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5 V to 6 kV DC-DC Converter Using Switching Regulator with Cockcroft-

Walton Voltage Multiplier for High Voltage Power Supply Module

Article  in  Recent Advances in Electrical & Electronic Engineering · June 2018

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Recent Advances in Electrical & Electronic Engineering, 2017, Volume 10 1

5 V to 6 kV DC-DC Converter Using Switching Regulator with Cockcroft-

Walton Voltage Multiplier for High Voltage Power Supply Module

Nor Afiqah Azmia, Sohiful Anuar Zainol Murad*b, Azizi Harun1, and Rizalafande Che Ismail2a

ab
School of Microelectronic, Universiti Malaysia Perlis, Arau Perlis, Malaysia

Abstract: This paper describes the design of 5 V to 6 kV DC-DC converter by using a switching regulator with Cockroft-
Walton (C-W) voltage multiplier for a high voltage power supply module. The proposed design consists of Pulse Width
Modulation (PWM) controller circuit, voltage multiplier, and feedback signal. A single unit of 5 V input triggers LT1618
controller circuit to generate 20 V which then produces 300 V from LT8331 output that is connected to diode-capacitor
multiplier circuit to achieve final 6 kV. A negative feedback signal is required to stabilize an output voltage. With the
implementation of C-W voltage multiplier technique, the output is boosted up as required from the input signal voltage 5
V DC. The LTspice simulation results indicate that the proposed DC converter can generate 6.20 kV. Line regulation of
17 % and the load regulation of 14 % are obtained based on the proposed design. The proposed design is suitable for high
voltage power supply module.

Keywords: DC-DC Converter, High voltage, Power supply, Switching Regulator, Voltage multiplier

1. INTRODUCTION Due to several developments of the transformer circuit

design, the voltage multiplier has been divided into several
Nowadays, our society is administered by computers and sections and splitting sources as proposed in [10]. As a
other electronic appliances. A high voltage generating is power loss in a capacitor which is caused by increasing
widely used in industrial applications, such as plasma
frequency will affect the high voltage DC power supply, it is
generating, DC backup system, Scanning Electron necessary to retain the produced noise lower than 5% [11].
Microscopy (SEM), Photomultiplier Tube (PMT),
With an implemented of same values of capacitance, it is
capacitance microphones, ultrasonic transducer and many
believed that the voltage has dropped, the ripple voltage and
more [1]–[4]. In electronic appliances, a high voltage DC noise are reduced and the designs presented in [4], [12]–[14]
power supply is a critical element and must perform are the way to improve half-wave C-W voltage multiplier.
consistently. Based on a conventional method of DC high
Besides, there are other criteria influencing the high voltage
voltage power supply, a transformer is implemented in the management and several methods have been proposed in [1]
design as shown in Figure 1 [5]. The output of a secondary
to achieve the high voltage. However regarding to the
step up transformer will increase the voltage and conservative method which covers multiplier circuit and
consequently the design circuit involving Cockcroft-Walton transformer where utilizes AC source, the transformer will
(C-W) voltage multiplier will increase the voltage for each lead to the cost inefficiency and the ripple problem still
stage. unsolved [15].
The C-W voltage multiplier is very prevalent among high Pursuant to the above problems, step-up transformer is
voltage DC application due to the benefits of low voltage
replaced with boost type structure for carrying out the step-
stress on the diodes and capacitors, the circuit compactness up process. Instead of that, boost converter types provides
and cost efficiency. A conventional design of C-W voltage high voltage ratio compare to previous C-W voltage
multiplier is constructed by connecting a diode-capacitor multiplier based converter design [16]–[19]. Besides,
ladder stage where each stage constitutes of two capacitors regarding to another aspects, it is compactable series with
and two diodes [6]. A voltage-fed modified C-W topologies compactness design. However, the low frequency applied
applied in [7]–[9] are discussed where the usage of high turn
(50-60 Hz) to the converter can caused high ripple voltage
ratio transformer leads to large winding capacitance and appears at the output [19]. The output voltage value also
leakage inductance, which leads to high current and voltage
gives an impact that produces the value lesser than
stresses and higher switching losses on the switches. theoretical due to the non-ideal characteristic of the circuit
elements.
*School of Microelectronic, Universiti Malaysia Perlis, Kampus Pauh Putra, By applying step-up converter and voltage multiplier
02600 Arau Perlis,Malaysia; Tel/Fax: +60 4-988 5509/5515, +604-9885510; method in one design to generates high voltage output, there
E-mails: [email protected],my are several technique applied. Among of the method

© 2017 Bentham Science Publishers

2 Recent Advances in Electrical & Electronic Engineering, 2017, Vol. 10, No. 2 N. A. Azmi, et al.

concerned is the flyback converter with switching circuit is

proposed in [18] by keeping an increase to a much higher
voltage value. Referring to the other converter aspect, a C-W 2. OPERATING PRINCIPLE OF PROPOSED
voltage multiplier with a step up converter by using an CIRCUIT
interleaved PWM controller which employs two independent
frequencies is presented in [20], [21]. It is suitable for a high A block diagram of the proposed C-W voltage multiplier
step up application using a boost inductor but it suffers in design is shown in Figure 2. In order to obtain DC high
switching losses of switch and diodes due to the different voltage 6 kV, step-up converter is needed by applying a
switches implemented in [22]. Other authors implement an voltage multiplier at the end of proposed model scheme. The
inverter in [19] with various frequencies thus stimulating an purpose of using DC-DC converter is to boost up the output
effect to the capacitor. Besides, the design of the DC-DC voltage. By applying this type of switching regulator, the
converter which consist a stage of diode-capacitor-inductor number of diode-capacitor multiplier stages is reduced and
at input and voltage multiplier at output to produce low thus improved the previous design which had applied 32
voltage stress is proposed in [22], [23]. Switched capacitor stages [32].
technique applied in [24], [25] is widely used to achieve high
voltage gain but the conduction losses increase caused by Regarding to the 5V DC input supply that provides a
high charging current which flow through the main switch. square wave signal with a switching frequency, the input
Moreover, many of the design implemented non-isolated pulse transfers into PWM step-up converter to drive the
step-up DC-DC converter as in [12] for a renewable energy MOSFET switch. The main purpose of using PWM step-up
application with a low DC input voltage. A system based on converter is to control the pulse width of the input signal and
a combination of switched-coupled-inductor boost converter is used to drive MOSFET switches. Besides, the circuit
is presented by using a cascaded C-W voltage multiplier in which making a loop in this design is negative feedback
[25] and diode-capacitor voltage multiplier in [26], [27] as a function as to regulate an output voltage in the development
turn ratio of inductor which easily boosts the low input to a circuit.
very high output.
The output produced from the first MOSFET driver is 20
Besides of introduced design on literatures, most of the V DC with a 1.4 MHz switching frequency. Then, this value
switching regulator step-up converter has been design and will become as an input signal to another controller circuit
integrate in one chip to control voltage and current sense. and drives another switch. Based on this second output
Because of the switching loss, low voltage stress and low switch which is 300 V DC with 200 kHz and 600 V DC will
efficiency in conventional converter, built-in switching amplify by using a voltage multiplier circuit. This multiplier
regulator design which constitutes of control circuitry design circuit consists of twice capacitor-diode combination for
is implemented. Most of the commercial control ICs, where each stage where each of them can generate 300 V DC as in
the simplicity of the design are introduced instead of having a block diagram in Error! Reference source not found.. At
high performance, affordable price and other advantage in the end of this improvement circuit, negative feedback signal
terms of dc-dc conversion application [28]. Other than that,
which constitutes of voltage or current controlled sense is
there are several advantages by operating this method which
connected at the output voltage terminal and linked into
involves programmable switching frequency by setting with
an external resistor [29]. This step-up DC-DC switching PWM converter circuit. The input supply and negative
regulator operates with minimum input voltage or battery- feedback signal are compared until they reach the same value
powered system [30] and use controlled mode Pulse Width before obtaining the required output voltage as in Figure 3.
Modulation (PWM) method to provide precise output By referring to the proposed design, switching regulator
regulation and low noise [31]. Therefore, this paper DC-DC boost converter are implemented on both Linear
contribution includes: Technology Integrated Circuit. Common controlled method
 Propose transformer less dc-dc converter for high is divided into voltage-controlled mode and current-
voltage and low current power supply module. controlled mode. Current-controlled method is implemented
on this design with the operation in block diagram Figure 3
 Propose simple circuitry of dc-dc converter
to accomplish a project demand. Power stage consists of
employed boost converter and less number of voltage
diode, inductor and an output capacitor. The input voltage,
multiplier stages. Vin deliver into this building block and converted into the
Section 2 presents the operating principle of the proposed output voltage, Vout. Control section is conquering around
circuit and the selection of the components for the circuit this block with the involvement of voltage divider, error
design. Section 3 presents the simulations results and amplifier and PWM comparator in the comparator in the
discussions for the proposed circuit design and final modulator and voltage loop compensator subsection.
conclusion is given in the final section. In this method, it regulates the output current with an
infinite loop gain and the output is a high impedance source.
5 V to 6 kV DC-DC Converter Using Switching Regulator with Cockcroft- Recent Advances in Electrical &
Walton Voltage Multiplier for High Voltage Power Supply Module Electronic Engineering, 2017, Vol. 10 No. 2 3
Regarding to this method, the current loop is nested with a divider connection, the FBX pin is capable to pull up to 1.6V
slower voltage response because the inductor current internal bias voltage. LT8331 will stop switching if the
increases with a slopes are determining by the difference Shutdown and Under voltage Detect Pin (EN/UVLO) pin
input and output voltage and responds to the line and load obtained is lower than 1.6 V. The BIAS connection is used
changes, The Vout is subtracted from a reference voltage, Vref to improve efficiency across load. Concerning to the
to create an error signal, Verror. Then Verror commands an reference voltage at LT1618 and LT8331, the output value
output current rather than voltage which compared with the can be determined through specific resistor value on
ramp that generated by the slope of the inductor current and feedback divider according to the equations (1) and (2). By
applied to the PWM comparator. PWM ramp is generated by using a simple boost converter, a high voltage application
a signal derived from the output inductor current. Therefore can easily achieve. It is believed that based on this
application, an output voltage is acquired by applying
when the output voltage drops, current-controlled mode
straight boost configuration and it double the value as a two
supplies more current to the load.
stage boost with a few additional components.
2.1 Circuit Design and Component Selection
 Vout 
Figure 4 shows an illustration of LT1618 connection R1  R2   1 (1)
boost converter model schemes which operates as a current-  1.263 
controlled mode with a 1.4 MHz constant frequency to
provide an excellent line and load regulator. The power
R7  R8 
 Vout  1 
switch MOSFET that is connected with switch (SW) pin will  (2)
turn the oscillator cycle and start to operate. The input
 1.6 
voltage which is connected from SW pin flows through the In the proposed design, a voltage multiplier circuit
comparator inside known as a Vramp due to the summation of consists of coupled diode-capacitor combination which is
the smallest voltage drop together with the oscillator ramp as declared as one stage. This voltage multiplier circuit
illustrates in the block diagram in Figure 3. Besides, as the constitutes cascading clamping and half-wave rectifier
feedback voltage, Vfeedback from divider circuit will be circuit to generate the highest value. Therefore, for this
generated at the feedback (FB) pin is then being compared to purpose, 20 stages are required with 40 ceramic capacitors
reference voltage Vref and based on the comparison, the error with 0.1 µF value and 1N4007 type of diode as shown in
voltage, Verror is obtained. When the Vramp achieves greater Figure 6. The Peak Inverse Voltage (PIV) for the diode and
than Verror, an internal SR latch will reset in which makes the voltage rating for a capacitor is 1000 V. Working voltage in
power switch in off condition. If Verror increased, more each component must be larger than the input supply in order
output current is delivered to the output. to prevent damage to the circuit. The voltage in the
Based on this connection, the two inverting inputs are component needs to be considered as the number of stages
from the Vfeedback loop which are connected with the voltage increases to generate greater output voltage. Every stage will
divider circuit and current feedback loop from current sense produce a 300 V DC, so that the output can easily be
at negative (ISN) and positive (ISP) pin that are attached measured at any points depending on the voltage value
with the sense resistor, Rsense. As either one of them needed. Besides, the voltage drop and ripple voltage need to
generates high input, it will force a converter in a constant- take apart in circuit design as number of stages increase. The
current mode or constant-voltage mode. Moreover, current equations are shown on (3) and (4) where f is the 200 kHz
sense amplifier acts as a sense voltage between ISP and ISN frequency; C is 0.1 µF ceramic capacitor and n as the
pin and provide level-shifted version to the error amplifier. number of stages applied;
In this situation, current sense voltage is regulated to 50 mV
between ISP and ISN pin, then the output of the current I  2 3 n2 n 
V   n    (3)
sense amplifier provides 1.263 V to the non-inverting input fc  3 2 6 
of Verror. The converter is in constant-current mode as the FB
pin value is not more than 1.263 V. This circuitry IC design I  n ( n 1) 
operates with a wide input voltage range and high switching V    (4)
rip fc  2 
frequency 1.4MHz which allows the use of low profile
components used.
Before obtaining the required voltage value, an output
Regarding to this performance, an output voltage is
voltage is connected to a voltage divider and is declared as a
connecting with Vin pin for another LT8331 converter
negative feedback signal. The resistor values involved in this
topology as illustrate in Figure 5. At the beginning of each
divider network are 1 MΩ and 2.7 kΩ. The output voltage
clock cycle, an oscillator works as a turning on the internal
for the LT1618 feedback circuit is directly connected to the
power switch. The voltage on the feedback pin (FBX) then is
output in which is linked into LT8331 input voltage. As the
compared with the internal reference voltage which is 1.6 V
voltage divider circuit is connected, the output voltage
by using an internal error amplifier. As a load current
actually can be varied from 48 V to the required voltage with
increases, it will cause reduction in FBX voltage as the
a modifying circuit. An input supplied with a variable value
OUT2 connecting each other. Therefore, the error amplifier
in the range of 10 V to 48 V for the second converter and 5
will increase a voltage with specific load current. In order to
V from the input supply into Vin pin for the first topology.
keep output in regulation, the error amplifier is connected
This voltage values also acts as a reference to the input
with the FBX thus, establishing the correct peak switch
signal from the feedback signal. The PWM controller will
current level. LT8331 is able to generate positive or negative
constantly operate the square pulse if the reference voltage
output voltage with a single FBX pin. It can be increased
value is larger than the feedback voltage obtained. On the
permittedly to generate positive output voltage. With voltage
4 Recent Advances in Electrical & Electronic Engineering, 2017, Vol. 10, No. 2 N. A. Azmi, et al.

other side, when the voltage for both reference and feedback dc converter and this work. Based on the summary of the
are produced at the same value, the PWM controller is not results in Error! Reference source not found., the proposed
generating the PWM signal into MOSFET switches. The design generates low output power and low current as
pulse will stop amplifying and the voltage value remains compared to others. The proposed design is suitable for high
constant after gaining the voltage difference between them. voltage low current power supply module applications.
By adjusting the resistor value in the divider network, the
output voltage changes as required value. The voltage drop occurs as the associated power loss
through the technique of multiplier stages. The ripple voltage
3. RESULTS AND DISCUSSIONS value is about 0.42 V and there is no voltage drop yet but the
voltage increase by 3.33%. If voltage drop occurs, it is
Based on the components summarized on Table I considered low as compared to the largest number of stages
respectively, LTspice is applied to simulate the proposed multiplier applied. The voltage drop on output and ripple
converter. The systems specification for the simulation
voltage will increase as the load current and the number of
design as in Table II and the waveform are explained in stage is increased.
details the operation of the suggested DC-DC boost
converter with incorporation of C-W Voltage Multiplier. By comparing between different types of the power
supplies, there are two aspects that need to be considered in
Figure 7 shows an output performance for both PWM terms of voltage regulation and minimum load resistance. In
controller units. The output voltage of 20.35 V is generated the voltage regulation, the change of output voltage due to
from LT1618 controller with the input supply of 5 V DC at
the variation of load current based on the resistance value
1.4 MHz built-in frequency. Error! Reference source not from 5 kΩ to 300 kΩ is known as load regulation. With a
found. shows the 5 V DC to 600 V simulation output proper design of power supply, the no-load voltage (VNL) is
performances for the boost converter and a stage of
larger than full-load voltage (VFL) as shown in Figure 12.
multiplier circuit. The resulting output voltage value from The voltage regulation obtained based on the configuration is
cascading of LT1618 and LT8331 is 296.43 V. At Vout2 14 % when concern with 2.8 mA current value. For the line
connection, 591.88 V is generated from a stage of voltage
regulation which is declared as variation in the output
multiplier which connects through Vout1 point. voltage because of the change on input voltage in Figure 13
As both converters have been simulated, the load current and Figure 14 with 2 V and 8 V values another type of
and output power are measured and the waveform is shown regulation. Between two different minimum input supplies,
in Figure 9a)–b). The load resistance is varied and the the generated output is 5.17 kV and 6.20 kV with the 17 %
current value is measured. At resistor value RL = 250 Ω, line regulation.
ILoad = 79.9 mA and the power output produced Pout = 1.59 W
Therefore, according to the lower value achieved, the
with an output voltage, Vout = 20 V for the initial DC-DC differences between full load and no load voltage are lesser
converter. While for the forward boost regulator integrated and better in the power supply. There are some differences
circuit, when a resistor value RL = 20 kΩ applied, ILoad = with the presenting value due to the losses occurred during
14.3 mA and Pout = 4.06 W are generated at output voltage, the development process. Due to the different values in both
Vout = 300 V. In cascaded converter obtain Pout = 0.74W experimental and theoretical aspects, voltage drop problem
value and ILoad = 2.72 mA at the resistive load value RL =
should be encountered even though the number of stages has
100 kΩ when 300 V output produces from 5 V input voltage been reduced by using the dissimilar capacitance value in
as appear in Figure 10. every stage. Besides, ripple voltage can be minimized by
Then, the output from the second controller will be the increase the frequency values and implements low equivalent
input for the voltage multiplier circuit that consists of 20 series resistance.
stages cascaded diode and capacitor. As each stage obtains Figure 15 shows the efficiency of the proposed converter
300 V DC produced by LT8331 as shown in Figure 8, the
and cascaded between then in a boost mode. The maximum
final output at the end of multiplier circuit has successfully efficiency is around 87.7% at P out = 2.57 W and the full-load
generated 6 kV DC. In the designing of a high voltage power efficiency is approximately 87.5% at Pout = 1.00 W for the
supply, the output current is low with the value 0.038 mA first integrated circuit converter on Figure 15 a). The peak
and the power generated is 0.2 W. High voltage power
efficiency for the follows converter is 96.6% which is
supply can gain variable output performances as the achieve at Pout = 9.53 W while the efficiency at full load Pout
reference voltage in PWM controller unit is varied.
= 1.5 W is 89.5% on Figure 15 b). On the other side, the
As mentioned earlier, the 6 kV DC is obtained when 20 maximum efficiency of the cascaded converter for an input
stages of voltage multiplier with collaboration of PWM voltage 5 V with 300 V output is 91.8% at P out = 1.983 W
controller circuit is used. Figure 11 configurations states how and 80.55% when Pout = 0.729W at full-load efficiency for
the final output of 6.20 kV is obtained. Error! Reference Figure 16.
source not found. presents the comparison of the The results for the proposed design achieves lower
performances of the previously reported transformer less dc-
efficiency at the lower value of input voltage due to the
5 V to 6 kV DC-DC Converter Using Switching Regulator with Cockcroft- Recent Advances in Electrical &
Walton Voltage Multiplier for High Voltage Power Supply Module Electronic Engineering, 2017, Vol. 10 No. 2 5
higher conducting loss attended by higher input current. For 2468, September 2010.
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Received: March 20, 2014 Revised: April 16, 2014 Accepted: April 20, 2014

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