Boost Design Calc

Battery minimum voltage =
Battery maximum voltage =

Minimum Input Voltage : Vin(min) =
Maximum input voltage: Vin(max) =
Output voltage : Vo =
Output Voltage Ripple :dVout =
Diode drop voltage : VD =
Switch voltage drop : Vsw=
Fsw =
Required output Power =
9
12.5
27
37.5
75
0.25
0.01
0.01
50000.00
500
V
V
V
V
V
V
V
V
Hz
W
9
12.5
27
37.5
75
0.25
0.01
0.01
50000
500
Max output power efficiency =

100 %
Calculated power for the design : Pout =
Pdesign = Pout / Efficiency
500 W
Ts =
Ts = 1/ Fsw
2.00E-05 sec
calculate maximum output current : Io = 6.6666666667 A
Calculated from Pdesign
% load for RL calculation =
%
100
Load Resistor for % load =
11.25 ohm
Dmax =
1-((Vin(min)-Vsw)/(V0+VD))
0.64
Dmin =
1-((Vin(max)-Vsw)/(V0+VD))
0.50
Discontinous mode Design
To calculate Ton and Toff,
Ton/ Toff = (Vo-Vin)/Vin
Ton+Toff = 0.8Ts
Ton+Toff = 0.8*Ts =
1.60E-05 sec
"Ton" limited for DCM : Ton = 0.8*Ts*Dmax =
1.02E-05 uSec
Calculate range of inductor that will operate in discontinues mode :
Minimum Inductance, Lmin = (Vin^2*Ton) / (2*Io*Vo)
Lmin =
For DCM operation mode, we need "L" less tha
7.46 uH :
Exact inductor value calculation = L =[ (Vin^2 * Ton ) * (Ton+Toff)] / (2*Vo*Ts*Iout)
L=
Loop response will be poor
5.97 uH
Peak current calculation : Ipeak or I2 =
major ripple is from cap ESR. Maximum ripple voltage Vrr =
ESR =
For electrolytic Caps, assuming ESR*C = 80usec, C =
6.67 A
2.50E-01 V
3.75E-02 E
2133.33 uF
Continous conduction mode Design

Output average current = Io(avr) = 6.6666666667 A
Duticycle calculation
Dmax =
0.64
Dmin =
0.50
Inductor Current calculation
In Boost converter "Iin(avr)" and "IL(avr)" are same
At minimum input voltage condition:
Max average Inductor current (at Vin(max)) : Iin(max-avr)= 18.5278498209 A
At maximum input voltage condition:
Min average Inductor current(at Vin(min)) : Iin(min-avr) = 13.3386680893 A
Iin(avr) = Io/(1-D)
Iin(avr) = Io/(1-D)
Maximum Inductor DC Current = IL(dc) = 18.5278498209 A

Inductor ripple current ratio selection:
Maximum ripple current occure at maximum input DC voltage (D~min) (inductor current will be small), maximum peak current value occur
at minimum input voltage (D~max) . During minimum input voltage Inductor current will be high, ripple will reduce.
Selection of ripple current ratio should be for maximum input voltage.
Target maximum current ripple ratio of "r" =
r = diL/Iin(minimum)
0.100
Inductor current at Max Input Voltage
Inductor current at maximum input voltage : IL(min-avr) = 13.3386680893 A
Inductor ripple current (AC Current) = IL(ac) =
dIL = 2*[r*IL(min-avr)]
2.668 A
Peak Inductor Current : ILpk =
ILpk = (dIL/2)+Iin(min-avr)
14.673 A
Worst case "ripple current" occures is at max line voltage
Ipeak
Iavg
Imin
I = 2.77A
Iavr= 13.8A
ton tof
ton + tof = seconds
Inductor calculation for maximum input voltage and limiting maximum ripple current.
Inductor selection limit maximum ripple current at worst case situation.
"L" value to limit ripple at maximum input voltage : L = 140.624977506 uH
(Vin(max)*Dmin*Ts) /[IL(ac)]
Inductor current at Min Input Voltage
Worst case "peak current" occures is at minimum line voltage
Vin(min) =
27 V
Dmax =
0.64
Inductor ripple current for Vin(min) : IL(ac) = 2.4573861402 A
[(Vin-Vsw)*D(max)*Ts]/L
Average Inductor current at Vin min voltage : IL(min-avr) = 18.5278498209 A
Maximum Peak Inductor Current (at Vin(min)) : ILpk =
19.756542891 A
This current value required for Core Energy cal
Ripple current percentage = 0.1326320196 A
Ipeak
Iavg
Imin
I = 2.4A
Methode #2 by fixing minimum load current and reverse calculating "r".

tonDCM
tofat low load condition.
Reducing risk when possibility to enter
"Io" maximum = 6.6666666667
(10% of Io) Minimum load current "Io" minmum = 0.6666666667
Inductor ripple current ratio estimation (modified r ): r =
0.200
Re calculating "L"
"L" value to limit ripple at Dmin (Worse case) : Lmax = 101.2394810053
Output Capacitor :
C >= 224.9999640096
Selected capacitor =
A
A
r = 2*Io(min) / Io(max)
uH
(Vin(max)*Dmin*Ts) /(r*Iin(mmax)(avr)
uF
uF
C >= Dmin*Vout / Fsw*RL*dVout
Icrms =
RESR low =
RESR high =
2.33 mA
0.036 ohm @ TA = 20degC, 100KHz
0.13 ohm @ TA = -10degC , 100KHz
Ripple voltage calculation :

peak to peak ripple voltage = Iout/C*Fsw
C > Dmin*Vout/Fsw*RL*Vripple = 266.773319113 uF
Boost Inductor design :

Material : Iron Powder E core
1. Compute the product of LI^2 where:
L = inductance required with DC bias
I = DC current (A)
Minimum Inductance; L = 140.624977506 uH
19.756542891 A
Peak current calculated from Vin(min) conditio
LI^2 =
54.89 mH*A^2
Core selection from manufacture CORESELECTORCHARTS
Selected core number : ol Mu 77439-A7
Selected Core = K5528E060, pg 4-36

Part number : 00K5528E / (DIN 55/21)
all are in mm
A= 54.860.813
B= 27.560.406
C=
D=
E=
F=
L=
M=
20.60.381
18.5
37.49
16.80.381
8.38
10.2
Bobbin number : PCB5528WC \ OOB5528B1

Electric /Magnetic specification
AL =
219 nH/TURNS 8%
Magnetic Path length Le =
12.3 cm
Core area Ae =
350 mm2
Permeability :u =
60
Window area =
302 mm2
Step#1: Calculation of turns for inductance at zero current.
Assume 50% roll off, wind for: L(mod) = 281.249955012 uH
u=
60
Inductance factor from datasheet =
219 nH/T^2
Tolerance considered = (-%) =
0 %
Current = 19.756542891 A
Actual (AL) of this core : AL =
219 nH/T^2
; Inductance at 0Ampere current, Load current inductance will be less.
calculate Turns at 0Ampere "N" = sqrt ([L*1e3]/AL) : N =
36 Turns
Magnetic Path Length : le =
12.3 cm
Step#2 : Calculate DC Bias level,
determine the DC Bias level: H= NI/le= AT/cm
DC Bias Level : H = (N*I)/Ie : H =
57.8 A*T/cm
DC Biase calculation by using Amperes law = 72.6638165932 Oe
; Tolerance is AL 8%
;From core datashet
; Ie = path Lenth in "cm"

; 0.4pi*N^2*I/le
Fit Formula to find rolloff in per unit of initial permeability for the previously calculated bias level.
r "60" Kool Mu Core, (/ui) = a + bH + cH^2 + dH^3 + eH^4
a=
###
c= -8.76E-05
e= -2.62E-09
b=
###
d= 9.45E-07
tizing force(dc bias), yielding 48.5% of initial permeability =
60.4 %
The inductance at xxAmpere will decrease the inductance by xx% compared with 0Ampere. The permeability versus
DC bias curve shows xx% of initial permeability at xx AT/cm.
% rolloff value =
0.604
Step#3: Iteration: Recalculation of Inductance :
ecalculated Inductance with scaledown by %rolloff value ;L=
171.429696 uH ; %rolloffvalue*N^2*AL
This roll off value is less than target inductance at full load.
Recalculate Inductor Current
At High input Voltage ;
Initial Ipk =
14.673 A
DC Biase calculated in H = 42.9440045801 A*T/cm
% rolloff value =
0.713
ecalculated Inductance with scaledown by %rolloff value ;L=
202.366512 uH
Vin(max) =
37.5 VDC
Dutycycle when Vin(max) applied = Dmin = 0.5001999733
Recalculate Inductor ripple current:
Recalculated maximum Inductance ripple current at Vin(max)=
1.8533201778 A
Recalculate Inductor peak Current

Inductor current at maximum input voltage : IL(min-avr) =
Ipeak = Iavr+(Iripple/2) =
DC Biase calculation by using Amperes law =
DC Biase calculated in H =
% rolloff value =
At Low input Voltage ;
% rolloff value =
Iterate: Recalculate Inductance ;L=
Recalculate Inductor ripple current with scaled inductance :
Inductor ripple current for Vin(min) : IL(ac) =
Average inductor current at Vin(min) =
% rolloff value =
13.3386680893 A
14.2653281782 A
145.7426022948 Oe
41.7521800337
0.722
19.756542891 A
57.8240279737 A*T/cm
0.603
169.5937228722 uH
2.0383885741 A
18.5278498209 A
19.547044108 A
57.2108608039
0.608
170.9999726473 uH
Final Inductorvalue :
No Load Inductance ; L(nl) = 281.249955012 uH
Full load inductance L(fl) = 170.9999726473 uH
Inductor Max Ripple = 13.2632019577 %
Inductor Wire selection:
Turns =
AWG =
Resistance =
Wire area =
max current capacity =
Window area =
Fill Factor of the inductor =
Vin =
Vout=
75
Fs
50000
L=
140
rsense=
0.1
Fc=
5000
s = 2*pi*Fc 31415.9
Vramp =
5.2
36
11
0.00414
0.0445
20.8
302
0.5304635762
v
v
Hz
uh
ohm
Hz
V
ohm/meter
sq.cm2
A
sqcm2
%
Closed loop Voltage mode controller design

Gid = (Vou*Rsense)/(s*L*Vramp) = 0.32793
Gain of controller = Gea =
3.04944
9.6844 db
Rf = 3.04944 k
Ri=
1 k
The zero of the compensation network (fz) is placed at the crossover freq
Fz = Fc = Cz = 1/(2piRf*fc)
Fz =
5000 Hz
Rf = 3.04944 Kohm
C1 , Cz =
10.4383 nF
(switching frequency) and fs to attenuate noise,
fp =
25000 Hs
fp = 1/(2pi*Rf*(Cz*Cp/Cz*Cp))
C2, Cp = 1/(2pi*Rf*fp) = 2.08766 nf
0.05
System transfer function with standard negative feedback.

Vout(s)/Vcont(s) = G(s)/(1+G(s)H(s)) ;with H(s)=1
Considering open loop transfer function G(s)
G(s) = Gctr(s)*Gckt(s)
where Gctr(s) is propotional and integral controller
Gctr(s) = Kp+1/sTi
where Ti = RiCi
Gain of converter hardware.
For the converter 1.5V input yields Vout (scaled) = 1.5V in steady state. So the gain of the converter is 1.0
Converter transfer function : Gckt(s) =
Where T =
C=
R=
So open loop transfer function G(s) =
1/(1+sT)
RC
output DC capacitor.
Thevenin equivalent resistor
(Kp+1/sTi)*1/(1+sT)
Control to output transfer function given by,

Vout/Vcont=
Kp/T*(s+(1/Ti*Kp))
s2+s((1+kp)/T)+1/TTi
From standard second-order system equation form,

s2+2zns+n2
n2 =
1/ TTi
2zns = 1+Kp/T
Calculating Kp from above equation,
Kp = 2zns - 1 =2zsqrt[(T/Ti)-1]
As thumb rule, Considering Ti = 80%T and z > 0.447
out / Efficiency
rom Pdesign
)-Vsw)/(V0+VD))
x)-Vsw)/(V0+VD))
peration mode, we need "L" less than.
off)] / (2*Vo*Ts*Iout)
nse will be poor
)-Vsw)/(V0+VD))
)-Vsw)/(V0+VD))
1.9V
maximum peak current value occures

will reduce.
IL(min-avr)]
/2)+Iin(min-avr)
Dmin*Ts) /[IL(ac)]
*D(max)*Ts]/L
value required for Core Energy calc
Dmin*Ts) /(r*Iin(mmax)(avr)
*Vout / Fsw*RL*dVout
0.0199
50.251256
0.0122
0.6130653
t calculated from Vin(min) condition
Discontinues mode
Lenth in "cm"
bias level.
Analysis in Discontinues Mode Operation;

During Ton :
D1 = Off
VL = Vd
For inductor : VL = L (dI2(t)/ dt)
Or
I2 = (Vd Ton / L)
During Toff :
D1 = On
VL = Vd - Vo
VL = L (dIL(t)/dt)
IL(t) = 1/L integ(VL(t)dt + I2
:: I2 = Inductor peak cur
Or
0 =1/L (integ[(Vd-Vo)dt + I2] Lim(Ton-Ton+Toff)
Or
I2 = ((Vo-Vd)
L) * Tofpeak current
:: I2 = /Inductor
To Ensure discontinues mode choose Td = 0.2Ts
Ton + Toff <= 0.8Ts
Power balance : avg power delivered by source.
Pd = Vd <IL>
During Ton+Toff <IL^> = I2/2
So over Ts,
<IL> = <IL^> (Ton+Toff) / Ts
`= I2*0.5* ( (Ton+Toff)/Ts)
Or
Pd = ((Vd^2* Ton)/(2*L*Ts))*(Ton+Toff)
current boundry to maintain discontinuos mode :

Io <= ((Vd*Ton)/2L)*(Vd/Vo)
Capacitor RMS Ripple current:
During Toff Inductor supplies Io and charges Capacitor.
During Toff, the average inductor currnt is,

Ix = I2/2
gain of the converter is 1.0
Ipeak : Ipk =
Turns : N =
Area : A =
14.673 A
40 turns
2 cm^2
calculation to check peak flux density for a selected core = Bpk =
0.18568 Tesla
MOSFET Power Dissipation calculation for Boost Converter

Rds (on) =
0.025 Ohm
IRMS is the RMS of the switch current : IRMS = 14.830555 ARMS
For verification : IRMS = 14.824379 ARMS
To calculate the conduction loss of a mosfet = Pcond =
5.50 W
:: I2 = Inductor peak current
on-Ton+Toff)
Bpk = (L*Ipk)/(N*A)
ation for Boost Converter

IRMS = [Io/(1-Dmax)]*[sqrt(Dmax*(1+r^2/12))]
IRMS ~= IL(dc)*sqrtDmax
Discontinues mode
Analysis in Discontinues Mode Operation;

During Ton :
D1 = Off
VL = Vd
For inductor : VL = L (dI2(t)/ dt)
Or
I2 = (Vd Ton / L)
During Toff :
D1 = On
VL = Vd - Vo
VL = L (dIL(t)/dt)
IL(t) = 1/L integ(VL(t)dt + I2
:: I2 = Inductor peak current
Or
0 =1/L (integ[(Vd-Vo)dt + I2] Lim(Ton-Ton+Toff)
Or
I2 = ((Vo-Vd)::/I2
L)=*Inductor
Tof
peak current
To Ensure discontinues mode choose Td = 0.2Ts
Ton + Toff <= 0.8Ts
Power balance : avg power delivered by source.

Pd = Vd <IL>
During Ton+Toff <IL^> = I2/2
So over Ts,
<IL> = <IL^> (Ton+Toff) / Ts
`= I2*0.5* ( (Ton+Toff)/Ts)
Or
Pd = ((Vd^2* Ton)/(2*L*Ts))*(Ton+Toff)
current boundry to maintain discontinuos mode :

Io <= ((Vd*Ton)/2L)*(Vd/Vo)
Capacitor RMS Ripple current:
During Toff Inductor supplies Io and charges Capacitor.
During Toff, the average inductor currnt is,

Ix = I2/2
page 166
Minimum Input Voltage : Vin(min) =
Maximum input voltage: Vin(max) =
Output voltage : Vo =
Output Voltage Ripple :dVout =
Diode drop voltage : VD =
Switch voltage drop : Vsw=
Fsw =
Required output Power =
85
260
370
0.25
0.01
0.01
65000.00
650
V
V
V
V
V
V
Hz
W
150
480
600
1
1.5
60000
3000
Max output power efficiency =

96 %
Calculated power for the design : Pout = 677.0833333333 W
Ts =
1.54E-05 sec
calculate maximum output current : Io =
1.829954955 A
Pdesign = Pout / Efficiency

Ts = 1/ Fsw
Calculated from Pdesign
To calculate Ton and Toff,

Ton/ Toff = (Vo-Vin)/Vin
Ton+Toff = 0.8Ts
Ton+Toff = 0.8*Ts =
1.23E-05 sec
Dmax =
0.77
Dmin =
0.30
"Ton" limited for DCM : Ton = 0.8*Ts*Dmax =
9.48E-06 uSec
Discontinous mode Design
Calculate range of inductor that will operate in discontinues mode :
Minimum Inductance, Lmin = (Vin^2*Ton) / (2*Io*Vo)
Lmin =
For DCM operation mode, we need "L" less t
50.57 uH :
Exact inductor value calculation = L =[ (Vin^2 * Ton ) * (Ton+Toff)] / (2*Vo*Ts*Iout)
L=
Loop response will be poor
40.46 uH
Peak current calculation : Ipeak or I2 =
major ripple is from cap ESR. Maximum ripple voltage Vrr =
ESR =
For electrolytic Caps, assuming ESR*C = 80usec, C =
19.92 A
2.50E-01 V
1.26E-02 E
6373.47 uF
Continous mode Design

Output average current = Io(avr) =
1.829954955 A
Duticycle calculation
Dmax =
0.77
Dmin =
0.30
Inductor Current calculation
In Boost converter "Iin(avr)" and "IL(avr)" are same
At minimum input voltage condition:
Max average Inductor current (at Vin(max)) : Iin(max-avr)= 7.9668388385 A
Iin(avr) = Io/(1-D)
At maximum input voltage condition:
Min average Inductor current(at Vin(min)) : Iin(min-avr) = 2.6043372164 A
Iin(avr) = Io/(1-D)
Maximum Inductor DC Current = IL(dc) = 7.9668388385 A
Inductor ripple current ratio selection:
Maximum ripple current occure at maximum input DC voltage (D~min) (inductor current will be small), maximum peak current value occur
at minimum input voltage (D~max) . During minimum input voltage Inductor current will be high, ripple will reduce.
Selection of ripple current ratio should be for maximum input voltage.
Let target maximum current ripple ratio of "r" =
r = diL/Iin(minimum)
0.400
Inductor current at Max Input Voltage
Inductor current at maximum input voltage : IL(min-avr) = 2.6043372164 A
Inductor ripple current (AC Current) = IL(ac) =
dIL = 2*[r*IL(min-avr)]
2.083 A
Peak Inductor Current : ILpk =
A
ILpk = (dIL/2)+Iin(min-avr)
3.646
Worst case "ripple current" occures is at max line voltage
Ipeak
Iavg
Iavg
Imin
I = 2.08A
Iavr= 2.6A
ton tof
ton + tof = seconds
Inductor calculation for maximum input voltage and limiting maximum ripple current.
Inductor selection limit maximum ripple current at worst case situation.
Inductor current at Min Input Voltage
Worst case "peak current" occures is at minimum line voltage
Vin(min) =
85 V
Dmax =
0.77
Inductor ripple current for Vin(min) : IL(ac) = 1.7643525949 A
Average Inductor current at Vin min voltage : IL(min-avr) = 7.9668388385 A
8.8490151359 A
Ripple current percentage = 0.2214620668 A
(Vin(max)*Dmin*Ts) /[IL(ac)]
[(Vin-Vsw)*D(max)*Ts]/L
This current value required for Core Energy c
Ipeak
Iavg
Imin
I = 1.7A
Ipeak 8.4A
Iavr 7.9A
ton tof
Methode #2 by fixing minimum load current and reverse calculating "r".

Reducing risk when possibility to enter DCM at low load condition.
"Io" maximum =
1.829954955
(10% of Io) Minimum load current "Io" minmum = 0.1829954955
Inductor ripple current ratio estimation (modified r ): r =
0.200
Re calculating "L"
"L" value to limit ripple at Dmin (Worse case) : Lmax = 746.4524413602
Output Capacitor :
C >= 2599.616714539
Selected capacitor =
Icrms =
RESR low =
RESR high =
1500
2.33
0.036
0.13
A
A
r = 2*Io(min) / Io(max)
uH
(Vin(max)*Dmin*Ts) /(r*Iin(mmax)(avr)
uF
C >= Dmin*Vout / Fsw*RL*dVout
uF
mA
ohm @ TA = 20degC, 100KHz
ohm @ TA = -10degC , 100KHz
Boost Inductor design :

Material : =on Powder E core
1. Compute the product of LI^2 where:
L = inductance required with DC bias
I = DC current (A)
Minimum Inductance; L = 570.8617785305 uH
8.8490151359 A
Peak current calculated from Vin(min) condit
LI^2 =
44.70 mH*A^2
Core selection from manufacture CORESELECTORCHARTS
Selected core number : ol Mu 77439-A7
Step#1: Calculation of turns for inductance at zero current.

"L" value to limit ripple at maximum input voltage : L = 570.8617785305
Assume 50% roll off, wind for: L(mod) = 1141.723557061
u=
60
135
0
Current = 8.8490151359
Actual (AL) of this core : AL =
135
; Inductance at 0Ampere current, Load current inductance will be less.
calculate Turns at 0Ampere "N" = sqrt ([L*1e3]/AL) : N =
92
10.74
Step#2 : Calculate DC Bias level,
DC Bias Level : H = (N*I)/Ie : H =
75.8
DC Biase calculation by using Amperes law = 95.2551242722
uH
uH
nH/T^2
%
A
nH/T^2
Turns
cm
;From core datashet
A*T/cm
Oe

; 0.4pi*N^2*I/le
for "60" Kool Mu Core, (/ui) = a + bH + cH^2 + dH^3 + eH^4
a= 1
c= -8.76E-05
e= -2.62E-09
b= -4.45E-03
d= 9.45E-07
netizing force(dc bias), yielding 48.5% of initial permeability =
48.5 %
The inductance at xxAmpere will decrease the inductance by xx% compared with 0Ampere. The permeability versus
DC bias curve shows xx% of initial permeability at xx AT/cm.
% rolloff value =
0.485
Recalculated Inductance with scaledown by %rolloff value ;L=
554.1804 uH ; %rolloffvalue*N^2*AL
This roll off value is less than target inductance at full load.
At High input Voltage ;
Initial Ipk =
3.646 A
DC Biase calculated in H = 31.2326474365 A*T/cm
% rolloff value =
0.802
Recalculated Inductance with scaledown by %rolloff value ;L=
916.39728 uH
Vin(max) =
Dutycycle when Vin(max) applied = Dmin =
Recalculate Inductor ripple current:
Recalculated maximum Inductance ripple current at Vin(max)=
Inductor current at maximum input voltage : IL(min-avr) =
Ipeak = Iavr+(Iripple/2) =
DC Biase calculation by using Amperes law =
% rolloff value =
At Low input Voltage ;
% rolloff value =
Recalculate Inductor ripple current with scaled inductance :
Inductor ripple current for Vin(min) : IL(ac) =
Average inductor current at Vin(min) =
% rolloff value =
260 VDC
0.297343315
1.2978295997 A
2.6043372164 A
3.2532520162 A
38.0647770369 Oe
27.8677081463
0.827
8.8490151359 A
75.8016194138 A*T/cm
0.485
553.7359251746 uH
1.8191342167 A
7.9668388385 A
8.8764059468 A
76.0362520584
0.483
551.4524780605 uH
Inductor final value :
No Load Inductance ; L(nl) = 1141.723557 uH

Full load inductance L(fl) = 551.4524781 uH
Inductor Max Ripple = 22.14620668 %
Inductor Wire selection:
Turns =
AWG =
Resistance =
Wire area =
max current capacity =
Window area =
Fill Factor of the inductor =
92
14
0.00828
23.1
10.4
4.27
770.49180328
ohm/meter
23.1
sq.cm2
A
%
Ipeak : Ipk =
Turns : N =
Area : A =
3.646 A
40 turns
2 cm^2
calculation to check peak flux density for a selected core = Bpk =
0.3402024278 Tesla
Bpk = (L*Ipk)/(N*A)
MOSFET Power Dissipation calculation for Boost Converter

Rds (on) =
0.025 Ohm
IRMS is the RMS of the switch current : IRMS =

For verification : IRMS =
To calculate the conduction loss of a mosfet = Pcond =
7.0387109901 ARMS
6.9922503438 ARMS
1.24 W
IRMS = [Io/(1-Dmax)]*[sqrt(Dmax*(1+r^2
IRMS ~= IL(dc)*sqrtDmax
out / Efficiency
rom Pdesign
)-Vsw)/(V0+VD))
x)-Vsw)/(V0+VD))
peration mode, we need "L" less than.
f)] / (2*Vo*Ts*Iout)
nse will be poor
)-Vsw)/(V0+VD))
)-Vsw)/(V0+VD))
aximum peak current value occures
IL(min-avr)]
/2)+Iin(min-avr)
Dmin*Ts) /[IL(ac)]
*D(max)*Ts]/L
value required for Core Energy calc
Dmin*Ts) /(r*Iin(mmax)(avr)
*Vout / Fsw*RL*dVout
t calculated from Vin(min) condition
Lenth in "cm"
ias level.
/(1-Dmax)]*[sqrt(Dmax*(1+r^2/12))]
(dc)*sqrtDmax
Boost converter 150V- 480V input ; 600V output

Legend:
Parameter
Value
Unit
Vg_min
Vg_max
150 V
480 V
Vo
600 V
Po
3000 W
Io
5.000 A
Dmax
Actual Dmax
Dmin
Actual Dmin
Ig_max
0.750
0.767
0.200
0.206
21.431 A
Ig_min
R
6.298 A
120.000 ohms
Rl
Rg
Rc
alpha
0.200 ohms
0.200 ohms
0.200 ohms
3.33E-03
beta
Vsw
1.580 V
Vd
1.000 V
efficiency_min
0.933
efficiency_max
0.992
Pg_max
3214.680
Pg_min
3022.915
0.25
di
5.000 %
fs
6.00E+04 Hz
Ts
1.67E-005 s
L_min
L_max
L
K
Kcrit
Actual Current Ripple for
Vgmin
Actual Current Ripple for
Vgmax
Worst case inductor peak

current
Output voltage ripple
Output capacitor
rms capacitor current
1.79E-03
1.79
5.24E-03
5.235258777
5.24E-03
5.24
5.235258777
0.041732064
H
mH
H
mH
H
mH
0.017 A
0.050 A
21.440 A
0.1 %
106.49 uF
9.06 A
Losses in the converter for a specified operating condition.
IGBT
(a). Conduction losses
Operating Vg
Operating Duty ratio
Current ripple
420 V
0.307
0.410 A
Onstate drop
1.580 V
Average Inductor Current
7.213 A
Peak switch current

Isw, min.
9.418 A
7.008 A
Average switch current

rms switch current
Conduction loss in IGBT
(b). Switching Losses
tr
tf
Pon
Poff
Total Switching losses
2.213 A
3.995 A
3.496 W
115
390
14.506
52.072
66.578
ns
ns
W
W
W
Diode
(a). Conduction Losses
Vd
1.000 V
Diode peak current

Diode min. current
7.418 A
7.008 A
Average diode current

rms diode current
Conduction loss in Diode
5.000 A
6.006 A
5.000 W
Dynamic resistance of
diode at the operating
current
Loss in dynamic res.
0.010 ohms
0.361 W
Total conduction loss in

diode
(b). Switching Losses
trr
Irr
Qrr
Pdiode_sw
Output capacitor
ESR
Icp
Ic rms
Loss in ESR
ripple current in cap.
Voltage ripple due to ESR
Inductor
rms current in Inductor
Peak current in Inductor
Rl
Cu. Loss in the inductor
5.361 W
200.000 ns
2.000 A
2.000E-07 coloumb
3.600 W
0.02
4.418
9.064
1.643
7.418
0.148
ohms
A
A
W
A
V
7.214
7.418
0.200
10.407
A
A
ohms
W
Magnetic losses
Source
Source resistance
0.200 ohms
Source rms current
7.214 A
Loss in the source res.
Total losses
Efficiency
10.407 W
101.492 W
96.73 %
onverter 150V- 480V input ; 600V output

blue cells are design/spec inputs, orange cells are op.
Details
Formula if any
Further Comments
Minimum Input Voltage

Maximum Input Voltage
Output Voltage
Output Power; to be calculated from the actual op and
efficiency of the second stage.
Output Current
Po/Vo
1-(Vgmin/Vo)
Maximum Duty ratio
Cross check Vo=

1-(Vgmax/Vo)
Max. average input current; Corresponding to Dmax
Io/(1-Dmax)
Min. average input current; Corresponding to Dmin

Equivalent Load resistance
Io/(1-Dmin)
Vo/Io
Parasitic resistance of the boost inductor

Parasitic resistance of the source
ESR of the output capacitor
Factor for loss resistances, which affect the efficiency
(Rl+Rg)/R
Switch voltage drop; Vce(sat) of IGBT from Data sheet

Diode voltage drop; from data sheet.
Minimum approx. efficiency; Dmax ; switching losses neglected
Maximum approx. efficiency; Dmin; switching losses neglected
Corresponds to Dmax
Corresponds to Dmin
Only losses in Rg, Rl, approx. conducti
current ripple percentage of nominal inductor current

Switching frequency
Switching period
1/fs
Inductance for the required ripple current. Corr. To Vgmin
Vgmin*Dmax*Ts/(di)
This will ensure minimum current ripple in all conditions.

The boost inductor for ensuring less ripple.
Conduction parameter.
Percentage of output voltage.

This is the minimum value required to satisfy the output ripple
spec. Output ripple content due to ESR is present. To reduce
that, capacitor value chosen must be more. To reduce ESR,
several capacitors need to be parallelled, subject to space
availability and layout considerations.
converter for a specified operating condition.
Change this value to get the performance at different ip volts.

Considering a closed loop control to maintain the output Vo.
Peak to peak current ripple
Vce, sat, to be entered from datasheet
Irr effect of diode is counted here

effect of Irr neglected in this calc.
Rise time of IGBT, from datasheet: for worst case, look at the curves.
Fall time of IGBT, from datasheet.
Off-On losses
On-Off losses.
Switching losses in IGBT
To be entered from datasheet
Reverse recovery time, from datasheet

Reverse recovery current, from datasheet and circuit conditions
Reverse recovery charge, from datasheet/calculation

Peak capacitor current
rms current through capacitor.
Power loss in the capacitor.
To be entered from Inductor design, consider skin effect.
Magnetic losses in L
Magnetic design of L
600 V
ActualDmax
a
b
c
Dmax_disc
Dmax_act 1
Dmax_act 2
599.420
-1050.42
453.000
17233.136
0.9856987
0.7666953
Actual Dmin
a
b
c
Dmin_disc
Dmin_act 1
Dmin_act 2
599.420
-720.42
1.23E+02
4.73E+02
0.9957974
0.2060644
in Rg, Rl, approx. conduction loss in switch, diode are considered.
Actual Dmin
a
b
c
Dmin_disc
Dmin_act 1
Dmin_act 2
599.420
-780.42
1.83E+02
4.13E+02
0.9951869
0.3067716
Boost Inductor physical design: Area-Product method.
Value of L
5.24E-03 H
Max. possible
average current
in the inductor
21.431 A
Peak current
through the
Inductor
21.440 A
rms inductor
current
7.214 A
Obtained from the design of boost stage. Specifies the ripple

current
kw
0.4
Winding factor
Bm
J
0.2 T
3.5 A/mm^2
Max. flux density. 0.2T for ferrite

Current density
Ap= AcAw
Selected Ac
N
2.891691 mm^4
0.01 mm^2
56 turns
aw
2.061029 mm^2
Air gap lg.
7.539928 mm
Area prouct.
Input the selected core area in mm^2 here.; from core data sheet.
Number of turns.
Area of c.s of wire. Choose a gauge greater than this.
Check the core reluctance Rc << Rg, or l/mu_r << lg

Is lg <<
0.1 ??
If not, redesign
core data sheet.
L=
I=
600 uH
5 A (average)
LI^2 =
15000.00 mH*A^2
Select core from core selector sheet;\
Selected core =
55083
81 nH/T^2
8 %
Actual (AL) of this core =
74.52 nH/T^2
Step#1: Calculation of turns for inductance with DC bias
Turns "N" = sqrt ([L*1e3]/AL) =
90 Turns
9.84 cm
;From core datashet
Step#2 : To calculate Turns for full load, fist calculate DC Bia
DC Bias Level : H = (N*I)/Ie =
45.7 A*T/cm
Step#3 : from DC Bias level, find initial permiability using fi
for "60" Kool Mu Core, (/ui) = a + bH + cH^2 + dH^3 + eH^4
a= 1
c= -8.76E-05
e= -2.62E-09
b= -4.45E-03
d= 9.45E-07
Determine the per unit of initial permeability =
69.3 %
;The permeability versus DC bias curve shows
69.33% of initial permeability at 45.59 AT/cm.
Step#4: from per unit initial permiability, scale turns required for full load.
ated Turns to adjusted with rolloff value; "T" =
130 Turns
Step#5: To find modified AL value now calculate "H" value,
ecalculate "H" from modified Turns value; "H" =
66.1 A*T/cm
Step#6: from modified DC Bias level, find initial permiability.
Recheck formula for per unit rolloff value =
54.6 %
Step#7: Re-calculate
AL value
checkingAInductance
value with
Multiply
thefor
minimum
by
L
; Modified Turns vlaue, 90/0.69=130

;The permeability versus DC bias curve shows 54% of
initial permeability at 65.75 AT/cm.
initial permeability value in step#7; new AL

=
40.7 nH/T^2
Step#8: Calculate inductance of the core with recalculated Turns and 40.7
L = Turns^2 * AL /1000 =
687.83 uH
; using Turns 130, AL =40.7nH/T^2
Step#8: Calculate inductance of the core with recalculated Turns and 66.6
L = Turns^2 * AL /1000 = 1259.388 uH
; using Turns 130, AL =74.52nH/T^2

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Battery minimum voltage =

Battery maximum voltage =

Max output power efficiency =

Continous conduction mode Design

Maximum Inductor DC Current = IL(dc) = 18.5278498209 A

Methode #2 by fixing minimum load current and reverse calculating "r".

C >= Dmin*Vout / Fsw*RL*dVout

Ripple voltage calculation :

Boost Inductor design :

Selected Core = K5528E060, pg 4-36

Bobbin number : PCB5528WC \ OOB5528B1

;From core datashet

; Ie = path Lenth in "cm"

Recalculate Inductor peak Current

Closed loop Voltage mode controller design

System transfer function with standard negative feedback.

Control to output transfer function given by,

From standard second-order system equation form,

peration mode, we need "L" less than.

maximum peak current value occures

t calculated from Vin(min) condition

Analysis in Discontinues Mode Operation;

current boundry to maintain discontinuos mode :

During Toff Inductor supplies Io and charges Capacitor.

During Toff, the average inductor currnt is,

gain of the converter is 1.0

calculation to check peak flux density for a selected core = Bpk =

MOSFET Power Dissipation calculation for Boost Converter

:: I2 = Inductor peak current

ation for Boost Converter

Analysis in Discontinues Mode Operation;

Power balance : avg power delivered by source.

current boundry to maintain discontinuos mode :

During Toff Inductor supplies Io and charges Capacitor.

During Toff, the average inductor currnt is,

Max output power efficiency =

Pdesign = Pout / Efficiency

To calculate Ton and Toff,

Continous mode Design

This current value required for Core Energy c

Methode #2 by fixing minimum load current and reverse calculating "r".

C >= Dmin*Vout / Fsw*RL*dVout

Boost Inductor design :

Peak current calculated from Vin(min) condit

Step#1: Calculation of turns for inductance at zero current.

;From core datashet

; Ie = path Lenth in "cm"

Inductor final value :

No Load Inductance ; L(nl) = 1141.723557 uH

calculation to check peak flux density for a selected core = Bpk =

MOSFET Power Dissipation calculation for Boost Converter

IRMS is the RMS of the switch current : IRMS =

peration mode, we need "L" less than.

aximum peak current value occures

t calculated from Vin(min) condition

Boost converter 150V- 480V input ; 600V output

Worst case inductor peak

Output voltage ripple

Average Inductor Current

Peak switch current

Average switch current

Diode peak current

Average diode current

Total conduction loss in

C >= DminVout / FswRL*dVout

C >= DminVout / FswRL*dVout