適配器待機能耗降低方案
從為(wei)平板電腦(nao)或智能(neng)手機電池充(chong)電到為(wei)膝上型電腦(nao)或家用路由器(qi)供電,電源(yuan)適(shi)(shi)配器(qi)長(chang)期以來都是人們日(ri)常生活(huo)的(de)必要組成(cheng)部(bu)分。對于將電源(yuan)適(shi)(shi)配器(qi)與其產品(pin)搭(da)配到一起的(de)消費電子原設備制造商(shang)(OEM)而言,需(xu)(xu)要因應兩項關鍵推動因素,即確(que)保提(ti)供高能(neng)效等(deng)級(ji)并(bing)滿足安全(quan)規范(fan),同時(shi)還需(xu)(xu)提(ti)供緊湊的(de)外形(xing)因數(shu)。近(jin)年(nian)來,由于結合了政(zheng)府法規及美國“能(neng)源(yuan)之星”、歐盟生態設計指令及中國標準化(hua)研究(jiu)院(CNIS)等(deng)能(neng)效項目,業(ye)界非常注重通過減小(xiao)待機模式下的(de)使用的(de)電能(neng)來降低適(shi)(shi)配器(qi)的(de)總體能(neng)耗等(deng)級(ji)。本文將探討推動最新(xin)要求的(de)新(xin)興技術趨勢,包括要求減少(shao)使用的(de)外部(bu)元器(qi)件數(shu)量(liang)、使設計更時(shi)髦輕薄的(de)工藝。
待機能(neng)(neng)(neng)(neng)耗(hao)(hao)(hao)有時候也(ye)稱(cheng)作(zuo)“吸血鬼能(neng)(neng)(neng)(neng)耗(hao)(hao)(hao)”或是“虛負載”,指的(de)(de)是電子設備及電器在關斷電源(yuan)但仍然插在電源(yuan)插座(zuo)上時消耗(hao)(hao)(hao)的(de)(de)電能(neng)(neng)(neng)(neng)。以美國(guo)為例,待機能(neng)(neng)(neng)(neng)耗(hao)(hao)(hao)約占美國(guo)家庭平均總能(neng)(neng)(neng)(neng)耗(hao)(hao)(hao)約10%.這相當(dang)于(yu)令人驚(jing)愕的(de)(de)129太瓦時(即為1,290億千瓦時)的(de)(de)電能(neng)(neng)(neng)(neng),或者是36座(zuo)400兆(zhao)瓦發電廠(chang)輸出的(de)(de)電能(neng)(neng)(neng)(neng),導致(zhi)每年(nian)排放7,500萬(wan)噸(dun)二氧化碳。
在(zai)美(mei)國(guo),2008年7月1日(ri)生效的(de)現行聯(lian)邦標(biao)準(zhun)要求功率(lv)低(di)于250 W的(de)電源(yuan)空載(zai)能(neng)(neng)(neng)(neng)耗低(di)于500 mW.最(zui)近,美(mei)國(guo)能(neng)(neng)(neng)(neng)源(yuan)部(DOE)提(ti)出了更嚴格的(de)電池充電器及電子(zi)產(chan)品(pin)電源(yuan)能(neng)(neng)(neng)(neng)效標(biao)準(zhun),并將于2013年7月1日(ri)生效。根據新(xin)(xin)標(biao)準(zhun),銘牌輸出功率(lv)介于49至250 W之間(典(dian)型筆(bi)記(ji)本視(shi)頻器功率(lv)位于此(ci)(ci)范圍)的(de)交流(liu)-直流(liu)(AC-DC)外部電源(yuan)的(de)最(zui)大空載(zai)能(neng)(neng)(neng)(neng)耗必(bi)須(xu)低(di)于0.210 W.然而,這些國(guo)家(jia)標(biao)準(zhun)通(tong)常(chang)落后于其它標(biao)準(zhun)及市場要求。美(mei)國(guo)1975年能(neng)(neng)(neng)(neng)源(yuan)政策及節(jie)能(neng)(neng)(neng)(neng)法案(an)(EPCA)規定:任何新(xin)(xin)的(de)節(jie)能(neng)(neng)(neng)(neng)標(biao)準(zhun)的(de)制定必(bi)須(xu)旨在(zai)提(ti)供最(zui)大程度的(de)能(neng)(neng)(neng)(neng)效提(ti)升,不(bu)僅要在(zai)技術上(shang)可行,也要具(ju)備(bei)經濟合理性(xing)。因此(ci)(ci),這些國(guo)家(jia)標(biao)準(zhun)通(tong)常(chang)并不(bu)代表“一流(liu)的(de)”性(xing)能(neng)(neng)(neng)(neng)。諸(zhu)多電源(yuan)制造商要求將空載(zai)能(neng)(neng)(neng)(neng)耗限(xian)制到(dao)盡可能(neng)(neng)(neng)(neng)地低(di),從而將其產(chan)品(pin)與競爭產(chan)品(pin)區別開來。

圖(tu)1:美國能源部提出的AC-DC外(wai)部電源節能標準
在(zai)能(neng)(neng)(neng)效標準上最為(wei)進取的政府機(ji)構(gou)很可(ke)(ke)能(neng)(neng)(neng)是美(mei)國(guo)(guo)加州(zhou)(zhou)。電(dian)(dian)源制造商可(ke)(ke)不想提(ti)供(gong)僅(jin)針(zhen)對加州(zhou)(zhou)的特定(ding)型號(hao)產品,因此,加州(zhou)(zhou)標準的實(shi)際(ji)影響范圍要廣得多。例如,美(mei)國(guo)(guo)加州(zhou)(zhou)在(zai)2012年(nian)1月出臺的新的電(dian)(dian)器(qi)能(neng)(neng)(neng)效規范將電(dian)(dian)池充電(dian)(dian)器(qi)系統作為(wei)重要焦點。加州(zhou)(zhou)每年(nian)有(you)超(chao)過1.7億(yi)個(ge)充電(dian)(dian)器(qi)被用于(yu)充電(dian)(dian),根據推測,在(zai)此特別領域提(ti)升能(neng)(neng)(neng)效,每年(nian)將可(ke)(ke)節省2,200吉瓦時(即22億(yi)千(qian)瓦時)的電(dian)(dian)能(neng)(neng)(neng)。這些電(dian)(dian)路足夠為(wei)35萬個(ge)家(jia)庭供(gong)電(dian)(dian),相當于(yu)為(wei)住(zhu)宅/商業用電(dian)(dian)賬單(dan)每年(nian)節省3.06億(yi)美(mei)元(yuan)。美(mei)國(guo)(guo)加州(zhou)(zhou)能(neng)(neng)(neng)源委員會(CEC)實(shi)施的這些能(neng)(neng)(neng)效規范要求手機(ji)、個(ge)人(ren)照護設(she)備及電(dian)(dian)動工具所使用的所有(you)消費類(lei)充電(dian)(dian)器(qi)在(zai)2013年(nian)2月前必須(xu)遵從,而工業類(lei)充電(dian)(dian)器(qi)須(xu)在(zai)未(wei)來12個(ge)月內遵從。美(mei)國(guo)(guo)其他幾個(ge)州(zhou)(zhou)希(xi)望遵循(xun)加州(zhou)(zhou)降低(di)待機(ji)能(neng)(neng)(neng)耗限制值的范例。

圖2:電(dian)動(dong)工具所用(yong)的典型老式充電(dian)系統
圖2介紹了過去常用的基本充(chong)電(dian)器系統電(dian)路圖。此特別案例(li)使(shi)用鎳(nie)鉻(NiCd)電(dian)池(chi)(chi)來為電(dian)動工具充(chong)電(dian)。電(dian)池(chi)(chi)在1小(xiao)(xiao)時內(nei)的電(dian)量(liang)標為C.例(li)如,以0.5 C的充(chong)電(dian)速率來為額定容量(liang)600 mAh的電(dian)池(chi)(chi)充(chong)電(dian),使(shi)用300 mA充(chong)電(dian)電(dian)流要(yao)經歷超過2小(xiao)(xiao)時才能完全(quan)充(chong)滿電(dian)池(chi)(chi)。
圖2中的(de)(de)(de)電(dian)路能(neng)以0.1 C的(de)(de)(de)恒(heng)定充電(dian)速率。由于充電(dian)器的(de)(de)(de)60 Hz變壓(ya)器的(de)(de)(de)設計意(yi)圖是(shi)維持低成本,而非提供高能(neng)效(xiao)等級,空載(zai)能(neng)耗(hao)(hao)通常(chang)將高于0.5 W,如此高的(de)(de)(de)空載(zai)能(neng)耗(hao)(hao)不再能(neng)夠令(ling)人接受。早期(qi)想(xiang)法(fa)是(shi)使充電(dian)器能(neng)效(xiao)更高,但不注意(yi)事(shi)實上充電(dian)后電(dian)路會持續無限期(qi)地浪(lang)費電(dian)能(neng)。這已經被證(zheng)明是(shi)一種有點誤導(dao)的(de)(de)(de)視角。
即便是當今市場上的許多充(chong)(chong)(chong)(chong)電(dian)(dian)(dian)器,也(ye)仍然缺乏檢測電(dian)(dian)(dian)池是否完全(quan)充(chong)(chong)(chong)(chong)滿(man)的能力,且(qie)因(yin)此在充(chong)(chong)(chong)(chong)電(dian)(dian)(dian)過程完成后仍然持續提供電(dian)(dian)(dian)能給電(dian)(dian)(dian)池,因(yin)而浪費電(dian)(dian)(dian)能(釋放為熱量)。通(tong)過使用(yong)可以關閉完全(quan)充(chong)(chong)(chong)(chong)滿(man)之電(dian)(dian)(dian)池的充(chong)(chong)(chong)(chong)電(dian)(dian)(dian)通(tong)道,電(dian)(dian)(dian)能就不(bu)會無謂地浪費,電(dian)(dian)(dian)池也(ye)不(bu)會置(zhi)于損(sun)壞的風險。
提供低待(dai)機能耗工作的(de)創新方案(an)
家庭中(zhong)一項常見的(de)(de)待機能(neng)耗源頭就是筆(bi)(bi)記(ji)本(ben)(ben)適(shi)配器(qi)(qi)(qi)(qi)(qi)。這(zhe)些適(shi)配器(qi)(qi)(qi)(qi)(qi)相當多的(de)(de)使(shi)用時間是在(zai)筆(bi)(bi)記(ji)本(ben)(ben)電腦斷(duan)開(kai)連(lian)接或關斷(duan)的(de)(de)情況下在(zai)桌(zhuo)子底下度過的(de)(de)。如今典型的(de)(de)市(shi)售筆(bi)(bi)記(ji)本(ben)(ben)適(shi)配器(qi)(qi)(qi)(qi)(qi)在(zai)空載條件下約消耗300 mW至500 mW的(de)(de)能(neng)耗。然而,許多領先制(zhi)(zhi)造商如今要(yao)求(qiu)下一代(dai)筆(bi)(bi)記(ji)本(ben)(ben)適(shi)配器(qi)(qi)(qi)(qi)(qi)的(de)(de)空載能(neng)耗限制(zhi)(zhi)到低于30 mW,從而使(shi)其產品與(yu)競爭產品區域開(kai)來。圖3顯示(shi)了65 W筆(bi)(bi)記(ji)本(ben)(ben)適(shi)配器(qi)(qi)(qi)(qi)(qi)用下一代(dai)充電系統(tong)的(de)(de)簡化示(shi)例。此電路最重要(yao)的(de)(de)元(yuan)器(qi)(qi)(qi)(qi)(qi)件就是固定頻率電流模式(shi)控(kong)制(zhi)(zhi)器(qi)(qi)(qi)(qi)(qi)IC及次級端開(kai)關電源(SMPS)控(kong)制(zhi)(zhi)器(qi)(qi)(qi)(qi)(qi)IC.

圖(tu)3:帶空(kong)載(zai)檢測功能的先(xian)進充(chong)電(dian)電(dian)路(lu)簡化電(dian)路(lu)圖(tu)
這(zhe)示例中指定的(de)(de)(de)固定頻率電(dian)(dian)(dian)流(liu)模式控制器(即安(an)(an)森美半導體的(de)(de)(de)NCP1246)經過了(le)專(zhuan)門優化,在(zai)(zai)空載(zai)及輕(qing)載(zai)條件下消(xiao)耗(hao)(hao)極低的(de)(de)(de)能耗(hao)(hao)。交(jiao)(jiao)流(liu)-直(zhi)流(liu)(AC-DC)電(dian)(dian)(dian)源(yuan)空載(zai)條件下輸(shu)入(ru)(ru)能耗(hao)(hao)的(de)(de)(de)其中一(yi)(yi)項主要(yao)(yao)(yao)來(lai)源(yuan)是(shi)(shi)X2電(dian)(dian)(dian)容(rong)放(fang)電(dian)(dian)(dian)電(dian)(dian)(dian)路(lu)。典型(xing)適配(pei)器包(bao)含(han)高壓X2電(dian)(dian)(dian)容(rong),它連接至交(jiao)(jiao)流(liu)輸(shu)入(ru)(ru)端,作為(wei)電(dian)(dian)(dian)磁干擾(EMI)濾(lv)波器的(de)(de)(de)一(yi)(yi)部(bu)分。出于安(an)(an)全原因,強制要(yao)(yao)(yao)求(qiu)此(ci)(ci)電(dian)(dian)(dian)容(rong)在(zai)(zai)從墻上拔出適配(pei)器插(cha)頭后(hou)的(de)(de)(de)1秒(miao)時(shi)(shi)間內(nei)放(fang)電(dian)(dian)(dian)至安(an)(an)全電(dian)(dian)(dian)壓電(dian)(dian)(dian)平(ping)。否則,接觸交(jiao)(jiao)流(liu)插(cha)頭的(de)(de)(de)扁腳(prong)就面臨(lin)電(dian)(dian)(dian)擊(ji)的(de)(de)(de)危險。符合(he)此(ci)(ci)要(yao)(yao)(yao)求(qiu)的(de)(de)(de)標(biao)準(zhun)方法是(shi)(shi)使用(yong)一(yi)(yi)串與電(dian)(dian)(dian)容(rong)并(bing)聯的(de)(de)(de)高阻抗泄放(fang)電(dian)(dian)(dian)阻。當(dang)用(yong)于230 Vac應用(yong)時(shi)(shi),這(zhe)恒定的(de)(de)(de)電(dian)(dian)(dian)阻型(xing)消(xiao)耗(hao)(hao)源(yuan)約消(xiao)耗(hao)(hao)25 mW輸(shu)入(ru)(ru)能耗(hao)(hao)。當(dang)顧及到空載(zai)能耗(hao)(hao)時(shi)(shi),這(zhe)25 mW就變得相當(dang)大(da)了(le)。NCP1246解決此(ci)(ci)問題的(de)(de)(de)方法是(shi)(shi)加入(ru)(ru)帶(dai)有源(yuan)放(fang)電(dian)(dian)(dian)電(dian)(dian)(dian)路(lu)的(de)(de)(de)內(nei)置交(jiao)(jiao)流(liu)線路(lu)檢測器。這(zhe)控制器在(zai)(zai)檢測到不再存在(zai)(zai)交(jiao)(jiao)流(liu)信(xin)號時(shi)(shi),激活內(nei)置開關來(lai)使電(dian)(dian)(dian)容(rong)放(fang)電(dian)(dian)(dian)。有了(le)這(zhe)個功能,就不再需(xu)要(yao)(yao)(yao)泄放(fang)電(dian)(dian)(dian)阻了(le),消(xiao)除了(le)恒定的(de)(de)(de)25 mW能耗(hao)(hao)源(yuan)頭。
次(ci)級端(duan)開關(guan)電(dian)(dian)(dian)源控(kong)制(zhi)器(qi)(即安森美(mei)半導體的(de)(de)NCP4354)是NCP1246的(de)(de)伴(ban)侶IC,能(neng)夠檢測空載條件,并(bing)使電(dian)(dian)(dian)源進入低(di)能(neng)耗(hao)關(guan)閉(bi)模式。在關(guan)閉(bi)模式期(qi)間,初(chu)(chu)級端(duan)控(kong)制(zhi)器(qi)停止工作,能(neng)量由輸(shu)出(chu)電(dian)(dian)(dian)容(rong)提(ti)供(gong)(gong)。適(shi)配(pei)器(qi)的(de)(de)輸(shu)出(chu)電(dian)(dian)(dian)壓(ya)開始(shi)下(xia)降,因為初(chu)(chu)級端(duan)不(bu)再(zai)(zai)在存在開關(guan)工作。這并(bing)不(bu)構成什么問(wen)題,因為適(shi)配(pei)器(qi)在此(ci)(ci)模式下(xia)不(bu)再(zai)(zai)連(lian)接至(zhi)筆記本電(dian)(dian)(dian)腦。輸(shu)出(chu)電(dian)(dian)(dian)壓(ya)被允許下(xia)降至(zhi)某個可調節電(dian)(dian)(dian)平,直到NCP4354通知初(chu)(chu)級端(duan)重(zhong)啟,重(zhong)新為輸(shu)出(chu)電(dian)(dian)(dian)容(rong)充電(dian)(dian)(dian)并(bing)因此(ci)(ci)維持工作。當(dang)適(shi)配(pei)器(qi)重(zhong)新連(lian)接至(zhi)電(dian)(dian)(dian)池時,NCP4354控(kong)制(zhi)器(qi)自動重(zhong)啟初(chu)(chu)級端(duan)控(kong)制(zhi)器(qi)。能(neng)僅以一顆光耦提(ti)供(gong)(gong)反饋控(kong)制(zhi)及導通/關(guan)閉(bi)信號(hao)。當(dang)在此(ci)(ci)類電(dian)(dian)(dian)路中一起使用時,NCP1246和NCP4354能(neng)夠采用美(mei)國規(gui)格的(de)(de)交流主電(dian)(dian)(dian)源提(ti)供(gong)(gong)低(di)于10 mW的(de)(de)空載能(neng)耗(hao),且在寬交流主電(dian)(dian)(dian)源電(dian)(dian)(dian)壓(ya)范圍(wei)下(xia)提(ti)供(gong)(gong)低(di)于20 mW的(de)(de)空載能(neng)耗(hao)。

圖4:65 W適(shi)配器電路圖
雖然許多消費電(dian)子OEM生產高能(neng)效(xiao)產品(pin),但他們常(chang)常(chang)會對低(di)能(neng)耗的(de)充(chong)電(dian)系統感到(dao)失望。如(ru)今已經出現重要進展(zhan),電(dian)池充(chong)電(dian)器可以消耗更少電(dian)能(neng),同時提供市場所要求的(de)高性能(neng)基準(zhun)。諸(zhu)如(ru)本(ben)文所介紹的(de)系統致力于滿足這些標準(zhun),并降低(di)系統復雜度、節(jie)省珍(zhen)貴的(de)電(dian)路板空間及(ji)使物料單(BOM)成本(ben)受(shou)到(dao)控制。
