Design and implementation of high efficiency power conversion circuit for military and aerospace applications

introduction

Whether at home or in a wider world, sustainable development initiatives, “green” energy and environmental regulation are all part of everyday life. In response to commercial pressures and stricter emission reduction requirements, the commercial aviation industry has pioneered the use of lightweight materials, improved aerodynamics and more efficient engine technology. Electrical efficiency is becoming more and more important as aircraft move from traditional air venting systems and hydraulics to electric starters, pumps and compressors to drive large numbers of systems. On the Boeing 787, frost protection is now achieved by an electric heater pad instead of the hot air escaping from the engine, further reducing the load and improving fuel economy and thrust. Along with these advances, the aircraft's power needs have escalated over the past 30 years, with the Boeing 767 of approximately 300 kW and the Boeing 787 exceeding 1.4 MW, making power conversion efficiency more critical than ever. The military sector is also moving in the same direction, striving to make the system more energy efficient, reducing weight, reducing size and reducing heat generation to reduce procurement and operating expenses.

Selecting components for military and aerospace equipment requires not only the trade-offs and trade-offs required for all common designs, but also the rigorous performance specifications required to ensure the invulnerability of the equipment, and the extremes required for use under harsh environmental conditions. High requirements. In addition, enterprise component selection policies sometimes limit which types of products can be used as pre-approved components of component engineering, and reuse of mature standard circuit components is always encouraged.

Therefore, there is a desire to obtain products that are suitable for a variety of applications due to innovative architectures and clever chip designs to reduce the number of qualified or approved devices. The problem is that even in a relatively narrow application area, such as power conversion, applications and requirements are ever-changing. However, as we will see, some products are versatile, such as the LT8705, which was introduced not long ago, as a candidate for meeting these requirements.

High efficiency power conversion

The LT8705 is a very efficient (up to 98%) synchronous buck-boost DC/DC controller that operates at input voltages above, below or equal to the regulated output voltage. The device integrates four feedback loops to regulate input current, input voltage, output current, and output voltage. The input current loop and voltage feedback loop prevent overloading of energy-limited power supplies (such as solar cells) while the output current loop provides a stable output current for the battery charger or current source.

The LT8705 uses a single inductor and 4-switch synchronous rectification to operate over a wide input voltage range of 2.8V to 80V, producing an output from 1.3V to 80V. Its high input voltage helps simplify transient protection because it enables the device to meet the surge voltage requirements specified in MIL-STD-704 and DO-160. Combined with surge suppressors such as the LT4363, this protection can be further enhanced to meet the surge requirements of MIL-STD-1275.

A single LT8705 can deliver up to 250W of output power, making the device suitable for a range of loads by changing the switching power MOSFET accordingly. By connecting multiple circuits in parallel, higher output power can be achieved.

The operating frequency is selectable from 100kHz to 400kHz and can be synchronized to an external clock. The LT8705 features a proprietary current-mode control architecture that operates at constant frequency in buck or boost mode and provides four powerful on-chip N-channel MOSFET gate drivers. Users can choose between forced continuous, intermittent, and Burst Mode® to maximize efficiency at light loads.

Other features include a servo pin indicating that the feedback loop is operating, a 3.3V/12mA LDO, an adjustable soft start, an on-chip chip temperature monitor, and an accuracy of ±4°C to 125°C operating junction temperature 1% of the reference voltage. The LT8705 is available in a 38-pin 5mm x 7mm QFN package and a 38-lead TSSOP package with additional pin spacing to operate at high altitudes at high altitudes. Both packages are lead (Pb) free and feature a tin-lead termination coating.

application

The versatility of the LT8705 and its wide input and wide output range make this device suitable for a wide range of applications. Here are a few examples.

Voltage stabilizer

Military and aerospace systems often use a nominal 28V isolated power supply to power the LRU (Line Replaceable Unit), which is reduced to the intermediate bus voltage and used to load point regulators and higher voltages. The auxiliary circuit is powered. Isolated power supplies typically experience voltage transients, ripple, and long-duration offsets due to cold-start or backup power-switching events. One option is to use the LT8705 as a voltage stabilizer to provide a stable intermediate bus voltage within the LRU. Figure 1 shows an example of providing a 12V output. The efficiency curve shows an efficiency of >95% for a typical application with a 28V input.

12V output converter accepts 4V to 80V input (starting voltage is at least 5.5V)

Universal power conversion solution for military and aerospace applications

Efficiency varies with output current

Universal power conversion solution for military and aerospace applications

Input transient (4V to 80V)

Universal power conversion solution for military and aerospace applications

Figure 1: Typical voltage stabilizer

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