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The need for high performance power supply systems for LED lighting and, in general, the increasingly greater request for energy efficiency, both regarding running costs and compliance with recent Standards, has brought about a revaluation of the LLC series resonant topology.
In fact all the major manufacturers of active components for the SMPS market have added chips which have effectively contained the supporting circuitry needed to achieve a relatively complex but highly efficient SMPS PSU design whilst offering low EMI/EMC emissions.
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ADVANTAGES |
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- Typical range of efficiency for the simplest circuitry 94 - 96%, with the possibility of improvements through synchronous rectification and other small adjustments;
- Utilising correctly sized magnetic components, the design is rapid and noteably simplified;
- The current waveform at high frequencies it basically sinusoidal with significant reductions in harmonics with respect to other topologies;
- MOSFET commutation ON "ZVS" (Zero Voltage Switching) with associated elimination of commutation, reduction / elimination of dissipators and reduction of stress and disturbances which are often the causes of the most hostile design problems.
- The possibility to reduce consumption with low/zero load by utilizing the functions "burst mode" and "PFC stop" implemented on many controllers.
- The possibility of optimal sizing for continuous and temporary power including some significant improvements on conventional solutions( eg. One of our transformers having volume similar a classic EF25 can temporarily reach up to 200-250W).
With respect to other topologies, with the attributes described above, LLC supplies have reduced dimensions with a noteable reduction in EMI/EMC issues. |
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CRITICAL POINTS |
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- One necessary factor to be considered for the optimised design of power supplies is the magnetics, the ommission of which means to renounce a significant potential in improved efficiency;
- The selection of the optimised onboard transformer requires specific competence;
- Two MOSFETs are required (half bridge) rather than the single MOSFET for the Flyback;
- The controller is slightly less economic than the flyback; This cost increase tends to cancel itself, when it is not transformed into a saving, thanks to the minimal spendings on dissipators, EMC filters, the use of more compact transformers etc. |
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These comparative tests are interesting examples of how it's possible to increase the efficiency thanks to an optimised integrated transformer.
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Fairchild FEB212-003 24V-8A resonant converter demo-board based on chip FSFR2100 |
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Fairchild FEB212-003 24V-8A resonant converter demo-board based on chip FSFR2100 - comparative test |
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NXP UM10450 - 19,5V 90W resonant converter demo-board with PFC based on TEA1713 |
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NXP UM10450 - 19,5V 90W resonant converter demo-board with PFC based on TEA1713 - comparative test |
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STMicroelectronics EVL130W-SL-EU 130 W SMPS for LED street lighting applications based on L6599AT-6562AT |
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STMicroelectronics EVL130W-SL-EU 130 W SMPS for LED street lighting applications based on L6599AT-6562AT - comparative test |
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OUR CAPABILITIES |
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We are able to supply standard transformers with correctly tuned resonant tanks and we collaborate with electronics designers when defining custom resonance tanks to resolve every specific need.
We have made significant investment enabling us to provide a rapid and technically competent support.
With the aid and experience of internally developed proprietary software, we have the ability to offer design solutions which, amongst other factors, take into account skin effect,proximity effect and structural limitations.
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Don't waste your resources:
Even an optimum design of power units and elevated quality components can leave you with deluding results due to poorly optimised matching of your magnetic components.
The collaboration between our company and your electronic engineers at the design phase offers reduced development times without renouncing the best results in terms of efficiency, temperature, costs and footprint. |
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THE INTEGRATED TRANSFORMERS |
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This definition refers to a transformer which integrates its internal resonant inductance utilising the calibrated leaked inductance. (See our technical artical published in various sector magazines in Italy and abroad).
Our standard transformer series covers all the most popular power and voltage needs, see either our catalogue or the link to standard resonants.
To date is is still relatively common to find convertors which for design simplicity make use of discrete inductors in addition to conventional transformers, however their use is totally inefficient in every aspect, economically, and in terms of energy consumption and utilisation of space.
We have the capability to rapidly design and provide samples of custom integrated transformers for specific needs in terms of:
- continual and temporary loads;
- range of input voltage and output voltage;
- eventual preferences in terms of frequency and switching.
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All our integrated transformers can be utilised irresepectively with any controller present in todays markets, some of which we refer here: |