This invention relates to power supply circuits for providing relatively low voltage direct current (DC) from relatively high voltage alternating current (AC).
Many small appliances have a touchpad user interface, driven by a small low power microprocessor, featuring LED and LCD readouts, and controlling electronic functions such as motors, heaters etc. through either a Triac control or relays. Common examples include toaster ovens, coffee makers, and blenders, but there are many other such devices, both consumer and industrial.
These user interface and control circuits, which often control high power functions like a toaster grill heater element, all use very little power. They are rarely switched completely off, but instead sit in an idle state, where the microcontroller waits to detect a command from the user.
In most instances, these internal electronic control circuits are not electrically isolated from the AC mains, but rely upon physical isolation of the user interface. As configured, there is no reason for the electronics to be truly isolated, as there is no direct access, even though they run off low 3.3V or 5V supplies for example.
Similarly, another non-isolated power application is for low powered LED lighting. Nightlights use a small power supply to drive the sensor and one or more low power LEDs. Higher power emergency lighting may utilize a battery that is “trickle” charged to maintain its charge during the times AC is available, but may use the battery power to provide bright lighting when the AC is off for short periods, such as during a power outage.
These are all examples of electronic devices that consume small amounts of low voltage power, often in the region of less than 0.5 W in the case of the user interfaces, and less than around 150 mW per LED, in the case of illumination devices. Providing power from the high voltage AC to these devices has in the past used four main types of power supply—resistive droppers, capacitive droppers, linear transformer circuits, and switched mode power supplies.
The resistive dropper circuit is very simple and provides a low level of DC current. An exemplary resistive dropper circuit is shown on
The capacitive dropper circuit, e.g. as shown on
By using a linear transformer T1 as shown on
High frequency switching power supplies can be quite efficient, but are expensive to implement, are complex, and typically require considerable skill to achieve correct operation, and meet radio frequency interference requirements.
Although these methods each provide means of deriving a low voltage supply from the high voltage AC mains supply, each has significant disadvantages such as inefficiency, large footprint, costly components, and/or difficulty of implementation. Accordingly, it would be an advance in the art to provide an improved power supply approach.
The present approach provides a basically different concept for an AC to DC power supply. In this work, input AC voltage is first rectified. Either full wave or half wave rectification may be used. The rectified AC voltage is then provided to a series connected analog current blocking (ACB) element. After the series connected ACB element, a shunt capacitance can be provided as a charge reservoir (i.e., an integrating circuit) for the output DC voltage or current. The series connected ACB element has at least the following modes of operation: a low resistance (LR) mode and a high resistance (HR) mode, where the ACB element automatically transitions toward the HR mode when the current through the ACB element reaches a limit current Ilimit. It is advantageous to also incorporate a negative differential resistance (NDR) region between these two mode of operation, instead of a fast acting switch, approximating to an instantaneous transition between the LrR and HR modes. The ACB element also automatically transitions toward the LR mode when the voltage across the ACB element goes below a reset voltage Vreset. The limit current Ilimit can be altered by a control signal applied to the ACB element and is under feedback control as described below. Such control of Ilimit also leads to a corresponding variation in Vreset.
Such an ACB element can be provided by modifying a transient blocking unit (which automatically switches to a high resistance state when its predetermined current limit is reached, and which automatically resets for sufficiently low voltages) to have an electrically adjustable current limit. Transient blocking units are known in the art for providing transient and surge protection for electrical loads. This approach for providing the ACB element gives the preferred characteristics that current flow is negligible in the HR mode, and series resistance is negligible in the LR mode.
In operation, the net effect of the ACB element is to pass part of the rectified waveform to the output capacitor for integration, where the controllable Ilimit determines how much of the rectified waveform is passed through to the output capacitor, thereby determining the charging current, and hence the output voltage. Thus, the output can be set to a desired level by feedback control using an error signal to set Ilimit. An important aspect of this approach is that the parts of the rectified waveform that are selected by the ACB element are the low-voltage parts of the waveform, thereby decreasing power consumption in the AC to DC converter.
Significant advantages are provided by the present approach:
1) This approach inherently provides a current limiting capability. For example, if the output of such a power supply is shorted, the resulting flow of current will still be limited by the ACB element, and destruction of the power supply due to this fault can readily be avoided. In sharp contrast, the simpler power supply concept where a switch is operated under feedback control using the output voltage is vulnerable to destruction by an output short. In such a circuit, the short will cause the output voltage to be too low, and the feedback control will respond by opening the switch up continuously. Excessive and destructive current flow is likely to result from this.
2) In embodiments having an NDR mode between the LR mode and the HR mode, the introduction of a specified negative resistance in this transition region can advantageously reduce voltage spikes when the ACB transitions from one mode to another mode. Such voltage spikes are created by the combination of stray inductance and fast rates of change of current, due to the relationship V=L dI/dt.
A new power supply concept is provided that provides a simple and efficient solution as an alternative to the existing methods described above.
In essence, the ACB element operates as an active dropper circuit, acting like a low value resistor while the voltage across it is low, then transitioning to a high resistance state when the current through it exceeds a certain limit, which is set by the error amplifier. The error amplifier monitors the output voltage, and modulates the current limit value in response to load demand and AC line voltage. In this example, the control signal is an output of a differential amplifier (i.e., OA1) having as inputs a reference input (i.e., Vref) and the output of the integrating circuit (i.e., Vout).
In this way, ACB circuit 504 connected between the rectified AC and the load has a resistance characterized by having two or three distinct regions of operation:
1) a region of low resistance when the current through the device is below a threshold level corresponding to the current trigger threshold, (“Ilimit”), where Ilimit is controlled by a feedback signal. The resistance of the LR mode is preferably less than about 50 Ω, and is more preferably less than about 5 Ω.
2) optionally, a region of increasing resistance, whereby current initially limits at the trigger level, then reduces with increasing voltage across the device, giving rise to a current limiting and negative resistance characteristic. Preferably the NDR mode of the ACB element has an I/V slope of −1/RNEG, where RNEG is between about 0.2/Ilimitmax ohm and about 20/Ilimitmax ohm, where Ilimitmax is the maximum current limit of the apparatus.
3) a region of high resistance when the voltage is above a preset level (“Vreset”). The resistance of the HR mode is preferably greater than about 100 kΩ, and is more preferably greater than about 1 MΩ.
An exemplary I-V characteristic of the ACB element is shown on
When a simple switch is used, dI/dt becomes extremely high, and hence the voltage V induced across the switch can also be very large, and may easily exceed the voltage rating of a typical semiconductor switching device (e.g. a MOSFET), causing avalanche breakdown. The energy stored in the stray inductance, L, at the peak current I is given by E=½ LI2. This energy can easily exceed the maximum avalanche energy rating of the semiconductor switch, causing degradation of reliability, and failure. The use of a controlled negative resistance transition region allows the rate of current decrease to be controlled in such a way that the peak voltage is dramatically reduced, and safe operation of the circuit is ensured.
The NDR mode of the ACB element will have an I/V slope of −1/RNEG, where RNEG is approximately given by Vresetmax/Ilimitmax, and where Ilimitmax is the maximum current limit of the apparatus in amps, and Vresetmax is the reset voltage at Ilimitmax in volts. Note that the limit current Ilimit can be modulated, so Ilimitmax is its maximum value for a given circuit. From these considerations, it is preferred to set Vresetmax in the range of between 5V and 40V. At the lower end of the range, transition losses will be minimized but higher induced voltages may result. At the upper end of the range, lower voltages will be generated, but transition losses will be higher. A compromise value can be determined by consideration of the most important factors in the final application.
The advantage of a broader region of negative resistance is offset by additional power dissipation in operation. However, this is not usually a problem in the intended lower power applications. The exact value and width of the negative resistance region therefore becomes a design consideration depending upon the actual intended appliance application.
The current limit threshold is controlled by an error amplifier, which compares the output voltage to a set reference. The error amplifier can thereby continuously modulate the current limit in an analog closed loop regulated fashion, and precisely control the amount of power transferred to the output, thus closely controlling the output voltage. In this manner, a regulated output voltage can be provided.
A reservoir capacitor Cres acts to remove the high frequency content of the ACB output current waveform, providing a smoothed voltage at the output, as is typical for most power supplies. Any integrating circuit can be employed for this function.
The operation of the circuit is shown on
When the current reaches Ilimit, where Ilimit is controlled by the reference error amplifier, the ACB element current limits, and the resistance rapidly increases with rising input AC voltage, reducing the current to a low level, thereby creating the NDR region. The corresponding part of the ACB output current waveform is 806 on
Charge is stored by the reservoir capacitor, and gradually depleted by the load over the half rectified AC cycle. Because the resistance was low when the capacitor was charged, very little power was dissipated by the device connecting to the rectified AC. As the AC cycle continues, the rectified voltage drops back to a level below the reset voltage. The cycle reverses, and the resistance now begins to decrease, and current begins to flow again, recharging the reservoir capacitor. The corresponding part of the ACB output current waveform is 810 on
When the output voltage exceeds the desired level, the error amplifier responds by changing the control signal in such a manner as to decrease Ilimit. Similarly, if the output voltage is too low, the error amplifier responds by changing the control signal so as to increase Ilimit. By controlling Ilimit during each cycle, the average current 814 over the AC cycle provided to the capacitor can be controlled and made equal to the average current supplied to the load.
The operation of this circuit is as follows. M1 is a depletion mode N type MOSFET (NMOS) device and J1 is a P-type JPFET (PJFET). These devices are low resistance when the input rectified AC voltage 1002 is at zero. It is advantageous, though not a necessary requirement, to use depletion mode devices, as these require no bias to be initially conductive, and therefore allow the circuit to start up without any external biasing.
The linear error operational amplifier, OA1, provides an error voltage, VA, at point A given by:
V
A
=G
1*(VOUT−VREF)
where:
G1 is the error amplifier gain of amplifier OA1,
VOUT is the output voltage, and
VREF is the reference voltage.
The amplifier gain may be frequency dependent to provide the desired transient response characteristics, as is usual in analog control theory.
The linear operational amplifier, OA2 provides a voltage VC at point C, such that:
V
C
=G
2*(VA−VB)
where:
G2 is the error amplifier gain of amplifier OA2,
VA is the error voltage at the output of OA1 (point A), and
VB is the voltage developed at the source of J1 (point B).
As the rectified AC voltage 1002 rises above the output voltage, current flows in devices M1 and J1, causing a voltage drop across J1, thus increasing the voltage at B above the output voltage by I*RJ1, where RJ1 is the JFET on-state resistance. When the rectified AC voltage causes sufficient current to flow, the voltage at B will exceed the voltage at the error amplifier output, A. This will cause the amplifier OA2 to lower its output voltage, reducing the voltage at the gate of M1. This closed loop feedback action causes M1 to limit the current to a level that maintains the voltage at B equal to that of amplifier output A. It can be seen that the higher the voltage is at A, the higher will be the level of the current limiting, and conversely, a low level, will cause a low level limit. Thus the function of a current limiting action dependent upon a control signal is realized.
As the rectified AC voltage rises, the gate voltage of J1 also rises through R1. Increasing gate voltage begins to pinch off J1. OA2 continues to operate to maintain the voltage at B approximately constant. As the output voltage is approximately constant, the voltage differential across the JFET remains approximately constant. Increasing resistance of J1 with increasing rectified AC voltage therefore causes the current to drop. Decreasing current with increasing voltage creates the negative resistance region of the ACB element.
As the rectified AC voltage increases further, the gate voltage of J1 becomes sufficient to pinch off the JFET. Amplifier OA2 continues to drive the NMOS gate to try to control the voltage at B, resulting in a gate drive to M1 that also acts to turn it off. Thus the device enters the third region of high resistance.
When the AC voltage has reached its peak, and the voltage returns towards zero at the end of the cycle, the JFET gate voltage eventually drops below the level required to hold it pinched off, which is at a similar voltage to that which caused the conduction to stop during the previous cycle. This is advantageous, as it creates a current waveform that has a characteristic double triangular shape (see
J1 begins to conduct again, and current begins to flow, increasing until the limiting value of current is once again achieved. Further decrease in rectified AC voltage causes the current to then drop back to zero. The cycle then repeats, with the amplifier OA1 modulating the voltage at A in response to the level of the output voltage, thus regulating the output.
A particularly advantageous feature of this design, being of regulated current limiting, is that even under short circuit conditions, the device will only supply the maximum current that it is designed for, and thus is inherently safe under short circuit conditions, as is usually required for power supplies in general.
MOSFET devices instead of depletion mode devices. Resistors R1 and R2 supply bias to M2, a PMOS type device. Avalanche device D1, or some other type of clamp, may be required to limit the maximum voltage to prevent against damage during transient conditions. Use of a JFET (as in
Resistor R3 on
This simplified circuit works as follows. As the rectified AC voltage 1002 rises above the output voltage, current in devices M1 and J1 increases, causing a voltage drop across J1, thus increasing the voltage at B above the output voltage by I*RJ1, where RJ1 is the JFET on-state resistance. When the rectified AC voltage causes sufficient current to flow, the voltage at B will rise with respect to the steady state voltage at the error amplifier output, A. This will cause the MOSFET M1 Gate-Source voltage to drop below the level required to sustain the current level in M1, and hence will limit the current. It can be readily seen that the higher the voltage is at A, the higher will be the level of the current limiting, and conversely, a low level will cause a low level limit. Thus the function of a current limiting action dependent upon a control signal is realized.
Since the power supply circuit of the present approach is essentially a closed loop controlled current source, it is possible to use the circuit directly to control current, as a constant current source, as is usually required for such devices as LEDs.
R3 is chosen to set the current such that:
R3=1.25/Iout
where
1.25V is the reference voltage level.
Iout is the required average current level
Capacitor C1 is large enough to give a time constant of R3*C1 that is significantly longer than the rectified AC half cycle in order to provide a voltage across R3 that is proportional to the average output current. This circuit then maintains the required average current in the LEDs over a wide range of AC input voltages, number of LEDs, LED production variation and temperature of operation. Here the output of the power supply circuit is effectively a regulated current.
In summary, a simple power supply circuit is described that:
1) can efficiently provide a regulated voltage supply with intrinsic current limiting;
2) can efficiently provide a regulated constant current supply for driving devices such as LEDs;
3) is simple and easily integrated into a small footprint IC, giving a circuit that is much smaller, lower component count and lower cost than other solutions;
4) is easy to design with, requiring no special knowledge of high frequency switched mode power supplies;
5) does not cause high levels of electromagnetic interference, and thus requires neither special care in the implementation, nor large filtering components;
6) is inherently short circuit current limited; and
7) efficiently directly regulates the output to consume no more power than is needed by the load, and does not utilize wasteful shunt regulation or additional series regulation, as is used in other circuits.
This application claims the benefit of US provisional patent application 61/858,489, filed on Jul. 25, 2013, and hereby incorporated by reference in its entirety.
Number | Date | Country | |
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61858489 | Jul 2013 | US |