Patent Grant
9979285
The present disclosure generally relates to controllers for power converters.
DC/DC converters are a type of power supply which converts an input DC voltage to a different output DC voltage. Such converters typically include a transformer that is electrically coupled via a switching circuit between a voltage source and a load. Converters known as forward converters include at least one main switch connected between the voltage source and the primary winding of the transformer to provide forward power transfer to the secondary winding of the transformer when the switch is on and conducting. A metal oxide semiconductor field effect transistor (MOSFET) device is typically used for the one or more main switches.
Power converter designs are often constrained by various requirements, such as efficiency, input voltage range, output voltage, power density, and footprint area. These constraints require certain performance tradeoffs. For instance, achieving higher efficiencies may require a more narrow input voltage range. To further improve efficiencies, active-reset schemes and synchronous rectifications are often employed. These synchronous rectification schemes can either be active-control or self-driven.
Environments with high levels of ionizing radiation create special design challenges. A single charged particle can knock thousands of electrons loose, causing electronic noise and signal spikes. In the case of digital circuits, this can cause results which are inaccurate or unintelligible. This can be a particularly serious problem in the design of components for satellites, spacecraft, aircraft, power stations, etc.
A peak current mode control (PCMC) controller for a power converter, the power converter comprising one or more controllable switches that selectively electrically couples a power source to a load, may be summarized as including: a latch circuit comprising an analog comparator and a latching capacitor, the analog comparator comprising a first input node operatively coupled to the latching capacitor, a second input node operatively coupled to a latch circuit reference voltage circuit, and an output node; a peak current detector circuit comprising an analog comparator having a first input node operatively coupled to a current sensor circuit that, in operation, senses a current of the power converter, a second input node operatively coupled to an error control signal circuit, and an output node operatively coupled to the latching capacitor, in operation the peak current detector circuit compares a current sensor signal received from the current sensor circuit to an error control signal received from the error control signal circuit and, responsive to detecting that the current sensor signal exceeds the error control signal, causes the latching capacitor to discharge; a clock circuit comprising an analog comparator, in operation, the clock circuit generates a clock signal at a clock signal node and a charge signal at a charge signal node, the charge signal node being operatively coupled to the latching capacitor to selectively charge the latching capacitor; and a gate circuit comprising an analog comparator having a first input node operatively coupled to a gate circuit reference voltage circuit, a second input node operatively coupled to the clock signal node and to the output node of the analog comparator of the latch circuit via an OR-circuit, and an output node that, in operation, provides a control signal to the one or more controllable switches of the power converter.
The PCMC controller may further include a slope compensation circuit comprising an input node operatively coupled to the clock signal node, and an output node operatively coupled to the first input node of the analog comparator of the peak current detector circuit.
The PCMC controller may further include a current sensor circuit comprising a current transducer that, in operation, senses a current of the power converter.
The current transducer may include a transformer or a resistor. The OR-circuit may include a plurality of diodes. The analog comparator of the clock circuit may include first and second complementary output nodes, the clock signal may be generated at the first output node and the charge signal may be generated at the second output node. The output node of the peak current detector circuit may be operatively coupled to the latching capacitor via a diode. The charge signal node of the clock circuit may be operatively coupled to the latching capacitor via a diode and a resistor coupled together in series.
A power converter may be summarized as including: a transformer having a primary winding and a secondary winding, the primary winding electrically coupleable to an input voltage node and the secondary winding electrically coupleable to an output voltage node; a primary circuit electrically coupled to the primary winding, the primary winding comprising at least one controllable switch; and a peak current mode control (PCMC) controller, comprising: a latch circuit comprising an analog comparator and a latching capacitor, the analog comparator comprising a first input node operatively coupled to the latching capacitor, a second input node operatively coupled to a latch circuit reference voltage circuit, and an output node; a peak current detector circuit comprising an analog comparator having a first input node operatively coupled to a current sensor circuit that, in operation, senses a current of the power converter, a second input node operatively coupled to an error control signal circuit, and an output node operatively coupled to the latching capacitor, in operation the peak current detector circuit compares a current sensor signal received from the current sensor circuit to an error control signal received from the error control signal circuit and, responsive to detecting that the current sensor signal exceeds the error control signal, causes the latching capacitor to discharge; a clock circuit comprising an analog comparator, in operation, the clock circuit generates a clock signal at a clock signal node and a charge signal at a charge signal node, the charge signal node operatively coupled to the latching capacitor to selectively charge the latching capacitor; and a gate circuit comprising an analog comparator having a first input node operatively coupled to a gate circuit reference voltage circuit, a second input node operatively coupled to the clock signal and the output node of the analog comparator of the latch circuit via an OR-circuit, and an output node that, in operation, provides a control signal to the one or more controllable switches of the power converter.
The PCMC controller may further include a slope compensation circuit comprising an input node operatively coupled to the clock signal node, and an output node operatively coupled to the first input node of the analog comparator of the peak current detector circuit.
The power converter may further include a current sensor circuit comprising a current transducer that, in operation, senses a current of the power converter.
The output of the peak current detector circuit may be operatively coupled to the latching capacitor via a diode, and the charge signal of the clock circuit may be operatively coupled to the latching capacitor via a diode and a resistor coupled together in series.
A peak current mode control (PCMC) controller may be summarized as a PCMC controller for a power converter that, in operation, controls the power converter according to peak current mode control, the power converter comprising one or more controllable switches, the PCMC controller including: an analog latch circuit comprising an input and an output, the input operatively coupled to a latching capacitor; an analog peak current detector circuit comprising an output operatively coupled to the latching capacitor, in operation the analog peak current detector circuit compares a current sensor signal to an error control signal and, responsive to detecting that the current sensor signal exceeds the error control signal, causes the latching capacitor of the analog latch circuit to discharge; an analog clock circuit that, in operation, generates a clock signal and a charge signal, the charge signal operatively coupled to the latching capacitor to selectively charge the latching capacitor; and an analog gate circuit having an input operatively coupled to the clock signal and the output of the analog latch circuit via an OR-circuit, and an output that, in operation, provides a control signal to the one or more controllable switches of the power converter.
The PCMC controller may further include a slope compensation circuit comprising an input operatively coupled to the clock signal, and an output operatively coupled to the current sensor signal.
The PCMC controller may further include an analog current sensor circuit comprising a current transducer that, in operation, senses a current of the power converter.
The current transducer may include a transformer or a resistor. The OR-circuit may include a plurality of diodes. The analog clock circuit may include first and second complementary outputs, the clock signal may be generated by the first output and the charge signal may be generated by the second output. The output of the analog peak current detector circuit may be operatively coupled to the latching capacitor via a diode. The charge signal of the analog clock circuit may be operatively coupled to the latching capacitor via a diode and a resistor coupled together in series.
In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not necessarily intended to convey any information regarding the actual shape of the particular elements, and may have been solely selected for ease of recognition in the drawings.
In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed implementations. However, one skilled in the relevant art will recognize that implementations may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with computer systems, server computers, and/or communications networks have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the implementations.
Unless the context requires otherwise, throughout the specification and claims that follow, the word “comprising” is synonymous with “including,” and is inclusive or open-ended (i.e., does not exclude additional, unrecited elements or method acts).
Reference throughout this specification to “one implementation” or “an implementation” means that a particular feature, structure or characteristic described in connection with the implementation is included in at least one implementation. Thus, the appearances of the phrases “in one implementation” or “in an implementation” in various places throughout this specification are not necessarily all referring to the same implementation. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more implementations.
As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the context clearly dictates otherwise.
The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the implementations.
One or more implementations of the present disclosure provide peak current mode control (PCMC) circuitry for power converters using discrete analog components. As discussed further below with reference to the figures, in the implementations discussed herein, PCMC functionality for latching, set, reset, clocking, slope compensation, etc., is provided via use of analog components that advantageously provide improved performance, design flexibility, reliability and radiation tolerance.
A potential limitation of forward converters is that it may be necessary to reset the transformer core to prevent saturation (i.e., discharge the magnetizing current of the transformer during the off period of the main switch). This limitation results from the unipolar character of the transformer core excitation. Techniques exist for resetting the transformer of a forward converter. One such technique is to include a resistor-capacitor-diode (RCD) network in parallel with the primary winding. The RCD network clamps the voltage on the switch to the minimal peak voltage consistent with a given source voltage and switch duty cycle, thereby eliminating the need for dead time while allowing for a wide range of duty cycles. This tends to reduce the voltage stress applied to the switch. Nevertheless, this transformer resetting technique reduces the efficiency of the converter due to the dissipation of the magnetizing energy accumulated in the transformer during the on period of the switch. Instead of being recycled, this magnetizing energy is partially converted into heat by the RCD network.
Another method of transformer resetting is to use a series connection of a capacitor and an auxiliary switch connected across the transformer winding either on the primary side or on the secondary side (referred to as an “active clamp” or “active reset”). When the main switch is turned off, the auxiliary switch is turned on, and vice versa. Thus, magnetizing energy in the transformer is transferred to the clamping capacitor, and the clamping capacitor resonates with the magnetizing inductance to maintain the necessary level of reset voltage. This active clamp reset provides non-dissipative reset of the transformer and minimal voltage stress on the main switch under steady state conditions as dead time is almost zero. For this reason, the active clamp method is compatible with self-driven synchronous rectification.
In switching power supply circuits employing synchronous rectifiers, the diodes are replaced by power transistors to obtain a lower on-state voltage drop. The synchronous rectifier generally uses n-channel MOSFETs rather than diodes to avoid the turn-on voltage drop of diodes which can be significant for low output voltage power supplies. The transistors are biased to conduct when a diode would have been conducting from anode to cathode, and conversely, are gated to block current when a diode would have been blocking from cathode to anode. Although MOSFETs usually serve this purpose, bipolar transistors and other active semiconductor switches may also be suitable.
In these synchronous rectifier circuits, the gate signals can be self-driven, i.e., the gate signal can be tied to the power circuit, or controlled-driven, i.e., the gate signal is derived from some point in the circuit and goes through some active processing circuit before being fed to the MOSFET gate driver. In a power converter, the synchronous rectifier which conducts during the non-conducting period of the main power switch (or switches) may be referred to as a freewheeling or “catch” synchronous rectifier. The synchronous rectifier which conducts during the conducting period of the main power switch (switches) may be referred to as a forward synchronous rectifier.
In the example power converter 100 of
A secondary winding L2 of the transformer T1 is connected to an output lead Vour through a synchronous rectifier including MOSFET rectifying devices M3 and M4. Each rectifying device M3 and M4 includes a body diode. With the power switch M1 conducting, the input voltage VIN is applied across the primary winding L1. The secondary winding L2 is oriented in polarity to respond to the primary voltage with a current flow through an output inductor L3, through a load RLOAD connected to the output lead VOUT, and back through the MOSFET rectifier device M4 to the secondary winding L2. Continuity of the current flow in the inductor L3 when the power switch M1 is non-conducting is maintained by the current path provided by the conduction of the MOSFET rectifier device M3. An output filter capacitor C52 shunts the output of the converter 100.
Conductivity of the two rectifier devices M3 and M4 is controlled by gate drive logic 108 which may be part of or may receive signals from the PCMC controller 102. As shown in
The isolated secondary control or feedback circuit 106 includes a current sensor circuit 112 that is operative to sense the load current IoutLOAD of the power converter 100. The secondary control circuit 106 also includes a voltage sensor circuit 114 that is operative to sense the output voltage VOUT of the power converter 100. The current sensor circuit 112 and the voltage sensor circuit 114 may be coupled to a feedback isolator circuit 116 via error amplifiers 118 and 120, respectively. The feedback isolator circuit 116 provides an error control signal V_FB to the PCMC controller 102, as discussed further below. The current sensor circuit 112 and the voltage sensor circuit 114 may be any suitable circuits operative to sense current and voltage, respectively, and may include one or more transformers, one or more resistors, etc. The feedback isolator circuit 116 may be a circuit that is operatively to galvanically isolate the secondary control circuit 106 from the power train circuit 104 and the PCMC controller 102. For example, the feedback isolator circuit 116 may include a transformer or an optical isolator.
Referring to
Generally, in operation of the PCMC controller 102, a current (e.g., primary side current, secondary side current) of the power train circuit 104 is sensed and compared to a control input, which is a filtered version designated VFB_FILTERED of the feedback signal V_FB from the secondary control circuit 106. The value of the VFB_FILTERED signal sets the peak value of the sensed current when the power converter 100 is operating. Each switching cycle when the sensed current of the power train circuit 104 reaches the value of the VFB_FILTERED signal, the PCMC controller 102 turns off the main switch M1. This functionality is in contrast to duty cycle control where the duty cycle is set by a pulse width modulator, which in turn receives a control signal from a feedback circuit. In the PCMC controller 102, the switch M1 is turned off and the duty cycle of the switch is determined based on sensing a current in the power train circuit 104 itself.
At the beginning of each switching cycle, the clock circuit 122 of the PCMC controller 102 sets the latch circuit 128, which causes the main switch M1 to be turned on via the MAIN_GATE control signal output to the driver circuit 110 of the power train circuit 104. The sensed current in the power train circuit 104 then begins to ramp up. At a time when the sensed current reaches the command with the control input (e.g., VFB_FILTERED signal), the peak current detector circuit 126 outputs a reset signal. That reset signal resets the latch circuit 128, which causes the main switch M1 to be turned off. Thus, the MAIN_GATE control signal is high at the beginning of each switching cycle, then stays high and keep the switch M1 turned on until the sensed current reaches the control value VFB_FILTERED. Then, the MAIN_GATE control signal goes low and turns the switch M1 off, and the cycle repeats.
The clock circuit 122 includes an analog comparator U12, resistors R2, R3, R4, R5, R6, R7, and R13, capacitors C1 and C2, and diodes D2 and D6. As an overview, the clock circuit 122 sets the operating frequency and timing reference for the PCMC controller 102. The clock circuit 122 also sets the maximum allowable duty cycle for the PCMC controller 102. As noted above, the clock circuit 122 also provides the “set” command signal, and provides a signal used by the slope compensation circuit 132 to prevent subharmonic oscillation.
The current sensor circuit 124 includes a current transducer B1 (e.g., current transformer, resistor), resistors R1 and R14, capacitor C4, and zener diode D17. In operation, the current transducer B1 of the current sensor circuit 124 senses the peak primary switch current or peak current of the output inductor L3, for example. The current transducer B1 may be any type of current transducer, such as a current transformer or a resistor. The current transducer B1 may be part of the current sensor circuit 112, or may be separate therefrom.
The peak current detector circuit 126 includes an analog comparator U4, resistors R18 and R22, capacitor C9, zener diodes D4 and D8, and diode D5. Generally, the comparator U4 compares the peak current sensed by the current sensor circuit 124, translated to a voltage, to the filtered feedback voltage VFB_FILTERED from the secondary control circuit 106. When the sensed peak current crosses the level of the VFB_FILTERED signal, the comparator U4 generates a “reset” command by discharging a latching capacitor C3 of the latch circuit 128 which turns off the power switch M1 of the power train circuit 104 until the next switching cycle begins.
The latch circuit 128 comprises an analog comparator U8, the latching capacitor C3, and resistors R10 and R11. The latch circuit 128 keeps the switch M1 turned off for the remainder of a cycle after the reset signal is provided by the comparator U4.
The gate circuit 130 includes an analog comparator U13, resistors R8, R9, and R12, and an OR-circuit (or “ORing circuit”) formed by diodes D3 and D7. The comparator U13 receives inputs from both the latch circuit 128 and the clock circuit 122. The gate circuit 130 together with the clock circuit 122 guarantees that the MAIN_GATE control signal provided to the driver circuit 110 of the power train circuit 104 does not stay high for longer than the duty cycle of the clock circuit 122, thus setting the maximum duty cycle of the PCMC controller 102.
The slope compensation circuit 132 includes the diode D1, resistors R15, R16, and R17, capacitor C5, and a transistor Q6. A more detailed discussion of the operation of the circuits 122, 124, 126, 128, 130 and 132 is provided below.
In operation, the clock circuit 122 utilizes the comparator U12 to generate a clock signal at a CLOCK node and a charge signal at a LATCHCAP_CHARGE node. The clock sets the operating frequency of the PCMC controller 102 and establishes the maximum duty cycle of the power train circuit 104. The comparator U12 includes a non-inverting input terminal or node, an inverting input terminal, a non-inverting output terminal, and an inverting output terminal that is complementary to the non-inverting output terminal. The non-inverting output terminal is coupled to the CLOCK node and the inverting output terminal is coupled to the LATCHCAP_CHARGE node. The non-inverting input terminal of the comparator U12 is coupled to a voltage divider comprising the resistors R2, R3, and R5. The feedback resistor R4 is coupled between the non-inverting input terminal and the non-inverting output terminal of the comparator U12. A SYNC_IN signal is coupled between the resistors R3 and R5 to allow the PCMC controller 102 to be synchronized to a frequency of other components of a system. In at least some implementations, the PCMC controller 102 may be operative to be synchronized upward and downward to a range of frequencies (e.g., 450-550 kHz) via the SYNC_IN signal.
The inverting input terminal of the comparator U12 is coupled to the capacitor C1, and is also coupled to the non-inverting output terminal via the resistors R6 and R7 and the diode D2. When the non-inverting output terminal of the comparator U12 is high, the capacitor C1 charges via the resistors R7 and R6. When the voltage on the capacitor C1 reaches the voltage of the non-inverting input terminal, then the output of the comparator U12 switches to low. When the output of the comparator U12 transitions from high to low, the voltage at the non-inverting input terminal transitions from approximately 2/3 of VCCP to approximately 1/3 of VCCP. Further, when the output of the comparator U12 switches from high to low, the capacitor C1 is discharged through the resistors R6 and R7 and the diode D2. The ratio of the values of the resistors R6 and R7 sets the duty cycle of the clock circuit 122, and the charge/discharge time of the capacitor C1 sets the period of the clock circuit. Thus, by appropriate selection of the various components, the clock circuit 122 may be designed to have a desired frequency and duty cycle for a particular application.
The LATCHCAP_CHARGE node is operatively coupled to a LATCHCAP node of the latching capacitor C3 via the diode D6 and the resistor R13 to provide the “set” command by selectively charging the latching capacitor.
The CLOCK node is also coupled to the slope compensation circuit 132 via the diode D1. The slope compensation circuit 132 generates a ramp signal that is added to an output of the current sensor circuit 124 via the resistor R16 to generate a peak current slope compensation signal IPK_SLOPECOMP that is fed into the inverting input terminal of the comparator U4 of the peak current detector circuit 126. The slope compensation circuit 132 prevents subharmonic oscillation when the PCMC controller 102 is operating at more than 50% duty cycle, for example.
The current transducer B1 is operative to generate a current sensor signal that is proportional to a current in the primary side or secondary side of power train circuit 104. For example, the current transducer B1 may generate a signal that is proportional to the current through the inductor L3, designated IO(PEAK) in
As noted above, the slope compensated output of the current transducer B1, i.e., IPK_SLOPECOMP, is fed into the inverting input terminal of the comparator U4, also referred to herein as the pulse width modulation (PWM) comparator U4. The comparator U4 also receives the feedback signal V_FB from the secondary control circuit 106, which is fed into the zener diode D4 and divided by the resistors R22 and R18. The Zener diode D8 limits the feedback voltage (or feedback current) to a determined value.
When the output of the comparator U4 goes low as a result of the signal at the IPK_SLOPECOMP node being greater than the VFB_FILTERED signal, the latching capacitor C3 is discharged via the diode D5. At the beginning of each switching cycle, the output LATCHCAP_CHARGE node from the comparator U12 charges the capacitor C3 via the diode D6 and the resistor R13. The value of the resistor R13 controls how fast the latching capacitor C3 is charged each cycle. The value of the resistor R13 may be selected so that the latching capacitor C3 is not charged too quickly, which could cause an undesirable amount of electromagnetic interference (EMI).
The non-inverting input terminal of the comparator U8 of the latch circuit 128 is coupled to the latching capacitor C3 at a LATCHCAP node. The inverting input terminal of the comparator U8 is coupled to a latch circuit reference voltage circuit provided by the resistors R10 and R11. The comparator U8 buffers the logic output at the LATCHCAP node.
The non-inverting input terminal of the comparator U13 of the gate circuit 130 is coupled to the output of the comparator U8 and the CLOCK node via an ORing circuit formed from the diodes D3 and D7. The inverting input terminal of the comparator U13 is coupled to a gate circuit reference voltage circuit formed by the resistors R8 and R9. The non-inverting output terminal of the comparator U13 comprises the MAIN_GATE node that, in operation, provides a control signal to the driver circuit 110 of the power train circuit 104, which driver circuit is operative to control the operation of the switches M1 and M2 of the power converter 100. By utilizing the clock signal CLOCK, the gate circuit 130 guarantees that the MAIN_GATE control signal does not to stay high for longer than the duty cycle of the clock circuit 122. That is, the clock circuit 122 and gate circuit 130 set the maximum allowable duty cycle for the PCMC controller 102.
As can be seen from the graphs 402-414, the CLOCK signal provides the operating frequency and all timing references for the PCMC controller 102. The MAIN_GATE control signal causes the power switch M1 to turn on only during the rising edge of the CLOCK signal and causes the switch M1 to turn off when the peak current (IPK_SLOPECOMP) crosses the error control signal (VFB_FILTERED), thus providing peak current mode control for the power converter 100.
Advantageously, the implementations of the present disclosure provide high-performance, high-efficiency, and radiation tolerant controllers for power converters using readily available analog discrete components. The normally digital logic functions for latching, set, reset, and clocking are performed through a use of a minimal number of analog components, which provides PCMC controllers that are significantly more tolerant to radiation effects.
The foregoing detailed description has set forth various implementations of the devices and/or processes via the use of block diagrams, schematics, and examples. Insofar as such block diagrams, schematics, and examples contain one or more functions and/or operations, it will be understood by those skilled in the art that each function and/or operation within such block diagrams, flowcharts, or examples can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. In one implementation, the present subject matter may be implemented via Application Specific Integrated Circuits (ASICs). However, those skilled in the art will recognize that the implementations disclosed herein, in whole or in part, can be equivalently implemented in standard integrated circuits, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more controllers (e.g., microcontrollers) as one or more programs running on one or more processors (e.g., microprocessors), as firmware, or as virtually any combination thereof, and that designing the circuitry and/or writing the code for the software and or firmware would be well within the skill of one of ordinary skill in the art in light of this disclosure.
Those of skill in the art will recognize that many of the methods or algorithms set out herein may employ additional acts, may omit some acts, and/or may execute acts in a different order than specified.
In addition, those skilled in the art will appreciate that the mechanisms taught herein are capable of being distributed as a program product in a variety of forms, and that an illustrative implementation applies equally regardless of the particular type of signal bearing media used to actually carry out the distribution. Examples of signal bearing media include, but are not limited to, the following: recordable type media such as floppy disks, hard disk drives, CD ROMs, digital tape, and computer memory.
The various implementations described above can be combined to provide further implementations. These and other changes can be made to the implementations in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific implementations disclosed in the specification and the claims, but should be construed to include all possible implementations along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
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