Tips for designing circuits with LLC resonant controllers

To be the best, people are willing to put in efforts that others can't even imagine. For example, athletes train relentlessly just to gain a fraction of a second over their competitors. Students spend years studying and mastering complex subjects to achieve top academic honors. Companies invest decades into research and development, aiming to solve problems once thought only possible in science fiction. And at the core of it all—technical control—power engineers dedicate themselves to creating high-performance, high-density power converters.

I’m sure many of you have already pushed your personal limits when working on your circuits, achieving impressive results in power density and efficiency. After returning home, you might excitedly share this experience with your family, but they might just look at you like you’ve lost your mind.

Don’t worry—you won’t get that reaction here. Personally, I love exploring new technologies and pushing them further than before. That’s why I’m excited to introduce the UCC256301, a new controller from Texas Instruments that has been generating a lot of interest due to its exceptional performance.

The UCC256301 is the latest in TI's family of LLC controllers, as shown in Figure 1. It features integrated high-voltage start-up, x-cap discharge, robust fault protection, and a brand-new control method that offers unmatched reliability and performance.

During competitive analysis, the UCC256301 outperforms similar devices in terms of stability margin, ease of design, strong protection mechanisms, light-load efficiency, and transient response suppression.

Let me give you a real-world example. I modified a commercial gaming system using the UCC256301. Figure 2 shows the load transient response before and after the modification.

The original board performed well, but the UCC256301 took it to another level. The load transient response became almost negligible. For manufacturers, this could mean a 20% reduction in output capacitance, along with savings in other components. As shown in Figure 3, the block diagram highlights how this device simplifies the system-level design.

In the same gaming system, I achieved an additional improvement in burst mode output ripple voltage—10 times smaller—and a 10% increase in light-load efficiency. In another system, even with a high-voltage PFC input, I measured less than 40mW of no-load power while fully regulating the output. In my opinion, this demonstrates what an advanced device can do. I tried to explain it to my wife and kids, but they just gave me that stunned look again.

There’s a lot more to discuss about this device, but its key innovation lies in a new control architecture called Hybrid Hysteresis Control (HHC). This method combines the strengths of direct frequency control and charge control LLC, delivering superior performance compared to traditional solutions. In fact, this control technique not only improves efficiency but also enhances overall system reliability and stability.

Power Cord

A power cord, line cord, or mains cable is an electrical cable that temporarily connects an appliance to the mains electricity supply via a wall socket or extension cord. The terms are generally used for cables using a power plug to connect to a single-phase alternating current power source at the local line voltage-(generally 100 to 240 volts, depending on the location). The terms power cable, mains lead, flex or kettle lead are also used. A lamp cord (also known as a zip cord) is a light-weight, ungrounded, single-insulated two-wire cord used for small loads such as a table or floor lamp.

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