The present invention is directed, in general, to power electronics and, more specifically, to controller for a power converter and method of operating the same.
A switched-mode power converter (also referred to as a “power converter” or “regulator”) is a power supply or power processing circuit that converts an input voltage waveform into a specified output voltage waveform. AC-DC power converters convert an alternating current (“ac”) input voltage into a direct current (“dc”) output voltage. Controllers associated with the power converters manage an operation thereof by controlling the conduction periods of power switches employed therein. Generally, the controllers are coupled between an input and output of the power converter in a feedback loop configuration (also referred to as a “control loop” or “closed control loop”).
To produce a dc output voltage, power converters often employ diodes to rectify an ac voltage. The rectifying devices can introduce a power loss component in a power converter due to the forward voltage drop across the diode, particularly in a power converter that produces an output voltage of five volts or less. Schottky diodes, which have a relatively low forward voltage drop, are often employed in low-voltage power converter applications to reduce a diode forward voltage drop. However, passive rectifying devices such as Schottky diodes typically cannot achieve forward voltage drops of less than about 0.35 volts (“V”), and typically cannot sustain a reverse voltage greater than about 60 volts, thereby limiting a conversion efficiency of the power converter.
To achieve an acceptable level of efficiency, power converters often employ rectifying devices that may have forward voltage drops less than about 0.1 volts. To provide such reduction of power loss, an active switch or active semiconductor switch such as a metal-oxide semiconductor field-effect transistor (“MOSFET”), which provides a resistive voltage drop, is often employed to replace a diode. An active semiconductor switch, however, must be periodically driven into conduction and non-conduction modes or states in synchronism with a periodic waveform of an ac voltage (e.g., an ac voltage produced across an input to the power converter). The active semiconductor switches may thereby avoid the higher forward voltage drops inherent in the passive rectifying devices.
A design issue introduced by substituting an active semiconductor switch for a diode is the need to provide a drive signal therefor that is accurately synchronized with the operation of the power converter to control the conduction and non-conduction modes or states of the active semiconductor switches, and that avoids conduction overlap with other semiconductor switches including diodes. An active semiconductor switch substituted for a diode in a power converter is generally referred to as a “synchronous rectifier” or “synchronous rectifier switch.”
A conventional ac-to-dc power converter employs a bridge rectifier to transform an ac sinusoidal input voltage waveform, such as an input voltage waveform produced by an ac mains, into a rectified sinusoidal waveform. Following the bridge rectifier, a power factor correction (“PFC”) circuit converts the rectified sinusoidal waveform into a dc waveform with a dc voltage level higher than the peak voltage of the sinusoidal input voltage. The bridge rectifier is usually constructed with four diodes. Due to the forward voltage drop of the diodes, significant power losses are produced by the diodes.
A bridgeless boost PFC circuit may be employed to address the power loss problem associated with the forward voltage drop of the diodes. As a result, conduction losses of the diodes are reduced. However, a bridgeless boost PFC circuit has several significant remaining problems that limit its application in low-cost, high-volume circuits. On the ac side of the circuit, a two-inductor structure introduced by the circuit causes the output voltage to float with respect to the input line voltage. As a result, the circuit produces a high level of electromagnetic interference (“EMI”) noise. The location of the boost inductor on the ac side makes it difficult to sense the ac line voltage and the inductor current and the control is a more complicated process compared with control schemes used for a simpler boost PFC circuit or boost power converter coupled to a bridge rectifier. As a result, the bridgeless boost PFC circuit has found limited application.
U.S. Pat. No. 6,060,943, entitled “Circuit Simulating a Diode” to Jansen, issued May 9, 2000 and U.S. Pat. No. 6,469,564, entitled “Circuit Simulating a Diode” to Jansen, issued Oct. 22, 2002, which are both incorporated herein by reference, are directed to a circuit that performs the function of a diode to conduct current in one direction with a low forward voltage drop, but block current in the other direction to produce an improved rectification function. When the voltage at a designated anode terminal of the circuit is higher than the voltage at a designated cathode terminal, a forward current flows. When the polarity of the voltage at these designated terminals is reversed, the current is interrupted.
Each of these approaches, however, provides an efficiency and/or a cost limitation that limits or otherwise penalizes the use of a synchronous rectifier in many applications. Accordingly, what is needed in the art is a controller employable with a synchronous rectifier in a power converter and related method that avoid the deficiencies in the prior art.
These and other problems are generally solved or circumvented, and technical advantages are generally achieved, by advantageous embodiments of the present invention, including a controller for a power converter and method of operating the same employable with a bridge rectifier having first and second synchronous rectifier switches. In one embodiment, the controller includes an amplifier configured to enable a turn-on delay for the first synchronous rectifier switch. The controller also includes a discharge switch having first and second switched terminals coupled to gate and source terminals, respectively, of the first synchronous rectifier switch and configured to discharge a gate-to-source capacitance of the first synchronous rectifier switch to enable a turn off thereof.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter, which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures or processes for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
Corresponding numerals and symbols in the different FIGUREs generally refer to corresponding parts unless otherwise indicated, and may not be redescribed in the interest of brevity after the first instance. The FIGUREs are drawn to illustrate the relevant aspects of exemplary embodiments.
The making and using of the present exemplary embodiments are discussed in detail below. It should be appreciated, however, that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed are merely illustrative of specific ways to make and use the invention, and do not limit the scope of the invention.
The present invention will be described with respect to exemplary embodiments in a specific context, namely, a controller for a switch such as a synchronous rectifier switch with a delay turn on thereof, and a method of operating the same. While the principles of the present invention will be described in the environment of a power converter, any application that may benefit from a controller such as a power amplifier or a motor controller is well within the broad scope of the present invention. Additionally, while the principles of the present invention will be described with respect to field-effect transistors including gate, source and drain terminals, the principles are equally applicable to any types of switches having control and switched terminals.
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A significant source of power loss in the power converter illustrated in
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A controller for the synchronous rectifier switch SR includes an amplifier 510 with a threshold voltage produced in accordance with a plurality of series-coupled diodes D6, D15. The controller further includes a discharge switch Q3 (e.g., a pnp transistor) with switched terminals coupled between the source and gate terminals of the synchronous rectifier switch SR and a control terminal coupled to an output of the amplifier 510. The discharge switch Q3 is formed with emitter (designated “e”), base (designated “b”), and collector (designated “c”) terminals. The synchronous rectifier switch SR is formed with source (designated “s”), gate (designated “g”), and drain (designated “d”) terminals. The emitter of the discharge switch Q3 is connected to the gate of the synchronous rectifier switch SR, and the collector of discharge switch Q3 is connected to the source of synchronous rectifier switch SR. As a result, when a body diode D30 of synchronous rectifier switch SR is back biased, voltage of a node K is higher than voltage of a node A, and an amplifier switch (e.g., a npn transistor) Q12 turns on due to current flowing into its base from a bias voltage source VCC through a resistor R16. A charge switch (e.g., transistor) Q11 is turned off and the discharge switch Q3 is turned on. Turning on the discharge switch Q3, which has its emitter and collector terminals connected to the gate and source terminals, respectively, of the synchronous rectifier switch SR, causes the gate charge of the synchronous rectifier switch SR to be quickly discharged, enabling thereby fast turn off of the synchronous rectifier switch SR. Thus, a discharge switch Q3 coupled to terminals of a synchronous rectifier switch SR is configured to enable the quick discharge of a gate-to-source capacitance thereof in response to a back biased condition of the body diode D30 of the synchronous rectifier switch SR.
When the body diode D30 of synchronous rectifier power switch SR is forward biased, and voltage of the node K becomes sufficiently lower than voltage of the node A, the amplifier switch Q12 turns off. The diodes D6, D15 provide a threshold for the voltage of the node K being lower than the voltage of the node A to turn off the amplifier switch Q12, thereby introducing a turn-on delay for the synchronous rectifier switch SR. Turning off the amplifier switch Q12 enables a resistor R14 to provide a bias current from the bias voltage source VCC to the base of the charge switch Q11 that is thereby turned on. Turning on the charge switch Q11 provides a positive bias voltage from the bias voltage source VCC through a diode D12 to the gate of synchronous rectifier switch SR, enabling it to conduct. Note that voltage of the node A should be higher than voltage of the node K plus a threshold voltage Vthreshold to induce the synchronous rectifier switch SR turn on. A turn-on delay is produced by causing voltage of the node A to be higher than voltage of the node K plus a threshold voltage Vthreshold. Thus, a charge switch Q11 coupled to terminals of a synchronous rectifier switch SR is configured to charge a gate-to-source capacitance thereof after a delay in response to a forward biased condition of the synchronous rectifier switch SR. The remaining circuit elements illustrated in
For the controller illustrated in
VA=VM−VbeQ12 (1)
VK=VM−VfD15−VfD6 (2)
VA=VK+Vthreshold (3)
Vthreshold=VfD15+VfD6−VbeQ12 (4)
As opposed to the circuits described by Jansen in U.S. Pat. No. 6,060,943 and U.S. Pat. No. 6,469,564, the controller for the synchronous rectifier switch SR introduced herein has a turn-on delay generated by the series-coupled diodes D6, D15, preferably in the range of one microsecond (“μs”) to four milliseconds (“ms”). In the circuits described by Jansen, when voltage of node A is higher than voltage of node K, a current flows from node A to node K. However, in
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Thus, a controller for a switch has been introduced herein. In one embodiment, the controller for the switch (e.g., a synchronous rectifier switch) includes an amplifier (e.g., coupled to a bias voltage source) including a plurality of series-coupled diodes configured to produce an input offset voltage therefor and a discharge switch having first and second switched terminals coupled to gate and source terminals, respectively, of the switch and a control terminal coupled to an output of the amplifier. The discharge switch is configured to discharge a gate-to-source capacitance of the switch. In related embodiments, the gate terminal of the switch is coupled to a bias voltage source through a resistor, and/or the gate terminal of the switch is coupled to a bias voltage source through a charge switch with a control terminal coupled to the output of the amplifier. The amplifier may also include an amplifier switch having a base terminal coupled to an input of the amplifier and through the plurality of series-coupled diodes to a drain terminal of the switch, an emitter terminal coupled to the source terminal of the switch, and a collector terminal coupled to the output of the amplifier. The input offset voltage produced by the plurality of series-coupled diodes is configured to cause a turn-on delay (e.g., in a range of one microsecond to four milliseconds) for the switch. When employed with multiples switches, the controller may further include a mutual lock circuit including a first lock switch and a second lock switch coupled to a gate terminal of a switch and a gate terminal of another switch, respectively, wherein a switched terminal (e.g., drain terminal) of the first lock switch is coupled to a control terminal (e.g., gate terminal) of the second lock switch.
In a related embodiment, a controller for a power converter and method of operating the same employable with a bridge rectifier having first and second synchronous rectifier switches has been introduced herein. The controller includes an amplifier including an amplifier switch and a plurality of series-coupled diodes configured to produce a threshold voltage to enable a turn-on delay for the first synchronous rectifier switch. The turn-on delay is a function of a voltage at a source terminal of the first synchronous rectifier switch being higher than a voltage at a drain terminal of the first synchronous rectifier switch by the threshold voltage. Also, the amplifier switch is configured to be turned off when a voltage at the source terminal is higher than a voltage at the drain terminal of the first synchronous rectifier switch by the threshold voltage and a body diode of the first synchronous rectifier switch is forward biased, thereby causing a charge switch to provide a positive bias voltage to the gate terminal of the first synchronous rectifier switch to enable a conductivity thereof.
The controller also includes a discharge switch having first and second switched terminals coupled to gate and source terminals, respectively, of the first synchronous rectifier switch and a control terminal coupled to an output of the amplifier. The discharge switch is configured to discharge a gate-to-source capacitance of the first synchronous rectifier switch to enable a turn off thereof. The discharge switch is configured to be turned on and discharge the gate-to-source capacitance of the first synchronous rectifier switch when a body diode of the first synchronous rectifier switch is back biased. Additionally, the amplifier is configured to enable the turn-on delay for the first synchronous rectifier switch and the discharge switch is configured to enable the turn off of the first synchronous rectifier switch to substantially eliminate cross conduction with the second synchronous rectifier switch. Also, the gate terminal of the first synchronous rectifier switch is coupled to a bias voltage source through a charge switch with a control terminal coupled to the output of the amplifier, and the gate terminal of the first synchronous rectifier switch is coupled to a bias voltage source through a resistor. In accordance with the first and second synchronous rectifier switches, a mutual lock circuit includes a first lock switch and a second lock switch coupled to a gate terminal of the first and second synchronous rectifier switches, respectively, wherein a switched terminal (e.g., drain terminal) of the first lock switch is coupled to a control terminal (e.g., gate terminal) of the second lock switch.
Those skilled in the art should understand that the previously described embodiments of a synchronous rectifier power switch and related methods of operating the same are submitted for illustrative purposes only. In addition, various power converter topologies are well within the broad scope of the present invention. While the synchronous rectifier power switch has been described in the environment of a flyback power converter, it may also be applied to other systems such as, without limitation, a power amplifier and a motor controller.
For a better understanding of power converters, see “Modern DC-to-DC Power Switch-mode Power Converter Circuits,” by Rudolph P. Severns and Gordon Bloom, Van Nostrand Reinhold Company, New York, N.Y. (1985) and “Principles of Power Electronics,” by J. G. Kassakian, M. F. Schlecht and G. C. Verghese, Addison-Wesley (1991). The aforementioned references are incorporated herein by reference in their entirety.
Also, although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. For example, many of the processes discussed above can be implemented in different methodologies and replaced by other processes, or a combination thereof.
Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods, and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
This application claims the benefit of U.S. Provisional Application No. 61/145,657, entitled “Controller for a Synchronous Rectifier Switch and Power Converter Employing the Same,” filed on Jan. 19, 2009, which application is incorporated herein by reference.
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