
14.2 Working Principle

XV Current Sharing Technology

15.1 What is Current Sharing Technology?
15.2 Working Principle

Ⅰ Development History of Switching Power Supply

The switching power supply has replaced the transistor linear power supply for more than 30 years. The first
to appear in the series switching power supply. The main circuit topology is similar to that of the linear power
supply. However, after the power transistor is in the switching state, the pulse width modulation (PWM)
control technology has developed. It is used to control the switching converter to obtain PWM switching
power supply. It is characterized by 20kHz pulse frequency or pulse width modulation.

The efficiency of the PWM switching power supply can reach 65%~70%, while the efficiency of the linear
power supply is only 30%~40%. In the era of the global energy crisis, it has aroused widespread concern. The
linear power supply works at the power frequency, so it is replaced by a PWM switching power supply with a
working frequency of 20 kHz, which can greatly save energy. It is known as the 20 kHz revolution in the
history of power supply technology development. As ULSI chips continue to shrink in size, power supplies
are much larger than microprocessors; aerospace, submarine, military switching power supplies, and battery-
operated portable electronic devices (such as portable calculators, mobile phones, etc.) need the smaller and
lighter power supply.

Therefore, requirements of small size and lightweight are imposed on the switching power supply, including
the volume and weight of magnetic components and capacitors. In addition, the switching power supply is
required to have higher efficiency, better performance and higher reliability.
 12V 10A switching power supply (with schematic and explanation)

Ⅱ The Basic Principle of Switching Power Supply

2.1 The Basic Principle of PWM Switching Power Supply

It is quite easy to understand the working process of the switching power supply. In a linear power supply, the
power transistor is operated in a linear mode. Unlike a linear power supply, the PWM switching power supply
allows the power transistor to operate in the on and off states. In both states, the product of volt-ampere
applied to the power transistor is always small (the voltage is low and the current is large when turned on; the
voltage is high and the current is small when turned off). The product of volt-ampere on a power device is the
loss produced on a power semiconductor device.

Compared with linear power supplies, PWM switching power supplies work more efficiently by “chopper”,
which is to convert the input DC voltage into a pulse voltage with an amplitude equal to the input voltage
amplitude. The duty ratio of the pulse is regulated by the controller of the switching power supply. Once the
input voltage is clamped into an AC square wave, its amplitude can be raised or lowered by the transformer.
The number of voltage groups of the output can be increased by increasing the number of secondary windings
of the transformer. Finally, a DC output voltage is obtained after these AC waveforms are rectified and
filtered.

The main purpose of the controller is to ensure that the output voltage is stable, and its working process is very
similar to that of a linear controller. This means that the controller's functional block voltage reference and
error amplifier can be designed to be identical to a linear regulator. They differ in that the output of the error
amplifier (error voltage) passes through a voltage pulse conversion unit before driving the power transistor.

Switching power supplies have two main modes of operation: forward conversion and boost conversion.
Although the arrangement of the various parts differs little, the working process varies greatly and they have
different advantages in specific situations.

The advantage of the forward converter is that the output voltage has a lower ripple peak than the boost
converter, and can output relatively high power. The forward converter can provide several kilowatts of power.

The boost converter has a high peak current and is therefore only suitable for applications with a power of no
more than 150 W. In all topologies, these converters use the smallest components and are therefore popular in
applications with small to medium power.

2.2 Working Principle of Switching Power Supply

(1) AC power input is rectified and filtered into DC.

(2) Control the switching tube by high-frequency PWM (pulse width modulation) signal, and apply DC to the
primary switching transformer.
(3) The secondary of the switching transformer induces a high-frequency voltage, which supplies the load
through rectification and filtering.
(4) The output part feeds back to the control circuit through a certain circuit to control the PWM duty ratio to
achieve stable output.

Ⅲ Circuit Composition of the Switching Power Supply

The main circuit of the switching power supply is composed of an input electromagnetic interference filter
(EMI), a rectification and filtering circuit, a power conversion circuit, a PWM controller circuit, and an output
rectification and filtering circuit. The auxiliary circuit has an input over-voltage protection circuit, an output
over-voltage protection circuit, an output over-current protection circuit, and an output short-circuits
protection circuit.

The circuit block diagram of the switching power supply is as follows:

Figure 1. Block Diagram of Switching Power Supply Circuit

Ⅳ Principle of Input Circuit and Common Circuit

4.1 Principle of AC Input Rectification and Filtering Circuit

Figure 2. Schematic of Input Filter, Rectifier Circuit

① Lightning protection circuit: When there is a lightning strike and high voltage is generated through the
power grid, the circuit consists of MOV1, MOV2, MOV3, F1, F2, F3 and FDG1. When the voltage applied
across the varistor exceeds its operating voltage, its resistance decreases, so that the high-voltage energy is
consumed on the varistor. If the current is too large, F1, F2, and F3 will burn and protect the subsequent
circuit.

② Input filter circuit: The double π-type filter network composed of C1, L1, C2 and C3 mainly suppresses the
electromagnetic noise and clutter signals of the input power source to prevent interference to the power supply
and it also prevents high-frequency clutter generated by the power supply itself from interfering with the
power grid.

When the power is turned on, the C5 should be charged. Because the instantaneous current is large, adding
RT1 (thermistor) can effectively prevent the surge current. Since the instantaneous energy is completely
consumed on the resistor RT1, the resistance of RT1 decreases after the temperature rises after a certain time
(RT1 is the negative temperature coefficient component). At this time, the energy consumption is very small,
and the subsequent circuit can work normally.

③ Rectifier filter circuit: After the AC voltage is rectified by BRG1, it is filtered by C5 to obtain a relatively
pure DC voltage. If the capacity of C5 becomes smaller, the output AC ripple will increase.

4.2 Principle of DC Input Filter Circuit

Figure 3. DC Input Filter Circuit

① Input filter circuit: The double π-type filter network composed of C1, L1, C2 and C3 mainly suppresses the
electromagnetic noise and clutter signals of the input power source to prevent interference to the power supply
and it also prevents high-frequency clutter generated by the power supply itself from interfering with the
power grid. C3 and C4 are safety capacitors, and L2 and L3 are differential mode inductors.

② R1, R2, R3, Z1, C6, Q1, Z2, R4, R5, Q2, RT1 and C7 form an anti-surge circuit. At the moment of starting,
due to the presence of C6, Q2 does not conduct, and the current forms a loop through RT1. Q2 turns on when
the voltage on C6 is charged to the regulated value of Z1. If the C8 leakage or the subsequent circuit is short-
circuited, the voltage drop generated by the current on RT1 increases at the moment of starting, and Q1 is
turned on so that Q2 is not turned on without the gate voltage, and RT1 will burn out in a short time to protect
the subsequent circuit.

Ⅴ Power Conversion Circuit

5.1 Working Principle of MOS Transistor

At present, the most widely used insulated gate field effect transistor is a MOSFET (MOS transistor), which
works by utilizing the electroacoustic effect of the semiconductor surface and is also known as surface field-
effect devices. Since its gate is in a non-conducting state, the input resistance can be greatly improved up to
105 ohms. The MOS transistor uses the magnitude of the gate-source voltage to change the amount of induced
charge on the semiconductor surface, thereby controlling the drain current.

5.1.1 Common Schematics

Figure 4. Power Conversion Circuit

5.1.2 Working Principle
R4, C3, R5, R6, C4, D1 and D2 form a buffer, and are connected with the switch MOS transistor in parallel so
that the voltage stress of the switch tube is reduced, EMI is reduced, and secondary breakdown does not occur.
When the switch tube Q1 is turned off, it is easy for the primary winding of the transformer to produce spike
voltage and spike current. These components together can absorb the spike voltage and current well.

The current peak signal measured from R3 participates in the duty ratio control of the current working cycle
and is therefore the current limit of the current working cycle. When the voltage on R5 reaches 1V, UC3842
stops working and switch tube Q1 turns off immediately. The junction capacitances CGS and CGD in R1 and
Q1 together form an RC network, and the charge and discharge of the capacitor directly affect the switching
speed of the switching transistor.

If R1 is too small, it will cause oscillation and electromagnetic interference will be very large; if R1 is too
large, it will reduce the switching speed of the switching tube. Z1 usually limits the GS voltage of the MOS
transistor to 18V or less, thus protecting the MOS transistor. The gate-controlled voltage of Q1 is a saw-
shaped wave. When the duty ratio is larger, the longer the Q1 conduction time is the more energy the
transformer stores. When Q1 is cut off, the transformer releases energy through D1, D2, R5, R4 and C3.

At the same time, it achieves the purpose of magnetic field reset, which is ready for the next storage and
transmission of energy of the transformer. The IC adjusts the duty ratio of the saw-shaped wave of pin 6
according to the output voltage and current, thus stabilizing the output current and voltage of the whole
machine. C4 and R6 are spike voltage absorption loops.
5.2 Push-pull Power Conversion Circuit

Figure 5. Push-pull Power Conversion Circuit

Q1 and Q2 will turn on in turn.

5.3 Power Conversion Circuit with Drive Transformer

Figure 6. Power Conversion Circuit with Drive Transformer

T2 is the drive transformer, T1 is the switching transformer, and TR1 is the current loop.

Ⅵ Output Rectifier and Filter Circuit

6.1 Forward Rectifier Circuit

 Figure 7. Forward Rectifier Circuit
T1 is a switching transformer whose phase of the primary and secondary poles are in phase. D1 is a rectifier
diode, D2 is a freewheeling diode, and R1, C1, R2, and C2 are despiking circuits. L1 is a freewheeling
inductor, and C4, L2, and C5 form a π-type filter.

6.2 Flyback Rectifier Circuit

Figure 8. Flyback Rectifier Circuit

T1 is a switching transformer with opposite phases of the primary and secondary poles. D1 is a rectifier diode,
and R1 and C1 are Despiking circuits. L1 is a freewheeling inductor, R2 is a dummy load, and C4, L2, and C5
form a π-type filter.

6.3 Synchronous Rectifier Circuit

 Figure 9. Synchronous Rectifier Circuit
Working principle: When the upper end of the secondary of the transformer is positive, the current makes Q2
turn on through C2, R5, R6 and R7, the circuit forms the loop, and Q2 is the rectifier. The gate Q1 is turned
off due to the reverse bias. When the lower end of the secondary of the transformer is positive, the current
makes Q1 turn on through C3, R4, and R2, and Q1 is a freewheeling tube. The gate Q2 is turned off due to the
reverse bias. L2 is a freewheeling inductor, and C6, L1, and C7 form a π-type filter. R1, C1, R9, and C4 are
despiking circuits.

Ⅶ Principle of Voltage Regulation Loop

7.1 Schematic of Feedback Circuit

Figure 10. Schematic of Voltage Feedback Loop Circuit

7.2 Working Principle

When the output U0 rises after the voltage is divided by the sampling resistors R7, R8, R10, VR1, the voltage
of pin 3 of U1 rises. When it exceeds the reference voltage of pin 2 of U1, pin 1 of U1 outputs a high level, so
that Q1 is turned on, and the optocoupler OT1 LED lights, the phototransistor is turned on, and the potential of
pin 1 of the UC3842 is correspondingly low, thereby changing the output duty ratio of pin 6 of U1 to decrease,
and U0 is lowered.

When the output U0 decreases, the voltage of pin 3 of U1 decreases. When it is lower than the reference
voltage of pin 2 of U1, pin 1 of U1 outputs a low level, Q1 does not conduct, the optocoupler OT1 LED does
not emit light and the phototransistor does not conduct. The potential of pin 1 of the UC3842 rises high, thus
changing the output duty cycle of pin 6 of U1 to increases and U0 decreases. Repeatedly, the output voltage is
kept stable. Adjusting VR1 can change the output voltage value.

The feedback loop is an important circuit that affects the stability of the switching power supply. Feedback
resistor capacitance error, leakage, virtual soldering and so on will produce self-oscillation. The fault
phenomenon is waveform abnormality, empty or full load oscillation, output voltage instability and so on.

Ⅷ Short-circuit Protection Circuit

— In the case of a short circuit at the output, the PWM control circuit can limit the output current to a safe
range. It can implement the current limiting circuit in a variety of ways. When the power limiting current does
not work when it is short-circuited, only another part of the circuit will be added.
— There are usually two types of short-circuit protection circuits. The following figure shows a low-power
short-circuit protection circuit.

Figure 11. Short-circuit Protection Circuit

The principle is as follows:
When the output circuit is short-circuited, the output voltage disappears, the optocoupler OT1 is not turned on,
the voltage of pin 1 of UC3842 rises to about 5V, the voltage division of R1 and R2 exceeds the reference of
TL431 and makes it turn on. The VCC potential of pin 7 of UC3842 is pulled low, and the IC stops working.
After UC3842 stops working, the potential of pin 1 disappears and TL431 does not turn on. The potential of
pin 7 of UC3842 rises, and UC3842 restarts, and it starts again and again. When the short circuit disappears,
the circuit can automatically return to normal operation.

— The figure below is a medium power short-circuit protection circuit.

 Figure 12. Medium Power Short-circuit Protection Circuit
The principle is as follows:

When the output is short-circuited, the voltage of pin 1 of UC3842 rises, and the potential of pin 3 of U1 is
higher than that of pin 2. Pin 1 of the comparator outputs a high potential to charge C1. When the voltage
across C1 exceeds the reference voltage of pin5, pin 7 of U1 outputs a low potential. When the voltage of pin
1 of UC3842 is lower than 1V, UCC3842 stops working and the output voltage is 0V, the circuit starts again.
When the short circuit disappears, the circuit works normally. R2 and C1 are charge and discharge time
constants, and the short circuit protection does not work when the resistance value is incorrect.

— The figure below is a common current limiting and short-circuit protection circuit.

Figure 13. Current Limiting and Short-circuit Protection Circuit

Its working principle is briefly described as follows:

The output duty ratio of pin 6 of UC3842 is gradually increased. When the voltage of pin 3 exceeds 1V, the
UC3842 is turned off and has no output.
— The following figure is a protection circuit for sampling current with a current transformer. It has low
power consumption, but high cost and complicated circuit.
 Figure 14. A Protection Circuit
The working principle is as follows:

If the output circuit is short-circuited or the current is too large, The voltage induced by the TR1 secondary
coil will be higher. When pin 3 of UC3842 exceeds 1 volt, the UC3842 stops working and repeats. When the
short circuit or overload disappears, the circuit recovers itself.

Ⅸ Output Current Limiting Protection Circuit

Figure 15. Output Current Limiting Protection Circuit

The figure above is a common output current limiting protection circuit. Its working principle is as shown in
the above figure: When the output current is too large, the voltage across RS (manganese copper wire) rises,
the voltage of pin 3 of U1 is higher than the reference voltage of pin 2. Pin 1 of U1 outputs high voltage, Q1 is
turned on and the optocoupler has a photoelectric effect. The voltage of pin 1 of UC3842 is lowered, and the
output voltage is lowered, thereby achieving the purpose of output overload current limiting.

Ⅹ Principle of Output Overvoltage Protection Circuit

The function of the output overvoltage protection circuit is to limit the output voltage to a safe value when the
output voltage exceeds the designed value. When the internal voltage regulation loop of the switching power
supply fails or the output overvoltage phenomenon is caused by improper operation of the user, the
overvoltage protection circuit protects to prevent damage to the power equipment of the subsequent circuit.
The most common overvoltage protection circuits are as follows:

10.1 Thyristor Trigger Protection Circuit

When the output circuit is short-circuited or over-current, the primary current of the transformer increases, the
voltage drop across R3 increases, and the voltage of pin 3 rises.

Figure 16. Thyristor Trigger Protection Circuit

As shown in the figure above, when the Uo1 output rises and the Zener diode (Z3) breaks through, the control
terminal of the SCR1 (SCR1) gets the trigger voltage, so the SCR is turned on. The voltage of Uo2 is short-
circuited to the ground, and the overcurrent protection circuit or the short circuit protection circuit will work to
stop the operation of the entire power supply circuit. When the output overvoltage phenomenon is eliminated,
the control terminal trigger voltage of the thyristor is discharged to the ground through R, and the thyristor is
restored to the off state.

10.2 Photoelectric Coupling Protection Circuit

Figure 17. Photoelectric Coupling Protection Circuit

As shown above, when Uo has an overvoltage phenomenon, the Zener diode breaks through and conducts
current through the optocoupler (OT2) R6 to the ground, and the LED of the photocoupler lights, thereby
making the phototransistor of the photocoupler on. The base of Q1 is electrically turned on, and pin 3 of 3842
is reduced so that the IC is turned off and the operation of the entire power supply is stopped. Uo is zero, and
the cycle is repeated.

10.3 Output Voltage Limiting Protection Circuit

The output voltage limiting protection circuit is as shown in the figure below. When the output voltage rises,
the Zener diode and the optocoupler turn on, and the Q1 base turns on with a driving voltage. The voltage of
UC38423 rises, the output decreases, and the Zener tube does not conduct. The voltage of UC38423 is
lowered and the output voltage is raised. Repeatedly, the output voltage will stabilize within a range depending
on the voltage of the regulator.

Figure 18. Output Voltage Limiting Protection Circuit

10.4 Output Overvoltage Lockout Circuit

Figure 19. Output Overvoltage Lockout Circuit

The working principle of Figure 19(a) is that when the output voltage Uo rises, the Zener diode and the
optocoupler are turned on, and the base of Q2 is electrically turned on. Because Q2 is turned on, the base
voltage of Q1 is lowered and also turned on, and the Vcc voltage makes Q2 always on through R1. Q1 and
R2. Pin 3 of UC3842 is always high and stops working. In Figure 19(b), UO raises and the voltage of pin 3 of
U1 rises. Pin 1 outputs a high level and pin 1 of U1 always outputs a high level due to the presence of D1 and
R1. Q1 is always on, and pin 1 of UC3842 is always low and stops working.

Ⅺ Power Factor Correction Circuit (PFC)

Schematic Diagram

Figure 20. Power Factor Correction Circuit

Working Principle
In one way, the input voltage sends PFC inductor through EMI filter composed of L1, L2, L3, etc. and BRG1
rectification. In another way, it is divided by R1 and R2 and then sent to the PFC controller as a sampling of
input voltage for adjusting the duty ratio of the controlled signal, that is, changing the on and off time of Q1
and stabilizing the PFC output voltage. L4 is a PFC inductor that stores energy when Q1 is on and releases
energy when Q1 is off. D1 is the start diode, D2 is a PFC rectifier diode, and C6, C7 are filtered. The PFC
voltage is sent to the subsequent circuit, and it is divided by R3 and R4 and then sent to the PFC controller as
a sampling of input voltage for adjusting the duty ratio of the controlled signal and stabilizing the PFC output
voltage in another way.

XII Input Over/Under Voltage Protection Circuit

Schematic
 Figure 21. Input Over/Under Voltage Protection Circuit
Working Principle
The principles of input over or under-voltage protection of the AC input and DC input switching power
supplies are approximately the same. The sampling voltage of the protection circuit is derived from the input
filtered voltage. The sampling voltage is divided into two ways, one is divided by R1, R2, R3, R4 and then
input to pin 3 of the comparator. If the sampling voltage is higher than the reference voltage of pin 2, pin 1 of
the comparator outputs a high level to control the main controller to shut down and the power supply has no
output. The other way is divided by R6, R8, R9, R10 and then input to pin 6 of the comparator. If the sampling
voltage is lower than the reference voltage of pin 5, pin 7 of the comparator outputs a high level to control the
main controller to turn off, and the power supply has no output.

XIII Battery Management

13.1 Schematic of Battery Management

 Figure 22. Schematic of Battery Management
The parts in the dotted box A constitute the battery starting and shutdown circuit; the dotted box B is the
battery charging linear voltage regulated circuit; the dotted box C is the electronic switching circuit, and the
dotted box D is the battery charging current limiting circuit.

13.2 Start Principle of Battery

The input voltage is input from the INPUT and AGND terminals and is divided into three paths. The first way
is directly sent to the subsequent circuit and the battery starting and shutdown circuit via D7. The voltage after
the division of R28, R27 and R26 turns U3 on and the optocoupler OT1 is turned on. R25 provides the
operating voltage for U3, and R23 and R24 are the current limiting and protection resistors of the optocoupler.

After the optocoupler is turned on, the power supply provides a base bias voltage to Q4 via R22, OT1, and D9
and Q4 are turned on. R21 is the lower bias resistor of Q4. A current flows through the coil of the relay RLY1-
A, and the relay contact RLY1-B pulls in, and the battery BAT is connected to the circuit. D4 is to prevent the
electromotive force generated by the relay coil from affecting the subsequent circuit when Q4 is turned off,
and D5 releases the energy generated by the relay coil which is to prevent the electromotive force generated
by the relay coil from damaging Q4 when Q4 is turned off.

13.3 The Voltage Regulated Principle of Battery Charging

At the beginning of electrification, since Q3 is not biased and does not conduct, there is no voltage at the
positive terminal of D3. The power supply provides voltages to U1 and U2 via voltage drop of R1 and
regulation of Z1. R2 and U1 form the reference voltage, R13, R4, R5, R6 and VR1 form the battery voltage
detection circuit. When the detection voltage of pin 2 of U2 is lower than the voltage of pin 3, pin 1 output a
high level, and the bias voltage is supplied to Q2 via R14. Q2 is turned on and Q3 is also turned on. The
power supply charges the battery BAT via Q3, D3, and relay contacts RLY1-B and F1.
When the detection voltage of pin 2 of U2 is higher than the voltage of pin 3, its pin 1 outputs a low level, Q2

loses the bias voltage and is turned off. Q3 is turned off, the positive terminal of D3 has no voltage and its
negative voltage drops. The detection voltage of pin 2 of U2 also decreases. When the detection voltage of pin
2 of U2 is lower than the voltage of pin 3, pin 1 output a high level, and Q2 and Q3 are turned on to continue
charging. So that the negative terminal voltage of D3 is maintained at a certain set value. Adjusting VR1 can
change the charging voltage value.

13.4 The Principle of Battery Charging Current Limiting

Figure 23. Battery Charging

During charging, the current returns to ground (AGND) via Q3, RLY1-B, F1, BAT, and R20. At the beginning
of battery charging, because the battery voltage is relatively low, the current flowing through Q3, RLY1-B, F1,
BAT, and R20 will increase, and the voltage drop generated on R20 will increase (R20 is the current sampling
resistor). The upper terminal S of the resistor R20 is connected to the non-inverting input terminal 5 of U2B
via R11, and the inverting input terminal 6 of U2B has a fixed reference voltage.

When the voltage drop on R20 exceeds the reference voltage, pin 7 of U2 outputs a high level and provides a
bias voltage to Q1 through D2 and R15. And Q1 is thus turned on. After Q1 is turned on, Q2 is turned off due
to the loss of the base voltage, which will turn off the output of the linear regulator. No current flows through
the loops of Q3, RLY1-B, F1, BAT, and R20, and the voltage drop on R20 disappears. Pin 7 of U2 outputs low
level and Q1 is cut off. Q2 and Q3 are turned on to continue charging, so the charging current is limited to a
certain set value range. Adjusting R10 and R11 can change the current limit point.

13.5 The Principle of Battery Undervoltage Shutdown

When the input voltage is not available, the battery voltage is sent to the subsequent circuit and the battery
starting and shutdown circuit via D6. When the battery voltage drops, the voltage of pin 1 of U3 also drops.
When the battery voltage drops to the designed shutdown point (that is, when the voltage of pin 1 of U3 is
lower than 2.5V), U3 does not conduct, OT1 has no photoelectric coupling and Q4 is unbiased and cut off.
There is no current flows through the coil of the relay RLY1-A, and the relay contact RLY1-B is disconnected,
and the battery BAT is disconnected from the circuit to prevent the battery from being over-discharged and
damaged. Changing the resistance of R26 and R27 can change the voltage value when the battery is shut down
because of undervoltage.

XIV Intelligent Fan Cooling

14.1 Intelligent Heat Dissipation

In the switching power supply, there are many ways to dissipate heat from the power supply. Intelligent heat
dissipation is one of them. It adjusts the operating voltage of the cooling fan to change the wind pressure
according to the temperature of the power supply to achieve the best heat dissipation effect and the purpose of
energy saving. The schematic diagram is as follows:

Figure 24. Intelligent Heat Dissipation

14.2 Working Principle

The input voltage is input from the INPUT terminal (12~13V), R6 provides the working voltage for U2, and
the resistance values of R7 and R8 are the same. After the voltage division, the trigger voltage is provided for
TL431, so that the reference voltage of point A is +5V; RT1 is a negative temperature coefficient thermistor,
which is applied to the inverting input terminal 6 of U1 via voltage division of R1 and R2. R5 is the output
voltage sampling resistor, which is added to the non-inverting input terminal 5 of U1 after being divided by
R4; Q1 is the electronic switch tube; the fan voltage is output from the FANOUT terminal.

At the time of power-on, since Q1 is not turned on, there is no voltage at point C, and the voltage of pin 6 of
U1 is higher than pin 5. Therefore, pin 7 of U1 outputs a low level, Z1 is turned on, Q1 is turned on, and there
is the voltage at point C; the emitter of Q1 is connected to the input voltage terminal, so the voltage at point C
is approximately equal to the input voltage.

After being divided by R5 and R4, it is applied to pin 5 of the non-inverting input terminal of U1, so that the
voltage of pin 5 is higher than the voltage of pin 6, pin 7 of U1 outputs a high level. Z1 is not conducting, Q1
is not conducting, and there is no voltage output at point C; the voltage of pin 5 is lower than that of pin 6. Pin
7 of U1 outputs low level again, so repeatedly it makes voltage of C stable at some value (because the voltage
of pin 6 does not change); that is, the voltage at point C changes with the voltage at point B.

At the beginning of the switching power supply operation (or light load operation), the internal temperature is
low, the internal resistance of the thermistor RT1 is large, and the voltage at point B is relatively low, so the
output voltage at point C is also low, and the speed and wind power of the fan slow down due to the low
operating voltage. When the temperature inside the switching power supply is gradually increased (or full load
operation), the internal resistance of the thermistor RT1 gradually decreases, and the voltage at point B rises,
so the output voltage at point C rises, and the fan speeds up and the wind power increases because the
operating voltage rises.
When the temperature inside the machine drops, the internal resistance of the thermistor gradually increases,
the voltage at point B decreases, and the output voltage at point C also decreases. The fan has a slower rotation
speed and a lower wind power due to a lower operating voltage. When the voltage (temperature) at point B
rises to a certain level, the voltage of pin 3 of U1 is higher than the reference voltage of pin 2, and pin 1 of U1
outputs a high level and goes back to point B via D1 and R13, so that pin 1 of U1 always outputs a high level,
that is, self-locking. The other way will be output to the over-temperature protection circuit via D2 to realize
over-temperature protection.

XV Current Sharing Technology

15.1 What is Current Sharing Technology?

In communication equipment or other electrical equipment, in order to make the system work uninterruptedly,
the requirements for the power supply system are very high. In addition to requiring the performance of the
power supply itself to be stable, another method is to use the 1+1 backup method, that is, one device is
powered in parallel with two power supplies. When one of them is damaged, the other one can continue to
supply power to the system. In normal operation, each power supply provides the same energy, that is, the
voltage and current they output are basically the same. In order to make the voltage and current output of each
power supply basically the same, the current sharing technology is used.
The principle is as shown below:

Figure 25. Current Sharing Technology

15.2 Working Principle

U1A, R1 to R7, C1 to C5, VR1 form a current sampling voltage amplifier; U1B and D1 form a voltage
follower; R10 is a current sharing voltage output resistor; R11 to R14, U2A, C6 to C10 form a balanced
voltage comparator; R15 to R17 and Q1 are electronic switches; R30 to R33, C17, C18, and U2B form an
overcurrent protection circuit; R19 to 28, D2, D3, D4, C12 to C14, and Q2 are output voltage regulation loops
of the power supply, of which D2 D3 and R19 to R21 are output voltage sampling circuits. D6 is an output
isolation diode.
When the power supply is working, the current sampling voltage detected by the current loop or manganese
copper wire is amplified by the voltage amplifier composed of +IS and -IS added to U1A. After being divided
by R5, R6, R7 and VR1, the output is divided into two ways. One way is sent to the voltage follower U1B, D1
acts as an isolation to prevent the voltage change on the current sharing bus from affecting the previous stage
circuit, and the other is sent to the overcurrent protection circuit.

The current sampling voltage is divided into two ways after getting through the voltage follower. One gets
through the R10 and is output as the current sharing signal voltage JL+, and the other is sent to the balanced
voltage comparator composed of U2A through R11 and compared with the reference voltage of pin 2 of U2.
When the voltage of pin 3 of U2 is higher than that of pin 2, pin 1 output a high level. Base Q1 is electrically
conducted, and R17 and R18 are incorporated into the output voltage sampling circuit, so that the output
voltage rises and the output current decrease.

The detected current sampling voltage is also reduced, and the current sharing signal voltage JL+ is lowered.
The voltage of pin 3 of U2 is lower than the voltage of pin 2, and its pin 1 outputs a low level. Q1 is cut off,
R17 and R18 are exited from the output voltage sampling circuit, and the output voltage is lowered. This cycle
finally stabilizes the output voltage and current. As shown in the following figure, when the two power
supplies work in parallel, the output terminals are connected together, and the current sharing signal lines are
also connected.

Now suppose that the output current Io1 of the power supply A is larger than the output current Io2 of the
power supply B, then the current sampling voltage of A inside the two power supplies will be higher than B,
that is, JL1+ is higher than JL2+, and JL1+ and JL2+ are connected on the same line (current flow bus).
Therefore, JL2+ rises, the output voltage rises by the control of the internal current sharing circuit of power
supply B, Io2 increases and Io1 decreases (load current does not change); when Io2 is higher than Io1, its
control process is on the contrary. This cycle will eventually make the output voltage and current of the two
power supply consistent.

Figure 26. Parallel Current Sharing Diagram

The function of the circuit composed of Q3, C19, R34 to R36 is that Q3 is turned on when the output voltage
is low or the output is under voltage at the initial stage of power supply, so that pin 3 of U2A is at a low level.
Pin 1 of U2A outputs a low level, and Q1 is cut off, that is, the current sharing circuit does not work. VR1 can
adjust the voltage value of the current sharing signal, and can also adjust the output current limit point.

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