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Potential of Hybrid Converters in Compute Platform Power Delivery
Chris SchaefCircuits Research Lab, IntelOct 2018
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Power Delivery Today - Server
Source: SUPERMICRO
•12 V to 1.8 V still dominates•48 V not yet entering mainstream
Challenges Current levels approaching 1kA Large VRs and passives cause high
distribution losses and ac loadline Bottleneck for scaling in fixed-form
factor Efficiency is $ (expecting 95% for 12
to 1.8V)
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Power Delivery Today – Client
Source: ifixit.com
•Mobile most challenging•2/3S NVDC and 20V to 0.5-1.8V
Challenges Highly dynamic currents (7W TDP
SOC may require 50A for short time) Transient requirements (limited
decoupling) Low profile (~1mm) for passives Efficiency across wide load range
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Power Conversion Directions
Increase Switching Frequency
Can reduce size and increase bandwidth
Better devices and passives needed to maintain efficiency (e.g. GaN)
New topologies
Use devices and passives available today
Shift to topologies which use switched capacitor techniques
Recent work hybrid/resonant converters shows great potential
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Why capacitors?
Value 2.2 µF 1 µH
Size 1x0.5x0.5 mm 6.4x6.6x3.1 mm
Energy Density 440 µJ/mm3 2 µJ/mm3
Q @ 1MHz 2000 20*
Ceramic Capacitor (0402)Murata GRM155B31A225KE95
Ferrite InductorCoilcraft XAL6030-102ME
Murata GRM155B31A225KE95 (https://psearch.en.murata.com/capacitor/product/GRM155B31A225KE95%23.html)Coilcraft XAL6030-102ME (https://www.coilcraft.com/pdfs/xal60xx.pdf)
*includes core losses per Coilcraft calculator
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Why not only use Capacitors?
ix
Capacitors store energy very effectively but energy transfer is inefficient
Charge-Sharing losses grow with larger ΔV
Need large C to achieve high efficiency
Cannot achieve high Power Density and High efficiency
Vout
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Resonant Switched-Capacitor
ix
•Can charge/discharge capacitors through inductors•Resonant charge transfer eliminates charge-sharing losses•Very small inductor enough to achieve significant improvement
Source: C. Schaef, J. Rentmeister and J. T. Stauth, "Multimode Operation of Resonant and Hybrid Switched-Capacitor Topologies”, TPEL. 2018
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Beyond Resonant – Multimode OperationA hybrid converter can be operated in different modesOperating mode determined by conversion ratio and frequencyContinuous range from resonant to inductive
Inductor current waveforms for 3L buck converter in different operating modes:
Source: C. Schaef, J. Rentmeister and J. T. Stauth, "Multimode Operation of Resonant and Hybrid Switched-Capacitor Topologies”, TPEL. 2018
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Hybrid Topology Spectrum
Resonant Quasi-Resonant Inductive
Power Density & Efficiency
Regulation capabilitySwitched Capacitor
Buck
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Where do they fit?
~12-60 V
Input Bus / Battery
Intermediate Bus
~5-12 V
Conversion Stage• Fixed ratio• High efficiency (98%+)
Regulation Stage• Fast transient response• Small footprint
Resonant SC Inductive Hybrid
~0.5-1.8 V
Load
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Examples – Fixed Ratio
1 Z. Ye, Y. Lei, R.C.N. Pilawa-Podgurski “A Resonant Switched Capacitor based 4-to-1 Bus Converter Achieving 2180 W/in3 Power Density and 98.9% Peak Efficiency”, APEC 20182 S. Jiang, C. Nan, X. Li, C. Chung and M. Yazdani, "Switched tank converters," APEC 2018
Resonant DoublerYe (UCB), APEC 20181
Resonant Switched TankJiang (Google), APEC 20182
48 to 12 V
Switching Frequency 105 kHz
Power Density 1750 W/in3
Peak Efficiency 98.9 %
Max Load Efficiency 98 %
54 to 13.5 V
Switching Frequency 320kHz
Power Density 500 W/in3
Peak Efficiency 99 %
Max Load Efficiency 97.5 %
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Regulation Stage Example- 4L FCML
Vin 5 V
Iout 10A
Freq. 5 MHz
Size 7.8x9.7x1.2 mm
Package 4L FCCSP (coreless)
Capacitors 6x0402 2.2µF (Cx1,Cx2, Cin)01005 220nF (Cbs1-6)
Inductor 2512 10 nH
Integrated Design in 22nm FFL 4L powerstage gate drivers with nested bootstrapping
All passives on package
Inductor
Fl. Caps
Input Caps
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Flying Capacitor Multi-level Converter
Use of flying capacitors to produce additional voltage levels
4-Level FCML: 0,1/3, 2/3, 1 Vin
Each Switch only block 1/3 Vin
3x Frequency multiplication
Buck 4-Level FCML
Main benefitsReduced Vs stress on inductorSwitching Frequency multiplicationEqually rated devicesContinuous conversion ratio (0 to Vin)
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PWM-based Operation 3-phase PWM with 120deg phase shiftSwitching frequency equals 3x of
PWM frequency PWM duty cycle allows continuous control of output voltage
Conventional duty-cycle control
Improved transient response due to higher switching frequency and smaller inductance
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Closed-loop transient response
Feedback implemented with digital Type III controllerClosed-loop response to 6A load transient measuredOutput decoupling < 20 µFDemonstrates transient response improvement possible with hybrid approach compared to buck
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Efficiency Measurements
70%
72%
74%
76%
78%
80%
82%
84%
86%
88%
90%
92%
94%
96%
0 1 2 3 4 5 6 7 8 9 10
Eff
icie
ncy
Output Current (A)
5 to 1.8V (5 MHz)
5 to 1.2V (5 MHz)
Efficiency measured for 5 to 1.8 and 1.2 VPeak efficiency of 93.8 % at 3A loadOver 90% maintained up to 9A
High Efficiency with order-of-magnitude lower inductance
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Resistance contributions
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
Resistance (mΩ)
Package routing significant contributorAdvances in 3D packaging technology will bring further improvement
Inductor
Capacitors
Power FETs
Package Routing
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Hybrid Regulators - Practical challenges
Control
Several phase-shifted PWMs
Capacitor balancing loops
Gate-driving
Supply generation with nested/cascaded bootstrapping
Level shifting to different domains
Packaging
On-package capacitor placement
Package routing parasitics
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Summary
Hybrid topologies can address many of the challenges in compute platform power delivery today
A Range of fixed-ratio and regulated converters with great performance metrics have been demonstrated
Integrated designs most attractive to manage complexity and deliver competitive cost
Advancements in packaging critical to realize full performance potential
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Thank You!
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