Renesas Electronics (Tokyo Stock Exchange***6723), a global microcontroller manufacturer, combines expertise in embedded processing, analog, power, and connectivity to provide complete semiconductor solutions. The winning portfolio accelerates time-to-market for automotive, industrial, infrastructure and IoT applications, enabling billions of connected smart devices to improve the way people work and live.
The charging head network has obtained a PD fast charging reference design launched by Renesas, using Renesas IW9860+IW760 chipset solution, supporting 90-264VAC global wide voltage input and supporting 45W output power, which can meet the daily charging needs of mobile phones, tablets and thin and light notebooks.
The IW9860 is a high-performance primary controller with an astonishing no-load standby power consumption of less than 5MW. The IW760 is a secondary controller with integrated protocols and synchronous rectification control to simplify charger design and improve reliability, while also supporting zero standby power consumption. The following charging head network will bring the analysis of Renesas' 45W fast charging solution, and take a look at the design and materials of the solution.
Based on the Renesas IW9860+IW760 solution, the motherboard is square, and the mass-produced product based on this demo is more compact and portable, and compared with the cylindrical charger, the experience of using the plug-in wall plug will be better.
Looking at the front of the demo motherboard from a bird's-eye angle, there are small boards at the input and output terminals, and three electrolytic capacitors and two solid-state capacitors are used for the primary stage to filter.
At a glance on the back of the motherboard, the Renesas IW760 integrates the functions of a secondary synchronous rectification controller and a protocol chip, making the back of the motherboard look simpler than traditional solutions. In addition, the motherboard is hollowed out between the initial stages, and Mylar sheet insulation can be installed in the later stage of mass production.
The measured length of the PCBA module is 3718mm。
The width is 37mm.
The thickness is 2016mm。
In addition, the weight of the demo was measured to be about 413g。
Power on the PCBA module, and use the ChargerLab Power-Z KM003C to measure that the USB-C port supports PD30, PPS, QC4, DCP charging protocol.
PDO packets show that the USB-C port also has 5V3A, 9V3A, 15V3A, and 20V225A four sets of fixed voltage ranges, and 33-16v3a、3.3-21V3A two sets of PPS voltage ranges.
The actual standby power consumption of this DMEO designed based on the Renesas IW9860+IW760 solution is shown in the figure above, and the standby power consumption at 230VAC is much lower than 5MW, which is only about 225MW, the performance is very impressive.
After reading the appearance of Renesas' 45W fast charging demo, let's enter the analysis link and introduce the information of each device one by one.
The input side of the PCBA module is at a glance, the fuse is welded, the common mode inductor, and the rectifier bridge are welded to the back small board to strengthen heat dissipation.
The input fuse is 2A 250V.
Common mode inductors are wound with enameled and insulated wires.
The rectifier bridge model is FMB40M, and the specification is 4A 1000V.
Solder high voltage filter capacitors, differential mode inductors and blue Y capacitors on the side of the PCBA module.
The high-voltage filter capacitor is from Aihua and is specified at 400V22 F.
The total capacity of the three filter capacitors is 66 F.
The differential mode inductor is wound with an I-shaped core and insulated by a heat-shrinkable tube.
The primary main control chip from Renesas, model IW9860-01, silkscreen D001, is a zero-standby power consumption digitally controlled flyback controller, the chip features Renesas' patented constant frequency, quasi-resonant and adaptive multi-mode control. Multi-mode control includes PWM, PFM, and Burst Mode to optimize the performance of the flyback converter, including energy efficiency and EMI. By pairing the IW760, a compact fast-charging charger design can be realized, enabling an energy-efficient and cost-effective fast-charging solution.
Renesas IW9860 Fact Sheet Information.
The filter capacitor that supplies power to the main control chip is 100V10 F.
The primary switch is from Infineon, it is a CoolMOS C7 series, model IPL65R230C7, NMOS, withstand voltage 650V, conduction resistance 230M, and is available in a ThinPak 8*8 package.
The 200m sampling resistor is used to detect the switch current.
The transformer uses POT23 cores with a primary inductance of 300 h, which is produced by Bridge Electronics.
Close-up of blue plug-in Y capacitors.
The Renesas PS2381 optocoupler is used for output voltage feedback regulation.
The secondary controller is also from Renesas, model IW760, which is a secondary control chip with integrated protocol functions, synchronous rectification controller and VBUS control, and supports PD30 fast charging applications. Digital compensation is built into the chip for closed-loop control of the flyback converter. The chip adopts a hard-wired state machine, which does not require MCU coding, which eliminates the hidden danger of maliciously increasing the output voltage and causing equipment damage.
Renesas IW760 Profile Information.
The synchronous rectifier tube is from AOS, model AONS66940, NMOS, withstand voltage 100V, conduction resistance 107M in DFN5*6 package.
The output is welded with two filter capacitors and a USB-C receptacle board.
Both output filter capacitors are rated at 680 F 25V.
The VBUS switch is from Polyseimi, model PL03N6500P, NMOS, withstand voltage 30V, conduction resistance 57M, in PDFN3*3 package.
The USB-C receptacle is fixed by via soldering, and the black rubber core does not expose copper.
Through the analysis of Renesas' 45W fast charging reference design, it is found that the design uses the IW9860 primary controller and the IW760 secondary controller to achieve ultra-low standby power consumption, high conversion efficiency, and cost-effective fast charging solution.
The IW9860 offers advanced features to support single-sided applications and comprehensive protection. The IW760 integrates a synchronous rectification controller and protocol chip into a single chip, simplifying circuit design through digital compensation. The chip uses a hard-wired state machine, eliminating the need for MCU and firmware, eliminating the hidden danger of maliciously increasing the output voltage and causing equipment damage. In the reference design, the two Renesas controllers work together to provide an energy-efficient, cost-effective first-stage overall solution for PD fast charging.