The subject disclosure relates generally to electronic circuitry, and, in particular, to systems, methodologies, and devices that can provide a self-driven AC-DC synchronous rectifier that can be used, for example, in power applications.
Synchronous rectifiers, based on the use of power metal-oxide-semiconductor field-effect transistors (MOSFETs) to replace diodes for reducing conduction losses, have been used in low-voltage and high-current applications. Synchronous rectifier techniques are primarily applied to various versions of DC-DC converters such as buck converters, flyback converters, boost-buck converters, half-bridge converters, and LCC resonant converters. To reduce the cost of the gate drive circuits, self-driven techniques have been an active research topic in synchronous rectifiers, although a gate control integrated circuit for driving synchronous rectifiers is also commercially available. Other research aspects include the use of soft-switching techniques. Besides DC-DC converters, synchronous rectification techniques have been applied to three-phase full-bridge AC-DC converter based on a three-phase fully-controlled bridge and even to a five-level converter. While the self-driven technique uses the changing voltage polarity of the coupled windings to control the switching of the power MOSFETs, other techniques tend to use control integrated circuits to provide the gating signals. Another conventional approach replaces a general-purpose diode bridge with synchronous rectifier for low power and low voltage (e.g., 3V to 5V) applications in which the synchronous rectification technique is applied to a centre-tap rectifier topology. However, in such approach, a customized charge pump circuit is needed in order to provide a suitable DC power supply for the gate drive. Also, as this approach aims at low-voltage applications, it is not suitable for mains voltage operations.
A three-phase synchronous rectifier that can operate at mains frequency also has been developed and reported in U.S. Pat. No. 6,765,425. It is based on the detection of the phase-phase voltage, output voltage and timing circuits. Sophisticated logic and timing circuits are needed to provide the gating signals if the AC source has significant source inductance. However, the gating signals for synchronous rectifiers based on phase-phase and output voltages detection is not adequate because the diodes of a traditional bridge rectifier only turn off naturally after their current reverse-recovery processes. In U.S. Pat. No. 6,765,425, the three-phase synchronous rectifier circuit replaces the six diodes with power MOSFETs and uses “voltage-controlled gate drive circuits” and the appropriate logic circuits to control the switching of the six MOSFETs. Voltage control here refers to the detection of the output voltage and the AC input voltage or voltages which could be phase voltages or line voltages. To cope with different types of load, that synchronous rectifier circuit can be initially inactivated in order to allow the body-diodes of the 6 MOSFETs to conduct like a normal 3-phase diode rectifier. Using timing circuits, the conduction periods of the MOSFETs' bode diodes are then registered. Such conduction time information is then used to control the conduction time of the MOSFETS. However, this approach has at least three major limitations. First, with the use of voltage detection only, the logic circuits have to be tailor-made to cater for a particular application. Second, since a diode will turn off only when its current is reversed and has gone through the reverse-recovery process using voltage detection cannot guarantee equivalent diode bridge rectification functions under all types of loads and circumstances. Third, a DC power supply derived from the AC voltage supply is desired to power the control electronics. While a DC power supply for the control circuitry can be derived from the input AC voltage source with the aid of isolation transformers, transformers cannot be easily integrated into the same package with the MOSFETs in a compact way, and as a result, the control circuitry with the transformers will take up significant space and cannot be built in the same package with the MOSFETs, and as further result, will not be able to form a replacement block for a diode rectifier.
It is desirable to be able to provide a self-driven AC-DC synchronous rectification technique that can be used to develop an AC-DC synchronous rectifier that can behave like a diode bridge and be used in high-voltage power applications, but with significantly reduced conduction losses and without requiring control integrated circuits. It is also desirable to be able to use such an AC-DC synchronous rectifier in single-phase and multi-phase systems.
The following presents a simplified summary of the innovations in order to provide a basic understanding of some aspects described herein. This summary is not an extensive overview of the disclosed subject matter. It is intended to neither identify key or critical elements of the disclosed subject matter nor delineate the scope of the subject innovations. Its sole purpose is to present some concepts of the disclosed subject matter in a simplified form as a prelude to the more detailed description that is presented later.
The disclosed subject matter relates to systems, methods, and devices that can produce or comprise a single-phase and multi-phase (e.g., three-phase) AC-DC synchronous rectifier, which includes self-driven control circuitry, for use in high-voltage power applications are presented. In an aspect, the synchronous rectifier circuitry can behave like, function as, or emulate a diode bridge (e.g., a bridge rectifier), and also can provide benefits over conventional rectifiers, wherein, for example, one benefit can be a significantly smaller conduction loss as compared to a conventional diode bridge.
In an embodiment, a single-phase system can include a single-phase synchronous rectifier that can comprise a first pair of switches of a first conducting path and a second pair of switches of a second conducting path. In an aspect, to facilitate emulating the turn-on and turn-off conditions of a diode, a first type of switch (e.g., a power switch, which can be a voltage-controlled self-driven (VCSD) switch) can be associated with a high-side portion of a self-driven gate-drive (SDGD) subsystem, and can be turned on (e.g., placed in or transitioned to an on state) when the voltage across such switch is forward-biased; and there can be another type of switch (e.g., a power switch, which can be a current-controlled self-driven (CCSD) switch) that can be associated with a low-side portion of the SDGD subsystem and can be turned off (e.g., placed out or transitioned to an off state) when the switch current is reversed (e.g., similar to diode current reverse recovery). Thus, to facilitate emulating the turn-on and turn-off conditions of diodes in a bridge rectifier, there can be at least one current-controlled switch in each current path of the circuitry associated with the synchronous rectifier (e.g., the equivalent diode-bridge circuit). In an embodiment, one or more of the switches can be metal-oxide-semiconductor field-effect transistors (MOSFETs) (e.g., power MOSFETs), which each can have inherent body diodes.
In another aspect, the single-phase system can comprise an SDGD subsystem, comprising self-driven gate-drive circuitry, that can be associated with (e.g., electrically connected to) the first pair and second pair of switches to facilitate controlling respective switching of the switches. In an aspect, the SDGD subsystem can be low power (e.g., can employ components using low power), wherein the power supplied to the SDGD subsystem can be provided by the AC voltage source or preferably at least a portion of the rectified output signal from the synchronous rectifier. In an embodiment, the SDGD subsystem, or a desired portion thereof, can be formed as an integrated circuit. In an aspect, the SDGD subsystem can comprise a high-side portion and a low-side portion that can be symmetrical. With the arrangement of SDGD subsystem and the switches (e.g., power MOSFETs), the synchronous rectifier can thereby be a self-driven synchronous rectifier. In another aspect, the switches can form and/or emulate a diode bridge. In an aspect, even if the SDGD subsystem is not ready for full or steady-state operation, for example, immediately at the start-up of the synchronous rectifier (or at another period of time when the SDGD subsystem is not operating at steady-state operation), the synchronous rectifier can still function the same as or substantially similar to a diode bridge (e.g., bridge-rectifier type functionality is inherent in the synchronous rectifier) because the body diodes of the MOSFETs are arranged in the circuit to form a traditional diode rectifier circuit. Before the output DC voltage of the rectifier is ready to power the control circuitry for switching the MOSFETs, these body diodes can facilitate enabling the MOSFETs to act as a normal diode rectifier during the start-up process. In still another aspect, the system can include a zero-cross controller component(s) that can facilitate providing a desired positive voltage signal to a comparator(s) associated with a switch(es) (e.g., low-side switch) to facilitate ensuring that the associated switch(es) is in an off state at or near zero-crossing points during half-cycles of the signal. In yet another aspect, the synchronous rectifier can be employed in high-voltage power applications (e.g., 110 V or 220 V mains) and/or high frequency applications.
In an embodiment, a multi-phase system can comprise a multi-phase (e.g., three-phase) synchronous rectifier that can be employed to receive and synchronously rectify a multi-phase signal (e.g., multi-phase AC power signal) and produce a desired signal (e.g., rectified DC power signal) as an output. The multi-phase synchronous rectifier can comprise, for example, six (or more) switches (e.g., MOSFET switches), which can be power switches that can facilitate synchronously rectifying the multi-phase power signal. In an embodiment, the six (or more) switches can be situated in relation to each other to form and/or emulate a diode bridge.
In an aspect, the multi-phase system can comprise an SDGD subsystem that can be associated with the power switches, and can be designed such that the SDGD subsystem consumes a relatively low amount of power, and can receive a portion of the AC voltage source or preferably at least a portion of the rectified signal generated by the multi-phase synchronous rectifier to facilitate powering the SDGD subsystem. In an embodiment, the SDGD subsystem, or at least a desired portion, can be formed as an integrated circuit. In an aspect, the SDGD subsystem can be employed to facilitate controlling respective switching of the power switches. In another aspect, the SDGD subsystem and associated power switches can be divided into two parts, which can include a high-side portion that includes three (or more) of the switches (e.g., VCSD power switches) and a high-side portion of the SDGD subsystem, and a low-side portion that includes the other three (or more) switches (e.g., CCSD power switches) and a low-side portion of the SDGD subsystem, wherein the high-side portion and low-side portion of the system can be symmetrical.
In an aspect, as disclosed herein, the six (or more) switches can be situated in relation to each other to form and/or emulate a diode bridge, which can facilitate functioning to rectify an input signal to produce a rectified signal, even when the SDGD subsystem is not operating at steady state (e.g., during start up of the SDGD subsystem), as more fully disclosed herein. As a result, if the SDGD subsystem is not ready for operation immediately at the start-up of the synchronous rectifier (or at another time) (e.g., is not powered up to operate at steady state), the synchronous rectifier can still function to rectify an input power signal and produce a desired rectified signal as an output (e.g., diode-bridge type functionality is inherent in the synchronous rectifier). For example, the SDGD subsystem can operate to control the switches on the top-side portion and the switches on the low-side portion so that these switches will not change state (e.g., switch to an on state) until the SDGD subsystem has been set up, for example, during initial gate-drive start up, to operate at steady state. In still another aspect, the system can include a zero-cross controller component(s) that can facilitate providing a desired positive voltage signal to a comparator(s) associated with a switch(es) (e.g., low-side switch) to facilitate ensuring that the associated switch(es) is in an off state at or near zero-crossing points during half-cycles of the signal. In yet another aspect, the multi-phase synchronous rectifier can be employed in high-voltage power applications (e.g., 110 V or 220 V mains) and/or high frequency applications.
The following description and the annexed drawings set forth in detail certain illustrative aspects of the disclosed subject matter. These aspects are indicative, however, of but a few of the various ways in which the principles of the innovation may be employed and the disclosed subject matter is intended to include all such aspects and their equivalents. Other advantages and distinctive features of the disclosed subject matter will become apparent from the following detailed description of the innovation when considered in conjunction with the drawings.
The disclosed subject matter is described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments of the subject disclosure. It may be evident, however, that the disclosed subject matter may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the various embodiments herein.
Diode bridges, sometimes also referred to as bridge rectifiers, can be used to rectify a received AC signal and produce a DC signal as output. One significant drawback with diode bridges is a relatively high amount of conductive loss realized in processing the received signal. For example, the typical voltage drop Vd of a power diode is 1.0 volt (V). For a diode current Id of 10 amps (A), the conduction loss is 10 watts (W), in accordance with the equation Pd=Vd×Id.
Conventionally, to facilitate reducing conduction losses associated with bridge rectifiers, synchronous rectifiers, based on the use of power metal-oxide-semiconductor field-effect transistors (MOSFETs) to replace the diodes (e.g., the diode bridge), have been predominately used in low-voltage and high-current applications. Some power MOSFETs can have an on-state resistance, Ron, as low as 40 mΩ. For a current of 10 A, the conduction loss is I2Ron=4 W. This is a 6 W reduction from the power loss (e.g., 6 W power savings) when compared to a power diode. However, the conventional synchronous rectifiers suffer from a number of significant drawbacks, including, for example, requiring a customized charge pump circuit in order to provide a suitable DC power supply for a gate drive, only being suitable for low-voltage and high-frequency (>100 kHz) applications, but not mains voltage and mains frequency operations, requiring logic circuits that have to be tailor-made to cater for a particular application. For the synchronous rectifier proposed in U.S. Pat. No. 6,765,425 for mains voltage and main frequency operation, complicated timing circuits are needed to check the switching times for the MOSFETs in order to differentiate different types of loads. It is desirable to be able to provide a self-driven AC-DC synchronous rectification technique that can be used to develop an AC-DC synchronous rectifier that can behave like a diode bridge and be used in high-voltage power applications, but with significantly reduced conduction losses and without requiring control integrated circuits. It is also desirable to be able to use such an AC-DC synchronous rectifier in single-phase and multi-phase systems.
To that end, systems, methods, and devices that can produce, employ, or comprise a single-phase and multi-phase (e.g., three-phase) AC-DC synchronous rectifier, which includes self-driven control component (e.g., comprising self-driven control circuitry), for use in high-voltage power applications are presented. In an aspect, the synchronous rectifier circuitry can behave like or emulate a diode bridge (e.g., a bridge rectifier), while also being able to provide the benefit of a significantly smaller conduction loss as compared to a diode bridge. In accordance with the disclosed subject matter, the diodes in any single-phase or multiple rectifier circuit can be replaced with switches that each can include an anti-parallel diode and can have low on-state resistance. One example switch that can be employed is a MOSFET which has an inherent body diode in its structure. If each current loop of the rectifier circuit has at least one current-controlled gate drive, the combined actions of the MOSFET and its body diode can offer the diode functions (e.g., diode rectification functions) at low conduction loss. This can allow the low on-state resistance of the MOSFET to carry the current most of the time in a conducting period except for two small time regions at the beginning and the end of the conducting period in which the body diode of the MOSFET will conduct instead. Using the 10 A application as an example, when the current is high (e.g., 0.5 A to 10 A in a 10 A application), the I2Ron conduction loss for the MOSFET is reduced. If the MOSFET is controlled to conduct the current in the range of 0.5 A to 10 A, the conduction is reduced when compared with that of a power diode. When the current in the MOSFET drops to less than a certain predefined value (e.g., 0.5 A), the MOSFET is turned off and its body diode will take over (e.g., carry) the current at the expense of a relatively low conduction loss because the current is small, wherein conduction loss is determined as Yd×Id. If the body diode current is reversed, this body diode will be turned off similar to a normal power diode after the current reverse-recovery process is completed. In this way, the combined actions of the MOSFET and its body diode can emulate the diode behavior with a low-loss conduction mechanism and a diode natural turn-off mechanism, respectively. Since this current-controlled MOSFET can behave like a power diode, there is no need to include additional timing or control circuit to determine the type or nature of the loads, as required in conventional rectifiers.
Since the MOSFET with its inherent body diode can behave just like a diode under the disclosed switching control, there is no need to use sophisticated control and monitoring circuits which is either (i) used to determine the nature of the load or (ii) dependent on the nature of the load (as in conventional rectifiers). In other words, the disclosed subject matter can enable the disclosed synchronous rectifier to replace the diode rectifier without the need to know the nature of the load. In addition, the control electronics can be powered by a portion of the AC voltage source or preferably a portion of the rectified DC voltage of the power rectifier circuit without the need for another specially designed auxiliary switched mode power supply or transformers.
In an embodiment, the system 100 can include a first pair of switches, switch 102 (M1 in
In another aspect, the system 100 can comprise a self-driven gate-drive (SDGD) subsystem, which can comprise SDGD components 112 (also referred to as GR1 in
In an aspect, the SDGD subsystem can operate under low power (e.g., can employ components using low power), in contrast to the switches 102 through 108, which can be power devices. In an embodiment, the SDGD subsystem, or at least a desired portion thereof, can be formed as an integrated circuit. In another aspect, the SDGD subsystem can comprise a high-side portion, which can include SDGD component 112 and SDGD component 114, and a low-side portion, which can include SDGD component 116 and SDGD component 118, wherein the high-side portion and the low-side portion can be symmetrical. Thus, the synchronous rectifier of system 100 can be a self-driven synchronous rectifier (SDSR), wherein the switches 102, 104, 106, and 108, with the associated SDGD subsystem, can form, emulate, and/or function as a diode bridge, but with significant reduction in conduction loss as compared to conventional diode bridges or synchronous rectifiers.
Referring to
In accordance with an aspect, the switches 202, 204, 206, and/or 208 can be power switches (e.g., power MOSFETs). In another aspect, the switch 202 and switch 204 can be VCSD switches (e.g., n-type enhancement power MOSFETs) that each can be turned to the on state when such switch is forward-biased, and the switch 206 and switch 208 can be CCSD switches that each can be respectively controlled by sensing the current through such switch and can be turned or switched to the off state whenever the current sensed across such switch is reversed. While switch 202 and switch 204 are VCSD switches in the above embodiment, it is to be appreciated and understood that, in accordance with other embodiments, the switches 202 and/or 204 also can be CCSD switches, instead of VCSD switches.
In another aspect, the SDGD components 212, 214, 216, and 218 each can respectively be and/or can comprise low power components, as compared to the switches 202 through 208, which can be power devices. In an embodiment, the SDGD components 212, 214, 216, and 218, or a desired portion thereof, can be formed as an integrated circuit. In still another aspect, the SDGD component 212 and SDGD component 214 can be included in a high-side portion of the SDGD subsystem, and SDGD component 216 and SDGD component 218 can be included in a low-side portion of the SDGD subsystem, wherein the high-side portion and low-side portion can be symmetrical. In yet another aspect, the circuitry of the SDGD component 216 and SDGD component 218 can be grounded with the power circuits (e.g., circuitry associated with the power switches) and the power supplies for the SDGD component 216 and SDGD component 218 can be derived (e.g., obtained) from the output DC voltage from the synchronous rectifier of system 200.
In accordance with an embodiment, with regard to the high-side portion of the SDGD subsystem, each of SDGD component 212 and SDGD component 214 can respectively comprise three capacitors have respective desired capacitance values, wherein SDGD component 212 can comprise capacitors (C), C1 (e.g., 470.0 nano-Farads (nF)), C2 (e.g., 11.0 μF), and C3 (e.g., 2.2 μF), and SDGD component 214 can comprise capacitors, C4 (e.g., 470.0 nF), C5 (e.g., 11.0 μF), and C6 (e.g., 2.2 μF). Each of SDGD component 212 and SDGD component 214 (e.g., each upper gate drive) can include three driving stages. For example, the SDGD component 212, which is associated with switch 202, can comprise, for example, transistor Q2 and transistor Q3, switch M5 and switch M6, and transistor Q4 and transistor Q2 which can form the three driving stages. Transistors Q2 and Q3 can be employed for signal amplifying and providing a charging path for the power supplies of the driving circuit of switch 204 (M2), switches M5 and M6 can form an inverter, and transistors Q4 and Q5, which can be associated with resistor R18 (e.g., 10.0Ω), can be employed for desirably fast driving of the switch 202 (e.g., power MOSFET M1). Similarly, the SDGD component 214, which is associated with switch 204, can comprise, for example, transistor Q7 and transistor Q8, switch M7 and switch M8, and transistor Q9 and transistor Q10, which can form the three driving stages. Transistors Q7 and Q8 can be employed for signal amplifying and providing a charging path for the power supplies of the driving circuit of switch 202 (M1), switches M7 and M8, which can be respectively connected to R7 (e.g., 5.1 kΩ) and R8 (e.g., 5.1 kΩ), can form an inverter, and transistors Q9 and Q10, which can be associated with resistor R19 (e.g., 10.0Ω), can be employed for desirably fast driving of the switch 202.
In an aspect, capacitors C1 and C4 can be charged up as the power supplies of the first-stage driving pair. Before capacitors C1 and C4 have been charged up to a certain predefined threshold voltage (e.g., 10V), the respective driving logic in the respective circuits of the respective SDGD 212 and SDGD 214 will not be ready to operate in the desired steady state. Capacitors C3 and C6 can be charged as the power supplies for driving switch 202 and switch 206, respectively. During the start-up stage, the capacitors C2 and C5, which respectively can be associated with (e.g., connected to) R3 (e.g., 50.0 MΩ) and R6 (e.g., 50.0 MΩ), can be designed (e.g., can have desired capacitance values) to be charged up quicker than capacitors C1 and C4, until the capacitors C2 and C5 reach a certain defined voltage, which can be determined by the zener diodes DZ1 and DZ2, respectively, contained in the SDGD component 212 and SDGD component 214. In an aspect, the bipolar transistors Q1 and Q6 can be used to facilitate ensuring the capacitors C3 and C6 will not be charged before capacitors C1 and C4 have been charged up to a voltage higher than the voltage of capacitors C2 and C5. Therefore, as a result, the switch 202 and switch 204 will not switch before the respective driving logic of the SDGD component 212 and SDGD component 214 has been set up to operate in normal operating state (e.g., steady state operation).
In an aspect, the capacitors C1 and C4 can be charged and discharged at line frequency. For instance, the capacitors C1 and C4 can be charged up to a defined voltage V1 (e.g., approximately 13.0 volts (V)) in every charging period and can be discharged to a different defined voltage V2 (e.g., approximately 12.0 V), which can be a relatively lower voltage than voltage V1, after each discharging period.
Referring briefly to
Turning to
Referring to
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With regard to
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With regard to
Referring to
Referring to
In an aspect, current sensing resistors, RS1 (e.g., 2.0 mΩ) and RS2 (e.g., 2.0 MΩ), and the respective comparators CP1 and CP2 can be respectively associated with switch 206 and switch 208, wherein the resistors, RS1 and RS2, and the respective comparators CP1 and CP2 can be used to detect the currents in the respective switches 206 and 208, and can drive the respective switches 206 and 208. In an embodiment, if desired, respective on-state resistors (not shown) of the respective switches 206 and 208 also can be used to replace the sensing resistors, RS1 and RS2, respectively, in SDGD component 216 and SDGD component 218.
In another aspect, in system 500, the capacitor C9 (e.g., 220.0 nF) can be used to provide a positive voltage for the inverting inputs of the comparators CP1 and CP2, which can provide a safe margin set by the potential divider, comprising resistors R14 (e.g., 4.7 MΩ), R15 (e.g., 24.0 kΩ), R16 (e.g., 4.7 MΩ), and R17 (e.g., 24.0 kΩ), which can be respectively associated with capacitors C10 (e.g., 470.0 nF) and C11 (e.g., 470.0 nF) in the circuit of system 500 (and system 200). The voltage of the capacitor C7 (e.g., 3.3 μF), which can be stabilized by the zener diode DZ4, can be the power supply for the comparators CP1 and CP2. The capacitor C9 can be charged up to the desired designated voltage before the voltage of the capacitor C7 reaches a voltage level that is at a sufficiently high level for the comparators CP1 and CP2 to become operational (e.g., to drive the comparators CP1 and CP2). The output of comparator CP1 can be provided to transistors Q10 and Q11, which can be associated with resistor R20 (e.g., 10.0Ω) to facilitate controlling switching of switch 206; and output of comparator CP2 can be provided to transistors Q13 and Q14, which can be associated with resistor R21 (e.g., 10.0Ω) to facilitate controlling switching of switch 208. This circuitry of system 500 can facilitate ensuring that switch 206 and switch 208 (e.g., low-side MOSFETs M3 and M4) will be switched (e.g., from a first or an off state to a second or an on state) only when the proper logic control of the system 400 (e.g., and corresponding portion of system 200) is in a desired operational state (e.g., steady state).
In an aspect, the self-driven synchronous rectifier of system 200 is designed to manage resistive, capacitive, and/or inductive loads. Referring briefly to
In an aspect, when a self-driven synchronous rectifier is connected to an inductive load, the input current can commutate very quickly after every half cycle. If there is not additional circuitry (e.g., additional control circuit) to facilitate turning the comparators CP1 and CP2 to an off state at certain desired times (e.g., at or near a half cycle), the comparators CP1 and/or CP2 may not respond quickly enough to turn off switch 206 and switch 208 under such a fast current change, which can or may cause an undesirable (e.g., fatal) short circuit situation. Therefore, in accordance with an aspect, the system 200 can include additional circuitry to provide a desired relatively small positive signal to the non-inverting inputs of the comparators CP1 and CP2.
Referring briefly to
The following can provide an analysis of the power loss of the disclosed SDSR and the conventional diode bridge. The power loss of the SR circuit can be expressed as:
PSR=PDriver+PS+PSW, (1)
where, PDriver is the power loss of the driver of the SR circuit (not including current sensing loss); PS is the power loss of current sensing resistors; PSW is the power loss of the switches used in the SDSR circuit which in this paper are MOSFETs. PDriver is low enough to be neglected, however it mainly consist of the loss producing by R4, R5, and R9. Therefore,
where Rs is the current sensing resistance;
PSW=2I2RDS(on), (4)
where RDS(on) is the on state resistance of the MOSFETs.
For the power loss of the diode-bridge,
PDB=2VFI, (5)
where VF is the forward voltage of the diode and can be considered as a constant in a rough estimation.
From equation (1)-(5), we can find out the current range, within which the power loss of the SDSR can be lower than a diode bridge,
In the prototype, R4=R5=1.3 MΩ, R9=1 MΩ, Rs=0.002Ω, RDS(on)=0.045Ω; VF<1.1 V at 30 A (VF=1V is assumed for calculation).
When Vout=Vin=110V, PDriver≈31 milliwatts (mW), and the current range is 0.016<I<21.724 A. When Vout=Vin=220V, PDriver≈124 mW, and the current range is 0.062<I<21.677 A.
Since the body diodes of the MOSFETs are used during the start-up phase of the system (before the DC output is ready to power the control electronic circuit of the SDSR) and after the corresponding MOSFETS have turned off at near-zero current (about 0.5 A), the conduction loss of the body diodes of the MOSFETs is negligible. In general, the power loss of the diode rectifier and the SDSR for the capacitive load and inductive load can be analyzed in the same way as the resistive load. The major power loss reduction component comes from the difference between the conduction loss of the diodes in the diode bridge and the on-state resistance of the MOSFETs in the SDSR. For a current of 10 A, for example, a diode has a conduction loss of about 10 W, while a MOSFET (with on-state resistance of 45 mΩ) only dissipates 4.5 W.
Experimental verification based on a single-phase synchronous rectifier was performed to compare a SDSR, in accordance with aspects and embodiments of the subject specification, with a conventional diode bridge. As part of the comparison, a diode bridge comprising diodes 60EPF06PbF with forward voltage drop of about 0.85V are used to compare with a SDSR (e.g., as depicted in
The forward voltage drop of diode 60EPF06PbF is found out to be about 0.85V in experiments. Power loss of the diode bridge is PDB=2VFI. For MOSFET IPW60R045CP, RDS(on)=0.0455Ω. The power loss of the SDSR is approximately PSR=I2(2RDS(on)+RS) when the power losses of gate-drives, which can be relatively negligible, are ignored.
The subject specification can employ a SDSR (e.g., self-driven AC-DC synchronous rectifier) that can be employed to replace a diode bridge as a general-purpose AC-DC rectifier. The high-side portion and low-side portion (SDGD subsystem) of the SDSR can efficiently (e.g., with regard to reduced cost, relative ease of implementation, improved power loss reduction, etc.) provide the normal rectification functions for resistive, capacitive and inductive loads as a traditional diode rectifier would provide, except that the power loss of the SDSR can be up to 57% less than that of a traditional diode bridge. The subject specification can result in a net cost reduction stemming in part from a reduction in the size of the heatsink to be employed when using the SDSR as compared to a traditional diode rectifier as well as the energy-saving (e.g., power loss reduction), which can more than compensate for any potential minor increase in the component counts of the inexpensive and low-power components in the high-side portion and low-side portion. In another aspect, the subject specification can achieve high system compactness, due in part to reduced heat dissipation (relative to conventional rectifiers), as compared to conventional rectifiers. Also, as desired, the control circuit of the disclosed SDSR (e.g., single-phase SDSR, multi-phase SDSR) can in principle be built in the same module block with the power switches (e.g., power MOSFETs) so that the module can be a replacement of the diode rectifier module.
Turning to
In still another aspect, the six switches 2002 through 2012 can be associated with six SDGD components 2014, 2016, 2018, 2020, 2022, and 2024, wherein the SDGD components 2014, 2016, and 2018 can be part of a high-side portion of an SDGD subsystem, and the SDGD components 2020, 2022, and 2024 can be part of a low-side portion of the SDGD subsystem, which can be employed to facilitate controlling respective switching of the six switches 2002 through 2012. In an aspect, the high-side portion and low-side portion of the SDGD subsystem can be symmetrical. The six SDGD components 2014 through 2024 (e.g., self-driven gate-drive circuits) can be designed such that they consume a relatively low amount of power and do not require an extra or separate power supply in order to operate, as power to drive the six SDGD components 2014 through 2024 can be supplied by the output DC voltage from the multi-phase synchronous rectifier. In an embodiment, the six SDGD components 2014 through 2024 can be formed on an integrated circuit.
The system 2000 can include a power source 2026, such as, for example, a multi-phase (e.g., three-phase) power source, that can provide desired power to the six switches 2002 through 2012, which can generate a desired rectified DC signal as an output, wherein the output can be associated with (e.g., connected to) a desired load (e.g., resistive, capacitive, and/or inductive load), and wherein a desired relatively small portion of the output DC signal can be used to drive the SDGD subsystem (e.g., the six SDGD components 2014 through 2024).
In yet another aspect, if the six SDGD components 2014 through 2024 are not ready for operation (e.g., have not reached steady-state operation) immediately at the start-up of the SDSR of the system 2000, the SDSR, formed at least in part by the six switches 2002 through 2012, can still function to rectify an input power signal, as diode-bridge type functionality is inherent in the SDSR. For instance, switch 2002 can include body diode 2034, switch 2004 can include body diode 2036, switch 2006 can include body diode 2038, switch 2008 can include body diode 2040, switch 2010 can include body diode 2042, and switch 2012 can include body diode 2044, wherein the arrangement of the switches 2002, 2004, 2006, 2008, 2010, and 2012, and thus, the body diodes 2034, 2036, 2038, 2040, 2042, and 2044 in the circuit can be such that the body diodes 2034, 2036, 2038, 2040, 2042, and 2044 can be structured and can inherently function as a bridge-rectifier including during initial start-up of the SDSR (e.g., prior to the rectified DC voltage providing at least a portion of the desired power to the switches of the SDSR). That is, the six body diodes 2034, 2036, 2038, 2040, 2042, and 2044 of the six switches 2002, 2004, 2006, 2008, 2010, and 2012 can form a three-phase diode rectifier when all the switches 2002 through 2012 (e.g., MOSFETs) are not switched on.
As more fully described herein, an undesirable (e.g., fatal) short circuit situation can or may occur at or near zero-crossing points unless there is a controller component or circuitry to facilitate controlling certain components, such as comparators (not shown in
Turning to
The system 2100 can include a SDGD subsystem (e.g., highlighted in the shaded areas of
The respective switches 2102, 2104, 2106, 2108, 2110, and 2112, each can include respective body diodes 2128 (for reason of clarity, included but not expressly labeled in
The SDGD subsystem is designed to consume a relatively low amount of power, and can be powered by and receive power from the output rectified DC signal from the SDSR. In an embodiment, the SDGD subsystem can be formed as an integrated circuit. In an aspect, the SDGD subsystem can be divided into a desired number of parts, such as, for example, two parts comprising a high-side portion and low-side portion. The high-side portion and low-side portion can be symmetrical.
As disclosed, the switches 2102 through 2112, and associated body diodes 2128 through 2138, can be arranged in the circuit of system 2100 to form, at least in part, the multi-phase SDSR that can be in the form of, function as, or emulate a diode bridge (e.g., diode rectifier). As a result, even if the SDGD components are not ready for operation (e.g., steady state operation) immediately at the start-up of the system 2100, the diode bridge functionality is inherent in the system 2100 to desirably perform the function of multi-phase rectification of the input power signal, because the six body diodes 2128 through 2138 of the six switches 2102 through 2112 are arranged in the circuit to form a three-phase diode bridge that can rectify the applied input power signal to produce a desired rectified DC voltage as an output when the switches 2102 through 2012 are not turned on (e.g., during initial start-up of the SDSR prior to steady-state operation of the SDSR). In an aspect, the system 2100 can include a power source 2126, which can be a multi-phase (e.g., three-phase) AC source, that can be connected to, and can apply the input power signal (e.g., AC power signal) to, the power switches 2102 through 2112, wherein the switches 2102 through 2112 can facilitate performing multi-phase rectification of the input power signal to generate a desired DC signal as an output.
The SDGD subsystem can include desired circuitry to facilitate controlling switching of the power switches while also be self-driven and consuming a low amount of power. In accordance with various aspects, there can be, for example, three capacitors in each of the three high-side portion SDGD components 2114, 2116, and 2118, wherein SDGD component 2114 can include capacitors C1, C2 and C3 for use in conjunction with switch 2102 (M1); SDGD component 2116 can include capacitors C4, C5 and C6 for use in conjunction with switch 2104 (M2); and SDGD component 2118 can include capacitors C7, C8 and C9 for use in conjunction with switch 2106 (M3). Also, each of the three high-side portion SDGD components 2114, 2116, and 2118 can include three driving stages. Taking SDGD component 2114 and switch 2102 (M1) as an example, the transistors Q2, Q3, Q4, and Q5; switches M7 and M8; and transistors Q6 and Q7 can respectively form the three driving stages. The transistors Q2 through Q5 can be employed for signal amplifying and providing charging paths for the SDGD component 2114, wherein resistor R2 can be employed for use with transistor Q2 and switch M7, and wherein resistor R6 can be employed for use with transistors Q2 and Q4; the switches M7 and M8 can form an inverter; and the transistors Q6 and Q7 can be employed for desirably fast driving of the power switch 2102 (M1), wherein resistor R5 can be employed for use with transistors Q6 and Q7, and power switch 2102 (M1).
Initially, when powering up the system 2100, the SDGD subsystem can go through a start-up phase until steady state operation is achieved. During the start-up phase, the capacitors C1, C4 and C7 will be charged up as the power supplies of the first-stage. Before the capacitors C1, C4 and C7 have been charged up to an applicable predefined threshold voltage (e.g., 10V), the driving logic in the SDGD subsystem will not be ready to fully function to facilitate controlling respective switching of the switches 2102 through 2112.
In another aspect, the capacitors C3, C6 and C9 are to be charged as the power supplies to facilitate driving the switch 2102 (M1), the switch 2104 (M2), and the switch 2106 (M3), respectively. During the start-up stage, the capacitors C2, C5 and C8, which can be respectively associated with resistors R1, R9 and R17 for use by capacitors C2, C5 and C8, can be designed to be charged up more quickly than the capacitors C1, C4 and C7, until the capacitors C2, C5 and C8 respectively reach a predefined voltage, wherein the predefined voltage can be determined based at least in part on the respective zener diodes DZ1, DZ2 and DZ3. In still another aspect, bipolar transistors Q1, Q8, and Q15 can be used to facilitate ensuring the capacitors C3, C6 and C9 will not be charged (e.g., fully charged to a predefined voltage level) before a time that the capacitors C1, C4 and C7 have been charged up to a voltage level that is higher than the voltage level of the capacitors C2, C5 and C8. As a result, the power switches, switch 2102 (M1), switch 2104 (M2), and switch 2106 (M3), will not switch before the driving logic of the SDGD subsystem has been initialized and set up to operate at a desired steady-state operation.
To make the analysis more clear, assume that the voltage of the capacitors C1, C4 and C7 will remain constant at a voltage V. The voltage vBCn can represent the base-collector voltages of Qn (e.g., BJT Qn), wherein n can be an integer value. Referring briefly to
During this short time period, as shaded in
Referring to
Referring to
Turning to
Referring to
Turning to
Referring to
Referring again to
Turning to
In an aspect, the SDSR of system 2100 is designed to manage resistive, capacitive, and/or inductive loads. Referring briefly to
Referring briefly to
Referring again to
Turning to
Referring to
For an inductive-resistive load connected to a three-phase system comprising the SDSR (e.g., system 2100), the input voltage and current are substantially the same as that of the resistive load. A larger inductor typically only causes the fluctuation of the input current to be smaller, which does not affect the function of the driver. So the driving signals for an inductive-resistive load are the same, or at least substantially the same, as the driving signals with a resistive load.
The subject specification can employ a SDSR (e.g., self-driven multi-phase AC-DC synchronous rectifier) that can be employed to replace a diode bridge as a general-purpose multi-phase AC-DC rectifier. Similar to the single-phase SDSR disclosed herein, the high-side portion and low-side portion (SDGD subsystem) of the multi-phase SDSR can efficiently (e.g., with regard to reduced cost, relative ease of implementation, improved power loss reduction, etc.) provide the normal rectification functions for resistive, capacitive and inductive loads as a traditional diode rectifier would provide, except that the power loss of the multi-phase SDSR can be up to 69% less than that of a traditional diode bridge. The subject specification can result in a net cost reduction stemming in part from a reduction in the size of the heatsink to be employed when using the multi-phase SDSR as compared to a traditional diode rectifier as well as the energy-saving (e.g., power loss reduction), which can more than compensate for any potential minor increase in the component counts of the inexpensive and low-power components in the high-side portion and low-side portion. In another aspect, the multi-phase SDSR disclosed herein can achieve high system compactness as compared to conventional rectifiers, due at least in part to reduced heat dissipation of the multi-phase SDSR relative to conventional rectifiers.
It is to be appreciated and understood that various example component values (e.g., resistance values, capacitance values, etc.) have been disclosed herein with regard to various example components (e.g., resistors, capacitors, etc.). These example component values are but non-limiting examples of component values that can be employed in accordance with various aspects and embodiments of the disclosed subject matter, and the subject specification is no so limited, as in accordance with various other embodiments, other component values and component arrangements can be employed consistent with the disclosed subject matter to construct or create a SDSR that can function as disclosed herein, and all such embodiments are considered to be part of the subject specification.
In accordance with one embodiment of the disclosed subject matter, the systems, subsystems, devices, and/or other components disclosed herein, can be situated or implemented on a single integrated-circuit chip. In accordance with another embodiment, the systems, subsystems, devices, and/or other components disclosed herein, can be implemented on an application-specific integrated-circuit (ASIC) chip. In yet another embodiment, the systems, subsystems, devices, and/or other components disclosed herein, can be situated or implemented on multiple dies or chips.
The aforementioned systems and/or devices have been described with respect to interaction between several components. It should be appreciated that such systems and components can include those components or sub-components specified therein, some of the specified components or sub-components, and/or additional components. Sub-components could also be implemented as components communicatively coupled to other components rather than included within parent components. Further yet, one or more components and/or sub-components may be combined into a single component providing aggregate functionality. The components may also interact with one or more other components not specifically described herein for the sake of brevity, but known by those of skill in the art.
Referring to
Turning to
At 3504, during at least a start-up phase of operation when an SDGD system associated with the synchronous rectifier is not operating at steady state, switching of the subset of power switches can be controlled to maintain the subset of power switches in an off state.
In an aspect, during the start-up stage before the rectified DC output voltage is ready to power up the control circuitry (e.g., SDGD system) for the switches (e.g., MOSFETs), the body diodes of the switches, which are arranged in relation to each other to form the traditional diode bridge rectifier circuit, can provide the initial rectification function. During the initial start-up stage (prior to steady-state operation of the SDSR), the conduction loss can be equivalent to that of a power diode bridge, however, the start-up stage lasts for only a short period of time. Once the rectified DC output voltage is available to power the control circuitry for the switches, the normal synchronous rectification of the SDSR with the relatively low conduction loss (as compared to conventional rectifier bridges) can begin. It is noted that, for a single-phase SDSR, the diagonal pair of switches can be turned on and off together to form a conducting path. For instance, with regard briefly to
At 3506, a desired rectified power signal (e.g., rectified DC power signal) can be generated based at least in part on controlling of the switching of the power switches. As desired, the rectified power signal can be connected to a desired load (e.g., resistive, capacitive, and/or inductive load).
At 3604, a high-side portion of an SDGD subsystem, which can be associated with at least two power switches of the plurality of the power switches, can be formed. In an embodiment, the power switches (e.g., high-side power switches) can be VCSD MOSFET switches. It is to be appreciated and understood that, as desired, in accordance with other embodiments, the high-side power switches can be CCSD MOSFET switches.
At 3606, a low-side portion of the SDGD subsystem, which can be associated with at least two other power switches of the plurality of power switches, can be formed. In an embodiment, the two other power switches (e.g., low-side power switches) can be CCSD MOSFET switches.
At 3608, at least one zero-crossing controller component can be formed, wherein the at least one zero-crossing controller component can be associated with at least one power switch of the plurality of power switches to facilitate switching the at least one power switch to (or maintaining the at least one power switch in) an off state at or near a zero-crossing point (e.g., zero-voltage-crossing point at each half-cycle of an input AC voltage signal) associated with the at least one power switch. In an aspect, a zero-crossing controller component can supply a relatively small positive voltage signal to a non-inverting input of a comparator associated with the at least one power switch to facilitate ensuring that the at least one power switch is turned of at or near the zero-crossing point, wherein the comparator can be employed to facilitate controlling switching of the at least one power switch component. The zero-crossing controller component can thereby facilitate preventing an undesirable short circuit situation in the synchronous rectifier.
Some portions of the detailed description have been presented in terms of algorithms and/or symbolic representations of operations on data bits within a computer memory. These algorithmic descriptions and/or representations are the means employed by those cognizant in the art to most effectively convey the substance of their work to others equally skilled. An algorithm is here, generally, conceived to be a self-consistent sequence of acts leading to a desired result. The acts are those requiring physical manipulations of physical quantities. Typically, though not necessarily, these quantities take the form of electrical and/or magnetic signals capable of being stored, transferred, combined, compared, and/or otherwise manipulated.
It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like. It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the foregoing discussion, it is appreciated that throughout the disclosed subject matter, discussions utilizing terms such as processing, computing, calculating, determining, and/or displaying, and the like, refer to the action and processes of computer systems, and/or similar consumer and/or industrial electronic devices and/or machines, that manipulate and/or transform data represented as physical (electrical and/or electronic) quantities within the computer's and/or machine's registers and memories into other data similarly represented as physical quantities within the machine and/or computer system memories or registers or other such information storage, transmission and/or display devices.
It is to be appreciated and understood that components (e.g., synchronous rectifier, multi-phase synchronous rectifier, SDGD subsystem, SDGD component, zero-crossing controller component, etc.), as described with regard to a particular system, device, or methodology, can include the same or similar functionality, or a desired portion thereof, as respective components (e.g., respectively named components, similarly named components) as described with regard to other systems, devices, or methodologies disclosed herein. However, it is also to be appreciated and understood that a named component of one system, device, or methodology does not necessarily have to be the same or similar as, or have the same or similar functionality as, a same or similarly named component in another system, device, or methodology.
What has been described above includes examples of aspects of the disclosed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the disclosed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the disclosed subject matter are possible. Accordingly, the disclosed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the terms “includes,” “has,” or “having,” or variations thereof, are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.
This application is a continuation of, and claims the benefit of priority to each of, U.S. patent application Ser. No. 14/517,704 (U.S. Pat. No. 9,590,523), filed Oct. 17, 2014, and entitled “SELF-DRIVEN AC-DC SYNCHRONOUS RECTIFIER FOR POWER APPLICATIONS,” which is a continuation of U.S. patent application Ser. No. 12/898,898 (U.S. Pat. No. 8,913,409), filed Oct. 6, 2010, and entitled “SELF-DRIVEN AC-DC SYNCHRONOUS RECTIFIER FOR POWER APPLICATIONS,” which is a non-provisional of, and each of which applications further claim the benefit of priority to, U.S. Provisional Patent Application No. 61/304,097, filed Feb. 12, 2010, and entitled “CONTROL CIRCUITS FOR SELF-DRIVEN SYNCHRONOUS RECTIFIER AS ENERGY-EFFICIENT REPLACEMENT FOR DIODE RECTIFIER,” the respective entireties of U.S. patent application Ser. No. 14/517,704, U.S. patent application Ser. No. 12/898,898, and U.S. Provisional Patent Application No. 61/304,097 are hereby incorporated herein by reference.
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20170179846 A1 | Jun 2017 | US |
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Parent | 14517704 | Oct 2014 | US |
Child | 15449881 | US | |
Parent | 12898898 | Oct 2010 | US |
Child | 14517704 | US |