Soft Saturation | PartQuest™ Explore

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This example shows the performance of an ON Semiconductor NCV8876 Automotive Grade Start-Stop Boost Controller:http://www.onsemi.com/pub_link/Collateral/NCV8876-D.PDFFor vehicles with Start-Stop capability, the engine (ICE) is turned off during idle periods, for the purpose of fuel economy. But low-voltage nuisance drop-out of key electronic functions must be avoided during engine re-start. The NCV8876 is designed specifically for this purpose. It uses current-mode control, with many integrated functions to reduce the complexity of the external boost circuit.Simulation results show the output to the load during battery drop-out and recovery. Note that in this application, the output voltage (dark blue waveform) is maintained above 6.4V during the drop-out transient, and regulates at 6.8V during sustained low voltage (4V) battery operation (orange waveform).This circuit also demonstrates the value of soft-saturation inductor components from Coilcraft:http://www.coilcraft.com/pdfs/Doc1140_Beyond_the_data_sheet_Part1.pdfThe load current for the XAL4030-332 inductor in this application is 4A during nominal 12V operation. But during boost operation, the current reaches 6.6A peak (light blue waveform). This could saturate a typical inductor if it were sized for the nominal load, resulting in a collapse of the effective inductance. But notice that the actual instantaneous inductance (green waveform) only drops to 2.2uH, for this nominal 3.3uH part. This relatively small percentage drop in inductance can easily be accommodated by the converter design.

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Copy of NCV8876 - Automotive Start-Stop Boost Controller - on Mon, 02/03/2020 - 16:04

Designer229429

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Description

This example shows the performance of an ON Semiconductor NCV8876 Automotive Grade Start-Stop Boost Controller:http://www.onsemi.com/pub_link/Collateral/NCV8876-D.PDFFor vehicles with Start-Stop capability, the engine (ICE) is turned off during idle periods, for the purpose of fuel economy. But low-voltage nuisance drop-out of key electronic functions must be avoided during engine re-start. The NCV8876 is designed specifically for this purpose. It uses current-mode control, with many integrated functions to reduce the complexity of the external boost circuit.Simulation results show the output to the load during battery drop-out and recovery. Note that in this application, the output voltage (dark blue waveform) is maintained above 6.4V during the drop-out transient, and regulates at 6.8V during sustained low voltage (4V) battery operation (orange waveform).This circuit also demonstrates the value of soft-saturation inductor components from Coilcraft:http://www.coilcraft.com/pdfs/Doc1140_Beyond_the_data_sheet_Part1.pdfThe load current for the XAL4030-332 inductor in this application is 4A during nominal 12V operation. But during boost operation, the current reaches 6.6A peak (light blue waveform). This could saturate a typical inductor if it were sized for the nominal load, resulting in a collapse of the effective inductance. But notice that the actual instantaneous inductance (green waveform) only drops to 2.2uH, for this nominal 3.3uH part. This relatively small percentage drop in inductance can easily be accommodated by the converter design.

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Virtual Evaluation Board for NCV8876

Designer19

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Member of the PartQuest Explore Development Team. Focused on modeling and simulation of analog, mixed-signal and multi-discipline systems covering a broad range of applications, including power electronics, controls and mechatronic systems.

Description

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NCV887601BSTGEVB - Evaluation Board Test

Description

This design is a “Virtual Evaluation Board”. It represents the physical evaluation board for the NCV8876 Automotive Start-Stop Boost Controller IC, which is available from ON Semiconductor here:http://www.onsemi.com/PowerSolutions/evalBoard.do?id=NCV887601BSTGEVB,The schematic includes all of the components on the evaluation board, as well as user specified external test apparatus. The user can perform virtual testing on the NCV8876 component, to gain a better understanding of its features and behavior. Please see the related blog article, which describes this component's application and benefits:https://www.systemvision.com/blog/automotive-start-stop-%E2%80%A6-keep-lights-june-13-2016Simulation results show the output to the load during a fast battery drop-out and recovery. Note that in this particular test set-up, the output voltage (red waveform) is maintained above 6.3V during the drop-out transient, and regulates at 6.8V during sustained low voltage operation (2.6V, blue waveform).Also shown are the current in the N-channel Power MOSFET (brown waveform), and the current in the Vishay-Dale soft-saturation inductor (purple waveform). For this boost application, the soft-saturation behavior helps prevent inductance collapse during brief over-current conditions. The datasheet for the IHLP5050FDER2R2M01 can be found here: http://www.vishay.com/docs/34123/ihlp5050fd01.pdfNote that the user can move the waveform probes around to see the voltage waveform on any other nets (i.e. “wires”), or the current, power and other signals inside any component. The user can also make a copy of this design and freely change any of the component values, then rerun the simulation and see the effect of those changes.

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2 MOSFET circuit for alternate bypass

Designer19

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Member of the PartQuest Explore Development Team. Focused on modeling and simulation of analog, mixed-signal and multi-discipline systems covering a broad range of applications, including power electronics, controls and mechatronic systems.

NCV8876 - Circuit for alternate bypass development

Designer19

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Member of the PartQuest Explore Development Team. Focused on modeling and simulation of analog, mixed-signal and multi-discipline systems covering a broad range of applications, including power electronics, controls and mechatronic systems.

NCV8876 - Circuit Showing EMC Component Reuse

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Member of the PartQuest Explore Development Team. Focused on modeling and simulation of analog, mixed-signal and multi-discipline systems covering a broad range of applications, including power electronics, controls and mechatronic systems.

Description

This is a reference design for the ON Semiconductor NCV8876 Start-Stop Boost Controller (http://www.onsemi.com/pub_link/Collateral/NCV8876-D.PDF). It shows the reuse of a typical module's EMC components (i.e. the "pi" filter), which can serve a dual purpose as part of the boost converter. This includes the 4.7uF and 10uF capacitors, and the 1uH soft-saturation inductor.The NCV8876 is designed specifically for this application, requiring a minimum of new external components. These include the NMOS switch, the Schottky rectifier diode and the 0.011 Ohm current sense resistor. It also includes a few peripheral passives, such as the simple current-mode compensation network and the frequency programming resistor r9. The switching frequency can be adjusted to accommodate the available EMC component values.Simulation results show the output to the 5W load during battery drop-out and recovery. Note that in this application, the output voltage (red waveform) is maintained above 6.0V during the drop-out transient, and regulates at 6.8V as the input voltage at the PCB drops to a minimum value of 3V (light blue waveform).An alternate implementation reference design, with higher efficiency for higher power loads, is provided in the companion design: https://www.systemvision.com/design/ncv8876-power-saving-diode-bypass-circuit

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NCV8876 - With Power-Saving Diode Bypass Circuit

Designer19

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Member of the PartQuest Explore Development Team. Focused on modeling and simulation of analog, mixed-signal and multi-discipline systems covering a broad range of applications, including power electronics, controls and mechatronic systems.

Description

This is a reference design for the ON Semiconductor NCV8876 Start-Stop Boost Controller (http://www.onsemi.com/pub_link/Collateral/NCV8876-D.PDF). It is a more complex but higher efficiency implementation than the companion design: https://www.systemvision.com/design/ncv8876-circuit-showing-emc-component-reuse. This version is intended for use with higher power loads.This circuit includes a PMOS bypass switch, such that the rectifier diode voltage drop is not present under normal battery voltage conditions. All of the load current flows through the bypass PMOS during normal operation. When the battery voltage falls below the "wake-up" level, the NCV8876 status pin transition provides an early indication that the boost switching is about to begin. This signal is inverted and level-shifted by the BJT circuit. This deactivates the bypass PMOS, forcing the boosted load current through the rectifier diode. When the battery voltage recovers and the output voltage rises, the status re-activates the PMOS bypass and normal operation resumes.Simulation results show the output to the 20W load during battery drop-out and recovery. Note that in this application, the output voltage (red waveform) is maintained above 5.5V during the drop-out transient, and regulates at 6.8V as the input voltage at the PCB drops to a minimum value of 3V (light blue waveform). The bypass transition can also be observed, with the PMOS gate voltage (purple waveform) and the Ids current (dark green waveform) shown in the lower waveform viewer. Note that no bypass current flows during boost switching. The current transfer to the diode can be observed by moving one of the waveform probes to the diode and choosing to plot "id".

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NCV887601BSTGEVB - Evaluation Board Test

Designer19

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11 years 6 months

1,821

designs

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Member of the PartQuest Explore Development Team. Focused on modeling and simulation of analog, mixed-signal and multi-discipline systems covering a broad range of applications, including power electronics, controls and mechatronic systems.

Description

This design is a “Virtual Evaluation Board”. It represents the physical evaluation board for the NCV8876 Automotive Start-Stop Boost Controller IC, which is available from ON Semiconductor here:http://www.onsemi.com/PowerSolutions/evalBoard.do?id=NCV887601BSTGEVB,The schematic includes all of the components on the evaluation board, as well as user specified external test apparatus. The user can perform virtual testing on the NCV8876 component, to gain a better understanding of its features and behavior. Please see the related blog article, which describes this component's application and benefits:https://www.systemvision.com/blog/automotive-start-stop-%E2%80%A6-keep-lights-june-13-2016Simulation results show the output to the load during a fast battery drop-out and recovery. Note that in this particular test set-up, the output voltage (red waveform) is maintained above 6.3V during the drop-out transient, and regulates at 6.8V during sustained low voltage operation (2.6V, blue waveform).Also shown are the current in the N-channel Power MOSFET (brown waveform), and the current in the Vishay-Dale soft-saturation inductor (purple waveform). For this boost application, the soft-saturation behavior helps prevent inductance collapse during brief over-current conditions. The datasheet for the IHLP5050FDER2R2M01 can be found here: http://www.vishay.com/docs/34123/ihlp5050fd01.pdfNote that the user can move the waveform probes around to see the voltage waveform on any other nets (i.e. “wires”), or the current, power and other signals inside any component. The user can also make a copy of this design and freely change any of the component values, then rerun the simulation and see the effect of those changes.

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NCV8876 - Overcurrent Protection

Designer19

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11 years 6 months

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Member of the PartQuest Explore Development Team. Focused on modeling and simulation of analog, mixed-signal and multi-discipline systems covering a broad range of applications, including power electronics, controls and mechatronic systems.

Description

This example demonstrates the overcurrent protection capabilities of the ON Semiconductor NCV8876. It complements the design: https://www.systemvision.com/design/ncv8876-automotive-start-stop-boost-controller, which shows the performance of the device in normal operation. But in this design, the inductor element proves inadequate for boost operation under a heavy load condition. Inductance collapse, caused by core saturation, could lead to damaging peak current levels in multiple electronic components, were it not for the “hiccup-mode” overcurrent protection feature of the NCV8876. Simulation results show that the boost output voltage (dark blue waveform) falls to approximately 5V when the battery voltage (orange waveform) drops to 6V. This is in contrast to the nominal circuit operation, in which the NCV8876 would enter boost control mode and maintains a 6.8V boost output level. But because of the low drop-out voltage of the NCV59302 VLDO, the 5V regulated output voltage is only slightly reduced. The current through the 2.3 Ohm load resistor is maintained at just under 2.2A throughout the entire operation.While this load level is within the current rating of the inductor (2.3A RMS Max.), it is approaching the saturation inductance “cliff” for this traditional (i.e. non-soft-saturating) part. So when the NCV8876 activates boost control, it switches on the Power MOSFET briefly, effectively grounding the low side of the inductor through the small current sense resistance (0.03 Ohms). With the nominal 3.3uH inductance value, this would result in a slow current build-up (V/L = di/dt = 6V/3.3uH = 1.8A/us). But in this case the inductance collapses with further current increase, and the di/dt value becomes very large. The inductor current spikes to well over 10A (light blue waveform), and the corresponding inductance crashes to a small fraction of its nominal value (green waveform).The current spikes could have gone much higher, possibly resulting in damage to the NVGS3130 Power MOSFET, which has a rated pulse current maximum of 19A. If you zoom in on the magenta waveform, you'll see the Ids current rising, slowly at first while the inductance is intact, but then rapidly rising to over 11A as the inductance collapses, all in just 100ns! Fortunately the gate voltage (brown waveform) is cut off to prevent further current rise. This is thanks to the overcurrent protection feature of the NCV8876. When an overcurrent condition is detected, the device immediately goes into “hiccup-mode”, in which the gate drive is turned off and remains off for a count of 1024 clock cycles. After the mandatory hiccup period, the NCV8876 reattempts boost operation, but with continued overcurrent monitoring. Note that the current spikes are repeated with just over a 2ms period, because the clock is programmed to just over 2 us period (450 kHz switching frequency) in this design.To learn more about the capabilities of the ON Semiconductor NCV8876, click here: http://www.onsemi.com/pub_link/Collateral/NCV8876-D.PDFTo learn more about the benefits of Coilcraft's molded core soft saturation technology for reducing problems with current spikes, see page 4 of this document: http://www.coilcraft.com/pdfs/Doc1140_Beyond_the_data_sheet_Part1.pdf

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