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The Evolution of the Power Supply Architectures
Introduction to FPA and V▪I Chip as Enabling Technology to High Performance Power Systems
About Vicor
• Founded 1981
• Public listing 1984 (NASDAQ: VICR)
• Headquarters and principal manufacturing in Andover, MA
• Acknowledged pioneer in the power system industry– Introduced first high-density DC-DC “brick” power supply
– Introduced V•I Chips and Factorized Power Architecture
• Leadership in innovation and intellectual property– >100 patents in U.S., Europe & Japan
– Approximately twice the R&D investment of competitors*
* Annual R&D expense as a percentage of revenue
Vicor is leading the next generation of power management
Three Business Units – One Mission
To deliver differentiated power management solutions for which size, efficiency, speed, flexibility, or total cost of
ownership are critical to the customer.
Brick Business Unit
Vicor’s Continuum of Power System Solutions
CustomPower Systems
(VAR)
Configurable Power Supplies
Modular Power Components
(Bricks)Brick Business Unit
Next GenerationPower Components
• Unifying characteristics:– Use of proprietary Vicor products and technologies– High power applications– Innovative solutions
Vicor – Leading evolution of Power Architecture
1st Full-size
Brick at 100 W
Full-size Brick
at 600 W
VI Chips & Factorized
Power Architecture Introduced
Half-size Brick
at 300 W
Quarter-size Brick
at 150 W
VI Chips Established in Blue-Chip Applications
VI BricksIntroduced
1st Half-size
Brick
1988 1997 1997 1998 2003 2006 2008 1984
• Device performance and form factor are key competitive variables– Vicor has consistently led the industry in technical advances
• Customers turn to Vicor for innovative solutions to their specific power needs– Our mass customization model is a significant differentiator
– We do not compete for high volume commodity business
• We are well-positioned to benefit from well-defined trends– Particularly related to power consumption and thermal management
Architecture Progress
• Centralized Power Architecture– AC – to – load
• Distributed Power Architecture– AC-to-48V, 48-to-load
• Intermediate Bus Architecture– AC-48V, 48-12V, 12V-to-load
5 V1.0 V1.0 VAC inCentralPowerSupply
CentralPowerSupply
DC bus
Isolated DC-DC converter
System boardDC bus
Isolated DC-DC converter
System board
Non-isolated POL converters (niPOLs)
Isolated intermediate bus converter
Semi-regulated DC busSystem board
Non-isolated POL converters (niPOLs)
Isolated intermediate bus converter
Semi-regulated DC busSystem board
Distributed Power
48 Vdc
niPOL
niPOL
3.3 Vdc
DT=7% DT=28%
12 Vdc
IBA48 Vdc
IBC
3.3 Vdc
niPOL
48 Vdc
Brick
3.3V
¼ Brick
The Problem
• High distribution losses• Poor dynamic response for high di/dt loads• Shrinking board area space for power devices• Rising utility costs
The Reason
• Fundamental restrictions in existing power topologies– <1MHz Switching Freq– Duty cycle– Series inductance– Bulk capacitance
• Multiple power conversion stages– Adds size, cost, and may lower overall conversion
efficiencies
The Solution: FPA with V•I Chips
• Factorized Power Architecture– Separation of power conversion stages: Regulation & Voltage
Transformation• Reduces distribution losses in a system• Reduces duplicated functions in the DC-DC conversion path• Reduces power dissipation at the Point of Load while increasing total system
efficiency
• Flexible building blocks: V•I Chips• Small, powerful components for DC-DC conversion• Provide key advantages to the power designer
– Industry leading power density (size & weight)– High Efficiency– Design flexibility– Speed (fast response)
66
¼ Brick
FPA – Breaking the Duty Cycle Barrier
0.8 Vdc
FPA 48 Vdc
26V
100%
48 Vdc
niPOL
niPOL
0.8 Vdc
2%
IBA48 Vdc
0.8 Vdc
3.0 Vdc
26%
IBC
niPOL
IBA48 Vdc
0.8 Vdc
40%
2.0 Vdc
IBC
niPOL 7%
12 Vdc
IBA48 Vdc
IBC
0.8 Vdc
niPOL
Architecture Progress
• Centralized Power Architecture– AC – to – load
• Distributed Power Architecture– AC-to-48V, 48-to-load
• Intermediate Bus Architecture– AC-48V, 48-12V, 12V-to-load
• Factorized Power Architecture– AC-to-48V, 48V-direct-to-load
or, for high power systems– AC-to-380V, 380-48V, 48V-direct-to-load
5 V1.0 V1.0 VAC inCentralPowerSupply
CentralPowerSupply
DC bus
Isolated DC-DC converter
System boardDC bus
Isolated DC-DC converter
System board
Non-isolated POL converters (niPOLs)
Isolated intermediate bus converter
Semi-regulated DC busSystem board
Non-isolated POL converters (niPOLs)
Isolated intermediate bus converter
Semi-regulated DC busSystem board
Isolated POL converters (VTMs)
DC bus
Non-isolated pre-regulators (PRMs)
System board
Isolated POL converters (VTMs)
DC bus
Non-isolated pre-regulators (PRMs)
System boardDC bus
Non-isolated pre-regulators (PRMs)
System board
Higher Efficiency, Sm
aller Size, Lower System
Cost
PRM Pre-Regulation Module• Pre-Regulation Module (PRM)
– Non-Isolated– Regulated 26V – 55V output– Wide range input– ZVS Buck-Boost topology– ZVS, >1MHz switching frequency– Ideal for powering niPOLs / VRMs
• Performance– 320W in 1.1 in2 package (>68W / cm3)– 1105W/ in3
– >97% efficient at 300W out• Inputs
– 24V (18 – 36)– 30V (18 – 60)– 48V (38 – 55 or 36 – 75)
• Output– Regulated 26V – 55V to VTM
VTM Voltage Transformation Module• Voltage Transformation Module (VTM)
– Isolated– Voltage transformer / current multiplier– Sine Amplitude Converter Topology– ZVS, ZCS, >1Mhz switching frequency
• Performance– Up to 100A in 1.1 in2 package (>60W / cm3)
• Inputs– Regulated 26V – 55V from PRM
• Output– 0.8V – 55V, up to 100A (13 models)
V•I Chip Components: BCM• Bus Converter Module (BCM)
– Isolated– Unregulated– Voltage transformer / current multiplier– Sine Amplitude Converter Topology
• ZVS, ZCS, >1Mhz switching frequency– Ideal for powering POLs / VRMs
• Performance– 300W in 7.1cm2 (1.1in2) package– Power Density = >60W/cm3 (>1,000W/in3)– Efficiency = >95%
• 48V Versions (Telecom / Server)– Input : 48V (38-55V)– Output : 1.5 - 55V
• High Voltage Versions (350V distr., 380V post-PFC)– Input : 350V or 380V– Output : 10 – 13V 48V
U.S. and Foreign Patents and Patents Pending
Factorization
• Separate Regulation and Isolation Functions• Flexibility to locate PRM remotely-saves board
space• Factorized bus at ~48V saves I2R losses• VTM located directly at POL
Regulation
3 Regulation Options:
1. Local sense – 5%2. Adaptive Loop – 1%3. Remote sense – 0.2%
Bulk Capacitance Elimination
• Energy stored in a capacitor = ½ CV2
• VTMs have very fast transient response• Equivalent capacitance at VTM input, but 1/k2
smaller• Saves valuable POL board space• Better reliability (fewer bulk capacitors)• Saves cost of populating capacitors
The “48V to Processor” Challenge• Traditional synch buck PWMs are limited due to FET duty cycle
– 12V : 1.2V may be OK… but 12V : 0.8V or 48V : 1.2V...?
• FPA separates regulation & voltage transformation functions: PRM + VTM– High efficiency 48 : 1.2V transformation at the processor
• Allows power savings upstream– Physical separation of PRM and VTM
• Allows the PRM to be placed remotely, with 94% reduction in distribution losses (W/ohm)• Only the VTM is required to be at the processor, minimize high current traces / losses.• Enables minimal form factor solutions directly at / under the processor
– VTM: High bandwidth bi-directional transformation with low Q• Capacitance: Bulk
– Move from processor to MV factorized bus and reduce to ~ 1/1000 capacitance (1/K2)• Capacitance: Bypass (ceramics)
– Greatly reduced (only needed to support dynamic response within a time scale of 1 uS). – Excellent transient response
Processor Power Solutions: Baseline System
48 V:12 V IBC and 4 Phase VR powering 1.2 V, 100 A microprocessor.95% efficient and 85% 80.75% efficient from 48 V to 1.2 V load
48V-to-load Solution: PRM+VTM
PRM (97%) and VTM (91%) 88.3% efficiency from 48V to 1.2V load
FPA: Fast Transient Response
Move “bulk” capacitance upstream to higher voltageRequires only 1/1000 of original capacitance
FPA: Flexible•VTM placed directly at load minimizes track loss
•PRM moved to backplane frees valuable space on motherboard
HV BCM Full V•I Chip solution from PFC load
• B384F120T30 K=1/32 300W 384VIN 12VOUT Released• VIB0002 K=1/8 330W 384VIN 48VOUT Q4’07
0.8-55V375V 48V VFAC V
PFC(e.g. FE375)
HV BCM PRM VTM
Power & Size Comparison (8x 1.2V, 100A μP array)
Baseline system
FPA systemWith V•I Chips
The FPA Advantage: Efficiency, Size and $ Running Costs
• Applying FPA in higher power systems highlights the size, efficiency and value of the V•I Chips
• Efficiency 7.7%• Power Loss 31%• Size 45%• Save $30 / €24 per year,
per processor, in energy costs• $380,000 per year, per datacenter
V•I Chips for Solid State Lighting / Display (LED)
Lighting
Back Light
Displays
LED Progress – more Lumens per Watt
Cree, APEC 2007
LED Progress – Industry “Tipping Point”
Cree, APEC 2007
Constant Current Source• LEDs require constant current• PRM provides constant current with high control accuracy (IOUT + / - 2%)
– “Loss-less” differential current-sense and controlling amplifier into PRM’s voltage control pin
– Independent of VTM choice– Same PRM for any color / size LED
• 300W demonstration systemDual Op-Amp:ISENSE & control
To VTM
LED Power
• Multiple options to drive LEDs• PRM in constant current mode• PRM-to-VTM driving a series
array• BCM-to-LED driver in a parallel
array• High efficiency• Wide adjustment/intensity
range
Power Light• PRM+VTM
– Power = 300W– Power Density = 30 W/cm3
– Efficiency = 92%– PDISS / Light = <1W / 1,000 Lumens
• Power dissipated in powertrain per 1,000 Lumens emitted• Assumes 75 Lumens per 1W LED (Cree, APEC 2007)
22,500 Lumens
48V 24V325W 300W
92%
The Flexibility of FPA
More Application Examples
Battery Backup Systems
• High voltage and 48V BCM connected in ORing fashion• If primary supply BCM fails,48V backup provides charge• P12125 provides the ORing function
Regenerative Burn-In
• Burn-in normally can waste excessive energy• BCM can operate in reverse (output-to-input)• BCM ~96% efficient, and recycles burn-in output load• BCM’s input pins produce 48V of input for burn-in
AC-DC Server Solution
• Complete AC-DC server solution includes Picor products in conjunction with full suite of V•I Chips
• Very efficient• Flexible layout options with FPA
High current driveVarious output voltage levels availableUltra fast transient responseIncludes EMI filtering and ORing functions
Boost Systems
• Boost 12V to 48V with reverse VTM• PRM regulates the VF • Final stage VTM provides current multiplication
and isolation functions
Evolution of System Level Power Architectures (the summary)
12V5V3.3V,5A
Centralized Power Architecture (CPA)
ACAC-DC
AC-DC5V
3.3V
2.5V
DC-DCDC-DC
DC-DC
Distributed Power Architecture (DPA)
48VAC
Regulation, Isolation& Transformation
AC-DC5V
2.5V
DC-DC
DC-DC
niPOLniPOL
niPOL
3.3V
1.8VniPOL
Intermediate Bus Architecture (IBA)
48V
12V
12VAC
Isolation,Transformation
Regulation,Transformation
Vicor Product Focus
High VoltagesLow Currents
Large SizeLow Efficiency
CustomInflexible
Tim
e &
Tec
hnol
ogy
Adv
ance
s
FPA: The Future of System Level Power Architecture
Vicor Product Focus
AC-DC
0.8V,200A
PRMPRM
VTMVTM
1.8V
5V3.3V
BCM niPOLniPOL
Factorized Power Architecture (FPA)
48V12V
VF
VF
AC
Isolation,Transformation
Regulation,Transformation
Isolation,Transformation
Regulation
• Low Voltages• High Currents• Smallest Size• Higher Efficiency• Standard Blocks• Flexible
Thank you!