AC-DC power conversion for telecommunications infrastructure

AC-DC power converter solutions for telecommunication power supply units (PSU) for 5G small-cell and macro base stations

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Overview

Build more energy-efficient 5G telecom infrastructure and prepare for the higher power demands of AI integration with AD-DC converter circuit power semiconductor solutions. Choose from a wide range of recommended options that best fit your needs, regardless of preferred topology, switching configuration, or semiconductor material. Infineon has the answer for any challenge with our mastery of Si, SiC, and GaN power semiconductors, which help you to reduce electricity demand and save on TCO/OPEX.

Benefits

  • High and flat efficiency
  • High power density
  • High reliability
  • Thin form factors
  • Operation in harsh environment
  • Natural cooling
  • Monitoring capability
  • WBG solutions
  • SiC for hard switching
  • GaN for soft switching
  • Si, SiC, GaN hybrid solutions

Block diagram

About

About AC-DC power converter solutions for telecom infrastructure

Infineon provides system solutions for powering e.g. 5G small cells and base stations. These are applications that require the highest efficiency (99 percent) and high power density (73 W/in3 ). Converter system designers trust Infineon Wide Band Gap (WBG) (CoolGaN™ and CoolSiC™) and Super Junction (SJ) (CoolMOS™) power semiconductors combined with our gate driver ICs and microcontrollers, to deliver the highest power density, efficiency, and relibility.

Infineon CoolGaN™ devices are designed to meet the needs of typical telecom rectifier applications like industry lifetime and quality (cumulative failure rate) targets when operated in the totem pole, hard switching PFC topology.

With Infineon‘s semiconductor solutions, you can solve the typical telecom rectifier requirements like:

• High efficiency combined with a high power density
• High reliability, in order to minimize maintenance cost
• Low mechanical profile
• Outdoor harsh environmental operation, often in natural convection cooling
• Flat efficiency (typically from 30% to 100% load)

In the tabs below, discover the solutions Infineon offers and recommends for AC-DC power converters for telecom infrastructure. Explore our system solutions, evaluation boards and reference designs, and simulation tools, all designed to reduce your time to market.

Choosing the right topologies for PFC (hard switching)

Power factor correction (PFC) shapes the input current of the power supply to be in synchronization with the AC input voltage to maximize the real power drawn from the mains (AC supply). In a perfect PFC circuit, the input current is in phase with the input voltage (as it would be with a pure resistor), without any input current harmonics.

The boost converter is the most popular topology used in PFC applications. For low-power applications, the critical conduction mode (CrCM) boost topology has advantages in power saving and improving power density. At some medium- or high-power levels, the poor filtering ability and high peak current start to have significant disadvantages. For high-power applications, the continuous conduction mode (CCM) boost topology is the better choice. Explore our portfolio of power controllers, gate driver ICs, PFC boost diodes (CoolSiC™ Schottky diodes 600 V, 650 V to 1200 V), and switches (MOSFET, IGBTs, GaN HEMTs).

Choosing the right topologies for isolated DC-DC stage (soft switching)

In the isolated HV DC-DC stage, resonant topologies become increasing popular due to the intrinsic benefits in matters of efficiency and power density.

HB LLC and its variants are the preferred solutions in telecom rectifiers. This topology feature full resonance, resulting in less electromagnetic interference (EMI). It also achieves soft switching, which enables the highest efficiency. The design can be implemented in either a half bridge or full bridge configuration, and it uses variable frequency control to optimize performance.

On the other hand, The ZVS-PSFB (Zero Voltage Switching - Phase Shift Full Bridge) topology is design that utilizes soft switching techniques to improve efficiency and reduce switching losses. Soft switching on the primary side achieves Zero Voltage Switching (ZVS) and reduces switching losses. However, ZVS is lost at light loads, which can reduce efficiency. The secondary side uses hard switching, which can lead to higher switching losses. The topology operates at a fixed frequency with phase shift control, allowing for efficient power transfer and regulation. The ZVS-PSFB topology is a popular choice for high-power applications, such as datacenter power supplies, due to its high efficiency and reliability, but the loss of ZVS at light loads can be a limitation.

Explore our portfolio of power controllers, gate drivers, and power devices such as MOSFETs and GaN HEMTs as well as reference designs, evaluation boards, and simulation models for soft switching topologies.

Benefits of wide bandgap (WBG) in telecom PSUs

Studies show that e-mode GaN HEMTs provide a clear value in high-power telecom designs. We see that GaN enables the use of easier control schemes such as CCM modulation in the PFC due to its hard switching capabilities, while offering performance benefits over the next best Si alternative.

Infineon's CoolGaN™ HEMTs and dedicated GaN EiceDRIVER™ gate drivers are the perfect choice for hard-switching CCM-controlled AC-DC power conversion. In the PFC stage specifically, GaN-based solutions display a clear value with an efficiency benefit in the range of 0.3% at a significantly reduced complexity. The excellent switching figure of merit makes GaN the perfect solution for resonant soft switching applications, especially at high switching frequency operation.

Infineon's CoolSiC™ devices are also suitable for SMPS applications where high power is combined with high temperature operating conditions in totem-pole PFC and any hard- and soft-switching HB topologies, and leverages standard driving concepts.

Satellite-based communications and hybrid telecom power systems

Infineon has identified and analyzed the following trends in telecom rectifiers:

Satellite-based communications are utilizing power supply units (PSUs) in the range of 300-800W to support internet access kits. These PSUs are designed to complement 5G networks by leveraging existing satellite internet constellations. The design requirements for these PSUs include compact, fanless, and cost-sensitive solutions to accommodate high-volume production.

Hybrid Telecom Power systems are utilizing power supply units (PSUs) that integrate both rectifier and inverter functions, enabling bi-directional power conversion. These systems are designed to integrate with smart grids, photovoltaic (PV) systems, energy storage systems (ESS), and electric vehicle (EV) chargers. The use of wide bandgap (WBG) technologies, such as silicon carbide (SiC) or gallium nitride (GaN), is prevalent in these systems, allowing for more efficient and compact power conversion topologies.

Liquid cooling and RAN

Liquid Cooled Base Stations are utilizing power supply units (PSUs) that are cooled by the same pipeline used to cool the entire base station, reducing operational expenses (OPEX) through lower cooling costs. To address the high power output (Pout) requirements of up to 10-15kW, new PSU topologies are being developed, including surface mount device (SMD) top-side cooling solutions. These liquid-cooled PSUs also offer synergies with other applications, such as AI power and electric vehicle (EV) charging, where high-power density and efficient cooling are critical.

The Open and Cloud-based Radio Access Network (RAN) is driving the development of power supply units (PSUs) that are part of shared power architectures between telecom and datacenter applications. By leveraging the economies of scale of edge datacenters, these PSUs are designed to meet the specifications of the Open Compute Project (OCP) and the Microsoft Cloud Ready Power Supply (M-CRPS) standards, which are commonly used in server and datacenter applications. This convergence of telecom and datacenter power architectures enables more efficient and cost-effective power solutions.

About AC-DC power converter solutions for telecom infrastructure

Infineon provides system solutions for powering e.g. 5G small cells and base stations. These are applications that require the highest efficiency (99 percent) and high power density (73 W/in3 ). Converter system designers trust Infineon Wide Band Gap (WBG) (CoolGaN™ and CoolSiC™) and Super Junction (SJ) (CoolMOS™) power semiconductors combined with our gate driver ICs and microcontrollers, to deliver the highest power density, efficiency, and relibility.

Infineon CoolGaN™ devices are designed to meet the needs of typical telecom rectifier applications like industry lifetime and quality (cumulative failure rate) targets when operated in the totem pole, hard switching PFC topology.

With Infineon‘s semiconductor solutions, you can solve the typical telecom rectifier requirements like:

• High efficiency combined with a high power density
• High reliability, in order to minimize maintenance cost
• Low mechanical profile
• Outdoor harsh environmental operation, often in natural convection cooling
• Flat efficiency (typically from 30% to 100% load)

In the tabs below, discover the solutions Infineon offers and recommends for AC-DC power converters for telecom infrastructure. Explore our system solutions, evaluation boards and reference designs, and simulation tools, all designed to reduce your time to market.

Choosing the right topologies for PFC (hard switching)

Power factor correction (PFC) shapes the input current of the power supply to be in synchronization with the AC input voltage to maximize the real power drawn from the mains (AC supply). In a perfect PFC circuit, the input current is in phase with the input voltage (as it would be with a pure resistor), without any input current harmonics.

The boost converter is the most popular topology used in PFC applications. For low-power applications, the critical conduction mode (CrCM) boost topology has advantages in power saving and improving power density. At some medium- or high-power levels, the poor filtering ability and high peak current start to have significant disadvantages. For high-power applications, the continuous conduction mode (CCM) boost topology is the better choice. Explore our portfolio of power controllers, gate driver ICs, PFC boost diodes (CoolSiC™ Schottky diodes 600 V, 650 V to 1200 V), and switches (MOSFET, IGBTs, GaN HEMTs).

Choosing the right topologies for isolated DC-DC stage (soft switching)

In the isolated HV DC-DC stage, resonant topologies become increasing popular due to the intrinsic benefits in matters of efficiency and power density.

HB LLC and its variants are the preferred solutions in telecom rectifiers. This topology feature full resonance, resulting in less electromagnetic interference (EMI). It also achieves soft switching, which enables the highest efficiency. The design can be implemented in either a half bridge or full bridge configuration, and it uses variable frequency control to optimize performance.

On the other hand, The ZVS-PSFB (Zero Voltage Switching - Phase Shift Full Bridge) topology is design that utilizes soft switching techniques to improve efficiency and reduce switching losses. Soft switching on the primary side achieves Zero Voltage Switching (ZVS) and reduces switching losses. However, ZVS is lost at light loads, which can reduce efficiency. The secondary side uses hard switching, which can lead to higher switching losses. The topology operates at a fixed frequency with phase shift control, allowing for efficient power transfer and regulation. The ZVS-PSFB topology is a popular choice for high-power applications, such as datacenter power supplies, due to its high efficiency and reliability, but the loss of ZVS at light loads can be a limitation.

Explore our portfolio of power controllers, gate drivers, and power devices such as MOSFETs and GaN HEMTs as well as reference designs, evaluation boards, and simulation models for soft switching topologies.

Benefits of wide bandgap (WBG) in telecom PSUs

Studies show that e-mode GaN HEMTs provide a clear value in high-power telecom designs. We see that GaN enables the use of easier control schemes such as CCM modulation in the PFC due to its hard switching capabilities, while offering performance benefits over the next best Si alternative.

Infineon's CoolGaN™ HEMTs and dedicated GaN EiceDRIVER™ gate drivers are the perfect choice for hard-switching CCM-controlled AC-DC power conversion. In the PFC stage specifically, GaN-based solutions display a clear value with an efficiency benefit in the range of 0.3% at a significantly reduced complexity. The excellent switching figure of merit makes GaN the perfect solution for resonant soft switching applications, especially at high switching frequency operation.

Infineon's CoolSiC™ devices are also suitable for SMPS applications where high power is combined with high temperature operating conditions in totem-pole PFC and any hard- and soft-switching HB topologies, and leverages standard driving concepts.

Satellite-based communications and hybrid telecom power systems

Infineon has identified and analyzed the following trends in telecom rectifiers:

Satellite-based communications are utilizing power supply units (PSUs) in the range of 300-800W to support internet access kits. These PSUs are designed to complement 5G networks by leveraging existing satellite internet constellations. The design requirements for these PSUs include compact, fanless, and cost-sensitive solutions to accommodate high-volume production.

Hybrid Telecom Power systems are utilizing power supply units (PSUs) that integrate both rectifier and inverter functions, enabling bi-directional power conversion. These systems are designed to integrate with smart grids, photovoltaic (PV) systems, energy storage systems (ESS), and electric vehicle (EV) chargers. The use of wide bandgap (WBG) technologies, such as silicon carbide (SiC) or gallium nitride (GaN), is prevalent in these systems, allowing for more efficient and compact power conversion topologies.

Liquid cooling and RAN

Liquid Cooled Base Stations are utilizing power supply units (PSUs) that are cooled by the same pipeline used to cool the entire base station, reducing operational expenses (OPEX) through lower cooling costs. To address the high power output (Pout) requirements of up to 10-15kW, new PSU topologies are being developed, including surface mount device (SMD) top-side cooling solutions. These liquid-cooled PSUs also offer synergies with other applications, such as AI power and electric vehicle (EV) charging, where high-power density and efficient cooling are critical.

The Open and Cloud-based Radio Access Network (RAN) is driving the development of power supply units (PSUs) that are part of shared power architectures between telecom and datacenter applications. By leveraging the economies of scale of edge datacenters, these PSUs are designed to meet the specifications of the Open Compute Project (OCP) and the Microsoft Cloud Ready Power Supply (M-CRPS) standards, which are commonly used in server and datacenter applications. This convergence of telecom and datacenter power architectures enables more efficient and cost-effective power solutions.

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