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DC TO DC BUCK CONVERTER DESIGN

Submitted by:

Author

Project supervisor

Date
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Abstract

The report examines how to design a dc to dc converter system. All converters are derived from

two laid out basic converters: buck and boost converters.

The aim is to design converter from known parameters by using accurate calculations, design

configuration (CCM) and analyzing using established simulation software such as LTSpice or

MATLAB/SIMULINK.
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Table of Contents

Abstract .............................................................................................................................................................. 2

Table of Contents ............................................................................................................................................... 3

Design of the buck converter ............................................................................................................................. 4

Step 1 ................................................................................................................................................................. 5

1.Selection of components by calculation: .................................................................................................... 5

Explanation of components and choosing standard values ............................................................................... 6

Step 2 ................................................................................................................................................................. 7

2.Calculation of duty cycle and switch frequency ......................................................................................... 7

3.Simulation of the designed circuit .............................................................................................................. 7

Step 3 ................................................................................................................................................................. 8

4. Analysis of the converter performance ...................................................................................................... 8

I. Efficiency.................................................................................................................................................... 8

II. Voltage ripple ............................................................................................................................................ 8

III. Current ripple ........................................................................................................................................... 9

Step 4 ................................................................................................................................................................. 9

5.Optimization of the converter design ............................................................................................................. 9

6.Comparison of the simulated and theoretical results .................................................................................. 9

Step 5 ................................................................................................................................................................. 9

7. Design trade-off and Limitation................................................................................................................. 9

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Step 6 ............................................................................................................................................................... 10

8. Recommendation for future improvement ............................................................................................... 10

Step 7 ............................................................................................................................................................... 10

9 Epilogue .................................................................................................................................................... 10

SIMULATION RESULTS .............................................................................................................................. 10

Datasheets of the component used .................................................................................................................. 15

References........................................................................................................................................................ 18

Design of the buck converter

Dc to dc converter is an electronic circuit that converts dc voltage from one level to another level.

There are three different main types:

• Buck converter

• Boost converter

• Buck-boost converter.

Buck converter is used to convert high input voltage to lower output voltage level. Also called

step-down converter. (Taufik, 2017)

Boost converter is used to convert lower input voltage level to higher output voltage level.

It is also called step-up converter

Buck-boost converter is used when the output voltage is maintained low or higher depending on

the source input voltage. (Steve, 2015)

The exercise in question involves designing the buck converter given the following parameters

 Input voltage = 48V

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 Output voltage = 12V

 Maximum output current = 10A

 Switching frequency = 100kHz

Step 1

1.Selection of components by calculation:

Let start by calculating duty cycle;

𝐷 = 𝑉𝑜𝑢𝑡 == 𝟎. 𝟐𝟓
𝑉𝑖𝑛

Inductor: Let design inductor for 30 per cent ripple of the inductor current. Change in inductor

current is given by:

∆IL = 𝑅𝑖𝑝𝑝𝑙𝑒 % × 𝑜𝑢𝑡𝑝𝑢𝑡 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 = × 10 = 𝟑𝑨

𝐿= 𝑉𝑜𝑢𝑡 (1 − 𝐷)
𝑓𝑠𝑤 × ∆𝐼𝐿

𝐿 = 100 ×12103 × 3 (1 − 0.25) = 𝟑𝟎𝝁𝑯

Max Inductor current = 𝐼𝑜 + ∆2𝐼𝐿 = 10 + = 11.5𝑉

Capacitor: Capacitor is design by considering its resistance which has huge impact in

performance of the system. Consider:

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𝐶=8 𝑓𝑠∆∆𝐼𝑉𝐿𝑜𝑢𝑡 𝑏𝑢𝑡, ∆𝑉𝑜𝑢𝑡 = 𝐸𝑆𝑅 × ∆𝐼𝐿 = 0.02 × 3 = 0.06

𝐶=8 ×100×3103×0.06 = 𝟔𝟐. 𝟓𝝁𝑭

Max capacitor voltage = 𝑉𝑜𝑢𝑡 + ∆ 𝑉2𝑜𝑢𝑡 = 12 + 0.02 = 12.02𝑉

Diode: Direct current value of diode is computed as follow.

𝐼𝑑𝑖𝑜𝑑𝑒 = 𝐼𝑜 × (1 − 𝐷), 𝐼𝑜 = 𝐼𝑚𝑎𝑥/2

𝐼𝑑𝑖𝑜𝑑𝑒 = 5 × (1 − 0.25) = 𝟑. 𝟕𝟓A

Select diode of current rating lower than the given value.

MOSFET: Sizing the MOSFET

𝐼𝑀𝑂𝑆𝐹𝐸𝑇 = 𝐼𝑜 × 𝐷, 𝐼𝑜 = 𝐼𝑚𝑎𝑥/2

𝐼𝑀𝑂𝑆𝐹𝐸𝑇 = 5 × 0.25 = 𝟏. 𝟐𝟓 𝑨

Explanation of components and choosing standard values

Inductor: is used to store energy during switching period of on-time of MOSFET operation and

release the energy during off state.

The component should have higher saturation current with lower value of series resistance. Take

standard value of 33𝝁𝑯 from Bourns Inc. SRR1005-330Y series.

Capacitor: Mostly, used to filter out ac components for smooth dc output. Resistance selected

should have lower series resistance and ripple current of less than 5%. Take KEMET T520 series

with 60 𝝁𝑭 and 63V DC, Rser of 0.025 ohms

MOSFET: It should have lower gate charge and lower on state resistance value. Take

SiSHA14DN Vds should be equal or greater than 15V

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Diode: Select Schottky diode DFLS220L as fast recovery time, low turn on voltage and low loss

of energy on high frequency.

Step 2

2.Calculation of duty cycle and switch frequency

Duty cycle is a fraction of the commutation time during which the MOSFET switch is ON. It is

calculated as follows:

𝐷𝑢𝑡𝑦 𝑐𝑦𝑐𝑙𝑒, 𝐷 = 𝑉𝑜𝑢𝑡 = = 0.25

𝑉𝑖𝑛

From the requirements the switching frequency is set 100 kHz which is best selected for

optimization of capacitor and inductor sizes to be used.

3.Simulation of the designed circuit

The simulation software to be used in simulation of the circuit is LtSpice software.

The block diagram of the system is as shown below.

Figure 1.

Vin is the voltage signal that given to the system, the voltage level is 48v dc, it passes through

filter to remove any unwanted signal through inbuilt filter. The MOSFET npn is used as the

switch, which open and closes through PWM controller. The signal proceeds to arrangement of
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inductor, capacitor and freewheel diode for desired characteristic, inductor ensure desired

operation mode (continuous or discontinuous mode) and reduces output voltage ripples.

Capacitor filters voltage wave form to minimize the ripples.

Push-pull amplifier circuit if is included to improve the gate to source voltage.

Step 3

4. Analysis of the converter performance

I. Efficiency

The efficiency of the system is given as;

𝜂 = 𝑃𝑜𝑢𝑡
𝑃𝑖𝑛

𝑃𝑜𝑢𝑡 = 𝑉𝑜𝑢𝑡 × 𝐼𝑜𝑢𝑡 = 12 × 10 = 120𝑊

The configuration choose for operation is continuous conduction mode. Input current is

calculated as follows.

𝐼𝑜𝑢𝑡 10
𝐼𝑖𝑛 = == 40𝐴
𝐷𝑢𝑡𝑦 𝑐𝑦𝑐𝑙𝑒 0.25

Therefore, 𝑃𝑖𝑛 = 𝑉𝑖𝑛 × 𝐼𝑖𝑛 = 48 × 40 = 1920𝑊

Efficiency, 𝜂= × 100 = 6.25%

II. Voltage ripple

Voltage ripple is a series of wave that occurs at the output of the capacitor voltage. The choose

capacitor for the design has ESR of 0.02

Hence:

∆𝑉𝑜𝑢𝑡 = 𝐸𝑆𝑅 × ∆𝐼𝐿

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∆𝑉𝑜𝑢𝑡 = 0.02 × 3 = 0.06𝑉

III. Current ripple

Current ripple is also crucial characteristic which need to be analyzed. It is calculated as follows

∆𝑉𝑜𝑢𝑡 × 𝑑𝑢𝑡𝑦 𝑐𝑦𝑐𝑙𝑒

∆𝐼𝑜𝑢𝑡 =
𝑓×𝐿

(Steve, 2015) ∆𝐼𝑜𝑢𝑡 = 100 ×10123××033.25×10−6 = 0.91𝐴

Step 4.

5.Optimization of the converter design.

There are different proven methods that can be used for optimization of the converter design.

i) Use of the capacitor of lower equivalent series resistance, but also with higher

current ripple filtering capability ii) The MOSFET used should have lower Qg and

Rds to reduce losses

iii) The inductor used should have lower dc resistance between 0.1 to 3ohms

6.Comparison of the simulated and theoretical results

The result comparison significantly establishes any deviations seen from the design output. The

fundamental signal which is a voltage that need to be stepped down to exact value of 12V from

48V has shown some deviation of -0.5V, giving 12-0.5=11.5.

This is as result of use of non-ideal components and parasitic nature that offer some resistance.

Step 5.

7. Design trade-off and Limitation

Careful component selection is paramount, as it affects reliability, efficiency, cost and

performance of the system.

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It is observed, topology and the switching frequency heavily affects characteristics such as power

output, voltage output, and voltage ratio. As an example higher switching frequency level can

tremendously reduce component sizes.

Higher duty cycle increases conduction losses, but at the same time reduces output voltage

ripples.

Step 6.

8. Recommendation for future improvement.

It is recommended that:

i) Close loop system should be included in the design of the buck converter, which

give an accurate result even in the presence of non-linearity.

ii) High grade components should be used to improve the functionality of the system

iii) Chosen switching frequency should match the level of required output. iv)

The capacitor with much lower ESR is recommended.

Step 7.

9 Epilogue

The circuit designed is a step-down converter based on the provided parameters, which are

voltage, current, and frequency. Calculation for all components and use of recommended

simulation software LTSpice has also been implemented, and comparison of the theoretical and

simulation results provided.

Additionally, design trade-off and limitation, recommended future improvement has also been

discussed for better system design.

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SIMULATION RESULTS.
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Figure 2
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Figure 3
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Figure 4.
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Datasheets of the component used

Figure 5
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Figure 6
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Figure 7
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References

Steve, R. (2015). DC/DC Book of Knowledge. RECOM.

Taufik. (2017). Practical Design of Buck Converer. Cal poly, 10-100. Retrieved from

https://www.researchgate.net/publication/321903540