Overcurrent Protection in Power Supply Design
Jay Kim, CMO at Silicon Mitus
August 7, 2024
Introduction
Overcurrent protection is a critical safety feature in power supplies. It safeguards the
power supply, connected load, and users from potential damage due to excessive
current flow. This article delves into the importance of overcurrent protection, common
circuit topologies, and design considerations.
Understanding Overcurrent Protection
Overcurrent conditions can arise from a variety of factors, including short circuits,
overload conditions, and component failures.
If left unchecked, overcurrent can lead to overheating, component damage, and even
fire hazards.
Overcurrent Protection Circuit Topologies
Several circuit topologies are employed for overcurrent protection:
1. Current Limiting
• Principle: The output current is monitored, and when it exceeds a predetermined
threshold, the power supply reduces its output voltage to limit the current.
• Types:
o Constant current limiting: Maintains a constant output current.
o Foldback current limiting: Reduces the output current to a lower level after
the overcurrent threshold is reached.
o Hiccup mode: Cycles the power supply on and off to limit average current.
• Advantages: Protects both the power supply and load.
• Disadvantages: Can cause voltage droop during overcurrent conditions.
2. Overcurrent Shutdown
• Principle: The power supply is completely shut down when the output current
exceeds a predetermined threshold.
• Advantages: Simple to implement, effective for preventing catastrophic failures.
• Disadvantages: Slow response time compared to current limiting, requires
manual reset.
3. Fuse or Circuit Breaker
• Principle: A fuse or circuit breaker opens the circuit when the current exceeds its
rated value.
• Advantages: Simple and inexpensive, provides complete protection.
• Disadvantages: Requires replacement after a fault, can introduce additional
resistance in the circuit.
Design Considerations
• Trip current: Determine the appropriate overcurrent trip point based on load
requirements and safety margins.
• Response time: The protection circuit should respond quickly to prevent
damage.
• Power dissipation: Consider the power dissipation in the protection
components, especially for high-power supplies.
• Hysteresis: Incorporate hysteresis to prevent false triggering due to current
fluctuations.
• Reset mechanism: Implement a clear or reset function to restore normal
operation after the overcurrent condition is removed.
• Component selection: Choose components with appropriate current and
voltage ratings for reliable operation.
Additional Protection Measures
• Input surge protection: Use transient voltage suppressors (TVS diodes) or
metal oxide varistors (MOVs) to protect against current surges.
• Output filtering: Employ capacitors and inductors to filter out current ripple and
transients.
• Thermal protection: Include thermal shutdown circuitry to protect against
overheating.
Conclusion
Overcurrent protection is a crucial aspect of power supply design. By carefully selecting
the appropriate circuit topology and considering the design parameters, engineers can
ensure the safety and reliability of their power supplies.
