Designing High-Efficiency AC-DC Converters with the Infineon XDPS21061 Digital PWM Controller

The relentless pursuit of higher efficiency and power density in power electronics is driving a significant shift from traditional analog controllers to advanced digital solutions. At the forefront of this transition is the Infineon XDPS21061, a highly integrated Digital PWM Controller designed specifically for high-performance AC-DC power supplies. This controller empowers engineers to design systems that meet stringent global energy regulations, such as DOE Level VI and CoC Tier 2, while achieving remarkable power density and reliability.

The XDPS21061 belongs to the XDP™ digital power family and is architected for resonant half-bridge topologies, including LLC and LCC. Its core strength lies in its ability to implement sophisticated control algorithms that are difficult or impossible to achieve with analog ICs. It features a high-speed digital state machine, the Digital Engine for Power (DEP), which executes critical control loops with a latency of just 25 ns. This enables precise frequency modulation and allows for optimal operation at the resonant point, minimizing switching losses and maximizing overall efficiency across the entire load range.

A key advantage of the XDPS21061 is its high level of integration. The controller incorporates active burst mode operation for ultra-low standby power consumption, often below 30mW. Furthermore, it includes active bridge control for the synchronous rectification (SR) MOSFETs on the secondary side, eliminating the need for a separate SR controller and simplifying the design while enhancing cross-regulation in multi-output applications. This integration is crucial for achieving high power density.

From a design perspective, the controller significantly simplifies the development process. Infineon provides a comprehensive software tool, the XDPS Designer GUI, which offers an intuitive graphical interface for configuring all controller parameters. Designers can easily set protection thresholds (OVP, OCP, OTP, UVLO), modify the control loop response, and optimize the burst mode entry/exit points without writing a single line of code. This drastically reduces development time and allows for rapid prototyping and performance optimization.

The controller's digital nature also enables advanced protection and monitoring features. It provides comprehensive diagnostic capabilities, enhancing system reliability. Designs leveraging the XDPS21061 are ideal for a wide range of applications, including ultra-compact USB-PD adapters, gaming and computing power supplies, and industrial power systems.

ICGOODFIND: The Infineon XDPS21061 digital PWM controller represents a paradigm shift in AC-DC converter design. By merging high-speed digital control with a high degree of integration and user-friendly configuration software, it empowers engineers to push the boundaries of efficiency and power density, creating next-generation power supplies that are both compact and highly efficient.

Keywords: Digital PWM Controller, High-Efficiency, Resonant LLC Converter, Power Density, XDPS Designer GUI