CR1510-10 For 5V1A 手机充电器Ultra Charger DesignUSB

7. Efficiency Measurement（Meet DoE）
DOE (Final) for Low Voltage Model (Pno=5W)
0.0834*ln(5)-0.0014*5+0.609=73.62 lots of Margin!
VIN (VAC) IOUT (mA) 250 500 750 1000 250 500 750 1000 PIN (W) 1.666 3.279 4.924 6.615 1.712 3.345 4.953 6.573 VOUT_PCB (V) 5.17 5.17 5.17 5.17 5.16 5.17 5.17 5.17 Measure at end of PCB POUT_PCB (W) 1.293 2.585 3.878 5.170 1.290 2.585 3.878 5.170 EFF_PCB (%) 77.58 78.84 78.75 78.16 75.35 77.28 78.29 78.66 AV-EFF_PCB (%) Measure at end of Cable 26AWG/1m, RCable=0.286Ω VOUT_Cable POUT_Cable EFF_Cable AV-EFF_Cable (V) (W) (%) (%) 5.10 1.27 76.51 5.03 2.51 76.65 75.62 4.96 3.72 75.48 4.88 4.88 73.83 5.09 1.27 74.31 5.03 2.51 75.14 74.70 4.96 3.72 75.04 4.88 4.88 74.30
22 23 24
5
T1 EM-15, Horizontal Type PCB single Board, 94V0, FR-4 1mm L,N connecting line OD:0.3mm L=15mm
Jul 29, 2013
CR1510-10 for 5V1A Dialog Semiconductor Confidential
VIN (VAC) PIN (W)
0.026 1.672 3.309 5.016 6.796 0.027 1.666 3.279 4.924 6.615 0.036 1.712 3.345 4.953 6.573 0.041 1.738 3.389 5.012 6.625
VOUT (V)
5.17 5.17 5.17 5.16 5.16 5.10 5.17 5.17 5.17 5.17 5.17 5.16 5.17 5.17 5.17 5.16 5.16 5.16 5.17 5.17
34mm
4 CR1510-10 for 5V1A Dialog Semiconductor Confidential Jul 29, 2013
4. Bill of Material
Item Qty Primary Side component
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Reference
U1 C13, C2 C4 C3 C7 C1 BD1 D1 D2 F1 L1 L2 R5 R3 R16 R11 C8 C18 D3 R4 USB
Description
CR1510-10, Off-line Digital PSR & PWM & VMS Controller & BJT, SOIC-8 4.7uF, 400V, Low-ESR E-Cap, Ф8mm X 10mm 470pF, 250V, X7R, SMD-0805 220pF, 100V, X7R, SMD-0805 2.2uF, 25V, X7R, SMD-0805 22pF, 25V, X7R, SMD-0603 ABS8,1A800V, Rectifier Bridge TSC SRGC10MH(FR107),1A800V, Fast Rectifier Diode,SOD-123 SRGC10DH(FR102),1A200V, Fast Rectifier Diode,SOD-123 10R/1W, Fuse resistance, Surface mounting 330uH, Color Ring Inductor, 0410 4.7uH, Chip Inductor, LQM21FN4R7M80, SMD-0805 220Ω ±5%, SMD-0805 2.52Ω ±1%, SMD-0805 15KΩ ±1%, SMD-0603 3K78 ±1%,SMD-0603 330uF, 6.3V,solid- Capacitor
2. Schematic
CR1510
3
CR1510-10 for 5V1A Dialog Semiconductor Confidential
Jul 29, 2013
3. Circuit Board Photograph
Primary
Secondary
EM15
14mm
29mm
CR1510-10 Digital & Primary VMS Controller & BJT
EM15, the width of winding slot is 7mm
Jul 29, 2013
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CR1510-10 for 5V1A Dialog Semiconductor Confidential
6. Regulation, Ripple and Efficiency Measurement
1. Specification
Description
Input Voltage Frequency No-load Input Power (230VAC) Output Output Voltage VOUT 5.0 5.1 5.25 V
Measured at the end of USB-A
2UEW 0.14mmx1 45Ts– Primary (Clockwise)
2UEW 0.14mmx1 45Ts– Primary (Clockwise) 2UEW 0.14mmx1 45Ts– Primary (Clockwise)
6(S)
FINISHED :
1. 拔除pin3，pin4.并剪短pin7平bobbin面 2. Varnish the complete assembly
2Ts Tape
8(F)
Triple Insulated Wire 0.50mmx1 9Ts –Secondary (Anti-Clockwise)
9(S)
NC
Core is connected to Pin-2
2(F) 1(S)
2UEW 0.14mmx1 13Ts– Bias (Clockwise) Evenly covered 2UEW 0.14mmx1 14Ts– Forward (Clockwise) Evenly covered
Output Ripple Voltage
VRIPPLE
80
mVP_P
Total Output Power Continuous Output Power Over Current Protection Active Mode Efficiency (DOE Requirement) Environmental Conducted EMI Safety Ambient Temperature 2 TAMB Meets CISPR22B / EN55022B Designed to meet IEC60950, UL1950 Class II 0 35 Jul 29, 2013 °C
Rotating direction of winding machine
5 10 4 SEC
2
Forward 14Ts
• Electrical start could be different to Mechanical Winding start. • Core is connected to Pin-2(GND) by wire
1Ts Tape
ELECTRICAL SPECIFICATIONS:
1. Primary Inductance (Lp) = 1.68mH(± 5%)@10KHz 2. Electrical Strength = 3KV, 50/60Hz,1Min
2(S)
7(F) 5(F)
MATERIALS:
1. 2. 3. 4. 5. Core : EM15(Ferrite Material TDK PC40 or equivalent) Bobbin : EM15 Horizontal. Magnet Wires (Pri) : Type 2-UEW Magnet Wire (Sec) : Triple Insulated Wires Layer Insulation Tape :3M1298 or equivalent.
5. Transformer Design
SCHEMATIC
Instruction for start of first winding…
9 1 6
5ቤተ መጻሕፍቲ ባይዱ
Primary 135Ts 9Ts
8
6 1
Bias 13Ts Note:
• Dot (●) denote electrical start.
9
Winding Start pin-6 & End pin-5 in “Clockwise” direction – looking from Pin 5/9 side of the Bobbin. PRI
OCP (A)
Average η(% )
90
1.10
77.13
115
1.12
78.33
230
1.09
77.39
264
1.08
76.44
*Note: Output voltage is measured at the end of PCB.
7 CR1510-10 for 5V1A Dialog Semiconductor Confidential Jul 29, 2013
Secondary Side component 330uF, 6.3V, E-Capacitor
V3L45, 3A45V, Schottky Diode, SMD,DO-221AC Vishay 3K±1%,SMD-0603 USB Connnecter (Horizontal tape)
Other component
IOUT (A)
0 0.25 0.5 0.75 1 0 0.25 0.5 0.75 1 0 0.25 0.5 0.75 1 0 0.25 0.5 0.75 1
VRIPPLE (mVP-P)
18 34 46 62 72 18 32 46 58 71 20 44 42 52 68 18 44 42 54 64
POUT (W)
1.293 2.585 3.870 5.160 1.293 2.585 3.878 5.170 1.290 2.585 3.878 5.170 1.290 2.580 3.878 5.170
η (% )
77.30 78.12 77.15 75.93 77.58 78.84 78.75 78.16 75.35 77.28 78.29 78.66 74.22 76.13 77.36 78.04
Symbol
Min
Typ
Max
Units
Comment
VIN fLINE
90 47 50/60
264 63 0.1
VAC Hz W
2 Wire
Output Current
IOUT
1
A
Add 0.1uF Ceramic capacitor and 1uF E-cap at the end of connector and set oscilloscope at 20MHz bandwidth.
Free convection, sea level
POUT IOCP
5 1.2
W A
Auto-restart Measured at end of USB-Connector VIN = 115VAC and 230VAC (TAMB = 25 ℃).

68.2
%
CR1510-10 for 5V1A Dialog Semiconductor Confidential
CR1510-10 For 5V1A Charger Design
General Design Specification:
1. 2. 3. 4. 5. AC Input Range 90Vac-264Vac DC Output 5V, 1A Meet “DOE” Requirement Meet “MoU” Requirement Max Output Ripple & Noise < 80mV