The present invention relates to the field of instrumentation, and more particularly to the design of parallel interleaved LLC power supplies.
A switched-mode power supply (also referred to as a switching-mode power supply, switch-mode power supply, switched power supply, or switching power supply) is an electronic power supply that incorporates a switching regulator to efficiently convert electrical power. Unlike a linear power supply, the pass transistor of a switching power supply continually switches between low-dissipation, full-on and full-off states, remaining in high dissipation transition states for only brief periods of time, thereby reducing wasted energy. Voltage regulation is typically achieved by varying the ratio of the on-state and off-state of the pass transistor(s). In contrast, a linear power supply regulates the output voltage by continually dissipating power in the pass transistor. The higher power conversion efficiency is therefore an important advantage of a switching power supply, which may also be substantially smaller and lighter than a linear power supply due to the smaller transformer size and weight.
During the development of square-wave switching power conversion (e.g. pulse width modulated—PWM—switching), concerns regarding suddenly turning OFF current passing through an inductor lead to the design of “resonant topologies”. Switching power supplies featuring one such topology are referred to as LLC power supplies. The LLC topology features a unique combination of two inductors and one capacitor (hence the name, “LLC”), and offers a relatively narrow range of switching frequencies, which make possible the design of standard EMI filters combined with the capability of producing zero-voltage switching (soft-switching) through careful design, significantly improving electromagnetic interference (EMI) and efficiency over a wide load range.
Because LLC converters are part of the resonant converter family, voltage regulation is not performed in the exact same manner as it is in conventional PWM switching power converters. Running at 50% duty-cycle and fixed 180 degree phase shift, regulation is typically obtained through frequency modulation. All primary side switches turn on resonantly—zero voltage switching—resulting in full recycling of the energy contained in the MOSFETs' parasitic output capacitance. Furthermore, all secondary side switches turn off resonantly—zero current switching—to minimize switching losses normally associated with hard switching. Resonant operation of all switching devices in the LLC converter results in minimized dynamic loss, and thus increased overall efficiency, particularly at higher operating frequencies in the hundreds of kHz to MHz range.
LLC Converters are becoming more widely accepted in offline (AC-DC) power supplies due to their high efficiency and lower component count. Adoption has been limited, however, to moderate power levels (e.g. lower than 400W). At higher power levels, traditional approaches make use of multi-phase techniques to divide component stress and reduce the size of the components. In addition, multi-phase arrangements can reduce ripple currents on output filters/capacitors, greatly extending the life of these components. This is especially important in high output-current supplies. LLC converters operate on a variable frequency control scheme to regulate line and load variation, using the slope of the gain/frequency curve to adjust the gain.
Combining the outputs of several (more than one) LLC stages naturally allows sharing the load current if the supply is operating under ZVS (zero voltage switching), the respective inductors of each stage are equal in value (e.g. in inductance) to the corresponding respective inductors of all other stages, and the respective capacitors of each stage are equal in value (e.g. in capacitance) to the corresponding respective capacitors of all other stages. Unfortunately, when the inductances and capacitances of one stage differ from the corresponding inductances and capacitances of other stages by even several percentage points, the sharing of load current can become disparate by a large amount. This difference can also be exaggerated by changes in operating frequency. Normal component manufacturing tolerances (+/−10%) are sufficient to cause unworkable differences in stage current.
Other corresponding issues related to the prior art will become apparent to one skilled in the art after comparing such prior art with the present invention as described herein.
Various embodiments of systems disclosed herein include a novel topology/circuitry for a parallel interleaved multiphase LLC current sharing power supply system. In various embodiments, a multiphase power converter may include a number of different LLC converter stages coupled in a parallel interleaved current sharing configuration. The total sum current provided by the multiphase power converter may be balanced between the different LLC converter stages by sensing a respective output current in each LLC converter stage, with the sensed output current of one of the LLC converter stages used as a reference current, and performing one or more adjustments for each LLC converter stage other than the reference LLC converter stage, based on the sensed output currents. The adjustments may include adjusting the input voltage provided to the LLC converter stage, adjusting the resonant frequency of the LLC converter stage, and/or adjusting the effective resonance impedance of the LLC converter stage. The ability to sense the phase current, or power, therefore makes it possible to achieve balance between the different LLC converter stages in a multiphase LLC-stage current sharing configuration.
Pursuant to the above, in some embodiments, a method may be devised for controlling a number of parallel interleaved switching power supplies coupled in a current sharing configuration, where each switching power supply sources a respective portion of a total current provided by the current sharing configuration. The method may include balancing the total current between the plurality of parallel interleaved switching power supplies by sensing a respective output current in each switching power supply, where a first sensed output current corresponding to a first switching power supply is used as a reference current, and for each respective switching power supply other than the first switching power supply, adjusting, based on the first sensed output current and the sensed respective output current corresponding to the respective switching power supply, the input voltage provided to the respective switching power supply, the resonant frequency of the respective switching power supply, and/or the effective resonance impedance of the respective switching power supply.
In some embodiments, a multiphase current sharing configuration may include a number of different switching power supply stages, each switching power supply stage sourcing a respective portion of a total current provided by the current sharing configuration. The current sharing configuration may further include a number of different power factor correction stages, with one of the power factor correction stages designated as a reference stage. For each respective power factor correction stage, an output voltage of the respective power factor correction stage may be provided as an input voltage to a corresponding respective switching power supply stage, and a control circuit included in the current sharing configuration may be used to balance the total current between the plurality of switching power supply stages by adjusting the output voltage of each respective power factor correction stage except the reference stage. The output voltage of each respective power factor correction stage (except the reference stage) may be adjusted based on an output current of the respective switching power supply stage corresponding to the reference stage, and an output current of the respective switching power supply stage corresponding to respective power factor correction stage.
In some embodiments, a multiphase power converter may include a first LLC converter stage that provides a first output current having a first value, and may also include a second LLC converter stage coupled in parallel to the first LLC converter stage and providing a second output current having a second value. A total sum current including the sum of the first output current and the second output current may be provided at an output of the multiphase power converter. A control circuit included in the multiphase power converter may be operated to cause the first value to match the second value within a specified tolerance (e.g., the first value may be equal to the second value, or it may not differ from the second value by more than an specified tolerance value, etc.) In order to obtain matching values, the control circuit may obtain the first value and the second value, use the first value as a reference value, and adjust, based on the reference value and the second value, at least one of an input voltage provided to the second LLC converter stage, a resonant frequency of the second LLC converter stage, or an effective resonance impedance of the second LLC converter stage.
Other aspects of the present invention will become apparent with reference to the drawings and detailed description of the drawings that follow.
A better understanding of the present invention can be obtained when the following detailed description of the preferred embodiment is considered in conjunction with the following drawings, in which:
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
Embodiments of improved power supply systems include a parallel interleaved multiphase LLC current sharing configuration providing accurate balancing of the total output current among the different power converter stages connected in the current sharing configuration.
There are various power sharing configurations presently in use. The following brief descriptions are intended to provide an overview of two different impedance matching methods used to match the respective inductances and capacitances of each individual LLC power converter to the respective inductances and capacitances of all other individual LLC power converters in a power sharing configuration. As generally used herein, “matching” and “achieving balance” are used to refer to balancing the total sum current output by a multiphase power controller among the individual converters coupled together in a current sharing configuration. Such current/power balancing may include matching the respective LLC components of an LLC power converter to the respective LLC components of other LLC power converters in a power sharing configuration to obtain stage currents (a respective portions of the total current conducted by the LLC power converters in the power sharing configuration) equal to each other, or not to differ from each other by more than a specified (e.g. allowed) percentage.
According to one method, balance can be achieved by careful trimming of the resistive, magnetic and capacitive components of each phase of the LLC (e.g. of each LLC power converter that is a part of the power sharing configuration) to precisely match. However, this represents an expensive process for production, and is feasible only for small quantities. Factors like components aging over time will also affect the balance of the components and current balance during operation.
According to another previously proposed method, balance may be achieved among the different phases (e.g. among the different individual LLC power converters that are part of a power sharing configuration) by ‘floating’ the return (ground) connection of the phases connected in a ‘star’ configuration. A two-phase (2-phase) example is illustrated in
As shown in
A three-phase (3-phase) configuration is illustrated in
One advantage of multiphase LLC in general is the significant reduction of the output noise and ripple currents as the number of phases is increased. However, significant output noise and ripple current reduction may be most effectively obtained when each phase is operated at a more flexible relative phase shift with respect to each other phase than the 360 degrees/N which is required in the prior art configurations illustrated in
An LLC converter is essentially a frequency driven power supply, with a resulting gain curve illustrated in the exemplary voltage versus frequency diagram 400 shown in
Operation of a single LLC stage is considered simple with the use of a control loop to adjust the gain by varying the frequency of the LLC oscillator, to achieve the desired gain that maintains the desired output voltage (i.e., it provides a regulated output voltage). However, as shown in
The final output voltage of each LLC stage may have slight variations resulting from the tolerances (e.g. slight differences) between respective corresponding resonant components in the different stages, e.g. tolerances between the resonant capacitors (530, 532, 534), and between the resonant inductors (520, 522, 524). In a parallel LLC structure as shown in
The difference between the two methods, which will be further described in detail below, is in the means used to achieve the final output voltage balance between the stages. One of the goals is to maintain the desired phase difference between the stages, to maximize output ripple cancellation, without changing the fundamental operating frequency between the stages. In other words, adjustments to the operation of the stages are made in a manner that ensures that the operating frequency remains the same across the different LLC stages. It should also be noted that the various embodiments of multiphase LLC current sharing control disclosed herein are not necessarily limited to just three-stage LLC multiphase configurations and may be extended from a two-stage LLC multiphase configuration to any number (N) of LLC stages. In both methods, the adjustments may be implemented dynamically via a secondary feedback loop that is slower than the main voltage (primary) feedback loop of the multiphase LLC. While the various embodiments disclosed herein require no initial calibration when performing dynamic adjustments, other embodiments may implement an initial calibration performed to eliminate component imbalances according to the methods described herein without making dynamic adjustments.
In some embodiments, respective power factor correction (PFC) stages may be used to provide input voltages to corresponding the LLC stages in a power supply topology derived from the parallel LLC power sharing configuration 500 illustrated in
The current output (or output current) of each LLC phase (LLC stage) may be measured, and one of the LLC phases may be used as a reference to obtain error information corresponding to the other LLC phases (or to the respective output currents of the other LLC phases). As shown in
According to this method, the gain curves of the respective LLC phases may still be mismatched, and the input voltage to each of the LLC phases may be adjusted such that the output voltage (DC output) is matched. A matched output voltage between the LLC phases is achieved when the respective error output corresponding to the output current of each non-reference LLC phase is zero, effectively achieving equal power (or achieving a power balance) between all the LLC phases. The PFC phases and the LLC phases need not be linked or operate at the same frequency in the power sharing configuration 600 shown in
In some embodiments, according a second method, balance between the different LLC stages (phases) may be achieved by adjusting the effective resonance impedance (e.g. one or more of the component values of the resonant tank) in each LLC stage as may be necessary to achieve balance between the different LLC stages.
The respective value(s) of any one or more of the components in resonant tank 702 may be adjusted (changed) to adjust (change) the quality factor (Q), a ratio between primary inductance and resonant inductance (M), and the gain of the LLC converter (or Vout/Vin) for a fixed operating frequency. Maintaining a common operating frequency across the multiple LLC phases may ensure output ripple cancellation as previously outlined above.
In some embodiments, the effective value of Cr 720 may be adjusted to balance the LLC phases. However, in various other embodiments, the respective values of the other LLC resonant components (e.g. Lr 722 and/or LM 724) may be adjusted to achieve the same effect, making dynamic adjustments (changes) to the LLC gain curves. The resonant capacitor values (or resonant capacitances) may be adjusted based upon the current-balance error information (which may be obtained as described above with respect to the first method), effectively adjusting the gain curves of each resonant LLC stage to balance out the tolerances, as illustrated in
In order to sense the phase currents, or the respective output currents of the LLC phases (stages), traditional resistor sense strategies may be employed. However, when using such traditional strategies, efficiency may suffer due to resistive losses. Thus, in some embodiments, an alternative current sensing strategy may be used. As shown in
It should be noted that M3 takes advantage of the positive bias on capacitor 1104 to make use of only one switching device. Various embodiments featuring a series switch arrangement are also possible and are contemplated. It is also possible to allow the LLC phases to adjust “differentially” in order to maximize the gain control effect. For example, the duty-cycle in one LLC phase may be reduced while the ratio in the other LLC phase is increased, doubling the effect or reducing the required size of capacitor 1102 by a specified factor, for example by a factor of 2. The ability to sense phase current or power makes it possible to achieve balance between the different LLC stages in a multiphase LLC stage current sharing configuration. In other embodiments (not shown), and extra inductor may be duty-cycle switched (similar to the switch-controlled capacitor circuit) in order to adjust the resonant frequency Fr (in a manner similar to how thr Cr is adjusted in
Although the embodiments above have been described in considerable detail, numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
This application claims benefit of priority of U.S. Provisional Patent Application Ser. no. 62/442,037 titled “Parallel Interleaved Multiphase LLC Current Sharing Control”, filed on Jan. 4, 2017, which is hereby incorporated by reference as though fully and completely set forth herein.
Number | Date | Country | |
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62442037 | Jan 2017 | US |