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55 Year Old Transformer Manufacturer Develops High Power Resonant Power Supply
Increasing Efficiency And Scalability Without Increasing Bulk
The Main Problems With Conventional Power Supply Design
Larger Transformers Means Bulkier Design
The biggest issue with high voltage power supplies is that they must be larger due to their need of 60 Hz transformers. This adds bulk. This need for a larger transformer in the power supply means the overall design grows considerably.
The average conventional resonant high voltage power supply weighs in at 150lbs (68kg). Again, this is due to the need of large transformers. This is not including the DC Power Supply Input which normally weighs 15lbs ( kg).
Solutions to Resonant High Voltage Power Supply Design
A Better Option?
Increasing the frequency is one of the simplest ways to reduce the size. However, when you increase the operating frequency, a problem quickly becomes apparent caused from the high voltage transformers winding capacitance. The circulating current in this winding capacitance can far exceed the current of the power supply load!
The transformer winding capacitance can be greatly reduced by special winding techniques; however, some will always remain and external capacitance stems from the transformer mount, printed circuit board and diodes, making this a diminishing return.
The Solution: A Resonant High Voltage Power Supply Design.
A better option is to use the transformer’s winding capacitance as parts of a parallel LC resonant tank, consisting of C external, C winding and L transformer. The components in red make the circuit into a parallel LC resonant circuit as shown in Figure 1A. This type of circuit must be current fed requiring the feed choke. The current fed topology (no center-tap capacitor) is an excellent choice for HV designs. It is tolerant of arcs, spikes and shoot through.
Figure 1B shows how the resonant power supply is connected. It includes an input supply, transformer and a voltage multiplier. The resonant power supply receives power from the input supply.
Leightner Resonant Compact Power Supply
Leightner Electronics Inc. is proud to introduce “The Leightner Resonant Compact Power Supply” (LRCPS). The Leightner resonant power supply is unique in it’s ability to operate at higher frequencies using the winding capacitance of the high voltage transformer. Thereby seeing a reduction in bulk of former systems using 60hz power transformers.
Advantages of Leightner Resonant Power Supply
8 times lighter and 4 times smaller than a conventional power supply
Sine wave operation reduces EMI and RFI.
Operational frequencies of up to 100 kHz.
Efficiency is up to 95%.
Over voltage and current protection.
Lower EMI / RFI and switching loss due to zero volt switching.
Winding capacitance is cancelled, negating all high reactive currents.
Design is “Magnetics” based which yields a far more robust and forgiving circuit than conventional methods.
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Resonant Power Supply Features
The resonant supply includes a buck supply that uses a current mode pwm controller which has several advantages. It has one less pole to compensate for. It is much more responsive to current changes than a voltage mode controller. It is very tolerant to many of the abuses that can occur during operation and testing.
The supply has soft start and delayed start. Delayed start makes the resonant supply wait for a set amount of time before starting once it receives full Vin. This prevents the Vin supply and the resonant supply from trying to start at the same time.
Under voltage lockout prevents the resonant supply from starting if Vin is below a set amount. Trying to start with low levels of Vin can cause over current conditions.
Two separate over voltage shutdown circuits are used in the event the output should go too high for any reason.
Due to resonance, you will get zero volt switching. Both mosfets switch during the time the resonant capacitor passes through zero volts which reduces switching loss and EMI.
The efficiency and Q in resonant power supplies are greater.
| Type | Efficiency |
| Typical Hard Switching Converter | 75-85 % |
| Resonant Converter | 85-95% |
The LC resonant supply regulates the output by varying a dc level at the input of the power transformer. This method is very stable. LLC converters regulate the output by varying the frequency which is more difficult to stabilize.
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Resonant Power Supply Gallery
About Leightner Electronics
Leightner Electronics, Inc. (LEI) was founded by Paul E Leightner in 1968 in Plano, Texas, and moved to its present location in 1975.
LEI specializes in the building of transformers and power supplies. Typical applications include ground and airborne military hardware, space, downhole test and drilling equipment, as well as other industrial applications. The experienced staff at LEI has met challenges with innovative designs and reliable products resulting in satisfied customers worldwide.
We at LEI operate under the guiding principles of honesty and integrity resulting in customer satisfaction through service, quality, and reliability… parts that work, and are there when needed.
To Find out more information about Leightner Electronics please visit our website: https://leightner.com or Call us: +1-972-542-0176