????(Product Design)

1
????(Product Design)

1. ????(Specification Review)
2. ????(Topology Selection)
3. ????(Circuitry Design)
4. ??????(Magnetic Devices Calculation)
5. ????(Components Evaluation)
6. ?????(PCB Layout)
7. ????(Mechanical Tooling)
8. ??????????(Sample Assembly, Debug Test)
9. ????????(Approval Sheet Product Documents)
10. ?????????????(Feedback, Assessment Correction
    by PP/MP)

2
????(Specification Review)

• 1. ????(Input Specification)??(Voltage),
  ??(Frequency), ??(Current), ????(Inrush Current)
• 2. ????(Output Specification)??????(CVCC),
  ????(RippleNoise), ????(Reverse Current),
  ??(Efficiency)
• 3. ????(Protection Features)???(OVP),
  ????(Single Fault), ???(OCP), ??(Short)
• 4. ????(Environment Specification)????(Operating
  Temp), ????(Storage Temp), ??(Altitude),
  ??(Vibration),
• 5. ????(International Standards)????(Safety
  Standard), ????(EMI), ????(EMC)
• 6. ????(Mechanical Specification)????(Outline
  Dimensions), ??(Cable), ???(Connector),
  ??(Label), ??(Package)
• 7. ???(Reliability)??????(MTBF), ??(Burn in)

3
????(Topology Selection)

• ???? ( Flyback ) PI, Fairchild, etc.--- 100W
• ?????? ( Ringing Choke Converter ) --- 20W
• ???? ( Forward ) --- 60W600W
• ???? ( Half-Bridge ) --- 200W 500W
• ???? ( Full-Bridge ) --- 500W
• ???? ( Push-Pull ) --- 500W
• ?CUK? --- ?????(Output Ripple-less)
• ?SEPIC? --- ?????(Input Ripple-less)
• ???? ( Resonant ) --- ???(Loss-less)

4
????(Circuitry Design)

• ???????????????????
• Block Diagram of Off-Line Switching Power Supply

???? ????? Auxiliary Power and Current Limit
???????? ?????? Extra Function and O.V.P.
???? ??? Isolated Power Transformer
?????? AC Input
???? ??? EMI Filter
???? Switching Device
????? Rectifier and Filter
????? Rectifier and Filter
?????? DC Output
???? Isolated Device
????? Feedback Control
5
??????(Magnetic Devices Calculation)

1. ?????(Faradys Law) VNAdB/dt
2. ????(Amperes Law) SNI?Hdl
3. ???(Permeability)???????????????(B-H
   Characteristics) uB/H
4. ??(Size)?????(Duty Cycle)? ??(AWG)???(Turn)???(Win
   ding)???(Gap)???(Inductance)
5. ????(Loss Calculation)???(Core Loss)???(Copper
   Loss)
6. ?????(Effect of Leakage Inductance)
7. ????(EMI)
8. ????(Safety)

6
????(Components Evaluation)

• 1. ??????????? (Transformer / Choke / Filter)
• ????(Electromagnetic)?????(Magnetic
  Material)???(Winding)
• 2. ??? (Capacitor)
• ????(Rectifier)?????(Life Time)??????(Stability)
• 3. ????? (Power Transistor)
• ?????(Characteristics)????????(Loss)?????(Protecti
  on)
• 4. ????? (Rectifier Diode)
• ?????(Characteristics)????????(Loss)?????(Protecti
  on)
• 5. ??? (Controller)
• ????(Feedback Control)?????(Response)?????(Driver)
  
• 6. ???? (Protection)
• ???(OVP)????(OCP)????(OPP)?????(Soft-Start)
• 7. ????? (Printed Circuit Board)
• ???(Insulation)????(Copper)?????(Printing)?????(Ho
  le)
• 8. ???? (Mechanical Parts)
• ???(Heat Sink)???(Wire)???(Case)????(Connector)???
  (Package)

7
?????(PCB Layout)

1. ????(Safety Standard)
2. ????(EMI)
3. ????(Thermal Distribution)
4. ??????????????(AI, MI SMT)
5. ???????????(Local Polarization Foolproof)
6. ???????(Mechanical Stress on Devices)
7. ?????(Copper Pattern Placement)
8. ????????????(Silkscreen, Logo, P/N, Revision)

8
????(Mechanical Tooling)

1. ????(Industrial Design)
2. ????(Safety Standard)
3. ?????(Ultrasonic Welding)
4. ????(Injection Molding)
5. ????(Assembly Interference)
6. ????(Thermal Management)
7. ????(Connection Device)
8. ????(Packing Consideration)

9
?????????? (Sample Assembly, Debug Test)

1. ????(Assembly Interference)
2. ?????????(Tolerance Analysis of Theory
   Experiment)
3. ???????(Stability Reliability)
4. ??????????(Calibration of Equipment Fixture)
5. ????????????(Worst Case Abnormal)
6. ??????????(Trade-off in Safety, EMI, Thermal)
7. ??????????????(Report by Table, Item Figure)
8. ???????(Design Handbook History)

10
????????(Approval Sheet Product Documents)

1. ???(Specification)
2. ???(Schematic)
3. ????(Bill of Materials)
4. ?????(PCB Layout)
5. ?????(Mechanical Drawings)
6. ????(Test Report)
7. ??????(Notice of Production)
8. ??(Golden Sample)

11
?????????????(Feedback, Assessment
Correction by PP/MP)

1. ?????(Pilot-run Meeting)???????(Documents
   Sample Review)?????(Materials)?????(Test Fixture)
2. ?????(Pilot-run Review Meeting)????(Repair
   Report)?????(Follow up issues)
3. ?????(Mass-Production Meeting)?????(Manual
   Instruction)??????(QC Flowchart)??????(Reliability
   Verification)????????????(DFMEA)
4. ?????(Mass-Production Review Meeting)??????(Stati
   stical Process Control)?????(Customers
   Complaint)???????(Quality Corrective Action)