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Overview

This design outlines a high-efficiency LED driver for lighting applications, utilizing Gallium Nitride (GaN) transistors to achieve superior efficiency, compact size, and thermal performance. The driver targets a 50W-1000W output, suitable for commercial and residential lighting.

Key Specifications

  • Input Voltage: 85–265V AC (universal input)
  • Output Power: 50W-1000W
  • Output Voltage: 30–350V DC (adjustable for LED string)
  • Output Current: (constant current)
  • Efficiency: >95% at full load
  • Power Factor: >0.98
  • Topology: Flyback with GaN FETs
  • Switching Frequency: 100–150 kHz
  • Protection: Over-voltage, over-current, short-circuit, thermal shutdown

Design Components

  1. GaN Transistor: GaN FET (e.g., EPC2045, 100V, 7mΩ) for high-speed switching and low RDS(on).
  2. Controller: PFC + PWM controller (e.g., NCP1399) for efficient power factor correction and LED current regulation.
  3. Transformer: Custom-designed high-frequency transformer for flyback topology, optimized for GaN switching.
  4. Output Stage: Schottky diode and low-ESR capacitors for smooth DC output.
  5. EMI Filter: Input EMI filter to comply with CISPR 22 standards.

Design Highlights

  • GaN Advantage: GaN transistors enable higher switching frequencies, reducing transformer size and improving efficiency compared to Si-based MOSFETs.
  • High Efficiency: Achieves >95% efficiency through minimized switching and conduction losses.
  • Compact Design: GaN’s high power density allows a smaller footprint, ideal for space-constrained lighting applications.
  • Thermal Management: GaN’s low thermal resistance enhances reliability in high-temperature environments.

Implementation Steps

  1. Schematic Design: Use GaN FETs in a flyback topology with a PFC-PWM controller.
  2. PCB Layout: Optimize for minimal parasitic inductance and high-frequency performance.
  3. Firmware: Program the controller for constant current output and protection features.
  4. Testing: Validate efficiency, thermal performance, and EMI compliance under full load.

Applications

  • Commercial LED lighting (e.g., office, retail)
  • Residential lighting systems
  • Industrial high-bay lighting

This design leverages TDLOGY’s expertise in GaN technology to deliver a robust, efficient, and compact LED driver for modern lighting solutions.