Flyback Switch Mode Power Supplies (SMPS) are well-known in the art to provide a controlled and well-regulated output. Switching power supplies use a low-side driver connected to the primary side winding of a voltage transformer to switch current at a set frequency through the primary winding. The current is related to the input voltage connected to the high-side of the primary winding. The transformer transfers energy to the secondary side winding to produce an output voltage that is related to the voltage applied across the primary winding. In some Flyback SMPS applications, an ASIC (Application Specific Integrated Circuit) is used to control a FET (Field Effect Transistor) by applying a known switching frequency and duty cycle. For example, the ASIC may provide a pulse width modulation (PWM) signal to the gate of the FET to turn on/off the FET at a known rate and for a known time based on a monitored reference voltage.
To maintain the output voltage across the secondary winding within a set range, an Auxiliary winding that shares the same core as the secondary output winding is used to maintain an in-direct close-loop control of the secondary winding output voltage. The Auxiliary winding output voltage can be used to power the ASIC once the Auxiliary winding voltage reaches a certain level. Typically, the SMPS ASIC has a minimum lower operating voltage in the range of 7 to 8.4 volts.
This lower operating voltage range is not suitable for low voltage applications of shunt trip and under voltage release (UVR) devices, e.g., 12 volt shunt trip and UVR units which are employed to monitor and respond to voltages well below 7 to 8 volts.
One attempt to overcome this deficiency involves the use of a boost circuit that boosts the voltage level to the ASIC. However, use of a boost circuit creates the requirement of different hardware configurations and topologies for different voltage levels that, in turn, increases the cost of manufacturing the SMPS.
Hence, there is a need in the industry for a low voltage SMPS configuration that does not significantly increase the manufacturing cost.
One aspect of the present invention relates to a device for engaging a switching power supply at a lower start voltage. The power supply comprises a transformer having a primary winding, secondary and auxiliary windings wherein an interrupted current in said primary winding induces a voltage in each of the secondary and auxiliary windings, a first driver circuit and a second driver circuit connected in parallel to said primary winding, a first controller receiving said voltage from said auxiliary winding and connected to said first driver circuit and a second controller connected to said second driver circuit, providing a control signal to said second driver circuit when said auxiliary is below a predetermined value.
The embodiments shown in the accompanying drawings, and described in the accompanying detailed description, are to be used as illustrative embodiments and should not be construed as the only manner of practicing the invention. Also, the same reference numerals, possibly supplemented with reference characters where appropriate, have been used to identify similar elements.
It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for the purpose of clarity many other elements found in conventional systems of the type described herein. Those of ordinary skill of the art may recognize that other elements and/or steps are desirable and/or required in implementing the present invention. However, because such elements and steps are well-known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements and steps is not provided herein.
Voltage 112 is further applied to primary winding 142 of transformer 140. Primary winding 142 is further connected to low side driver 180. Typically, low side driver 180 is an N-Channel FET transistor that operates to interrupt the current flow through winding 142. However, it would be recognized that the low side driver may be another type of switching device. Output 134 of ASIC 130 is applied to a control node 182 (e.g., gate node of an FET) to control the interruption of the current flow according to a known frequency and duty cycle.
As known in transformer technology, the interruption of the current flow in primary winding 142 induces an energy transfer into secondary windings 144 to create a secondary voltage. The secondary voltage, in this case, is rectified and filtered by the combination of diode 146 and capacitor 148 to produce output voltage 150.
The interruption of the current in primary winding 142 further induces a voltage in auxiliary winding 160, in a manner similar to that occurring in secondary winding 144. As with secondary winding 144, the voltage induced in the auxiliary winding 160 is rectified and filtered by diode 162 and capacitor 164 to produce a substantially constant voltage 170, with a desired imposed ripple voltage. Voltage 170 is then applied to power port 132 of ASIC 130.
As previously discussed, when voltage 170 is of a sufficient magnitude (e.g., 7 volts), ASIC 130 is activated and provides a control signal to low side driver 180 to cause an interruption in the current flowing through primary winding 142.
Also shown is a second controller such as a microprocessor 195 that receives a power signal at port 191 via 5 volt regulator 136. Regulator 136 maintains a substantially constant voltage, independent of the voltage at point 125, so as to maintain microprocessor 195 in a power-on state prior to the operating threshold of ASIC 130. An output of microprocessor 195 is provided to a control port 192 of second low side driver 190. Port 194 of second low side driver 190 is connected in common with port 184 of first low side driver 180 to primary winding 142. Microprocessor 195 provides a control signal to second low side driver 190 to interrupt the flow of current in primary winding 142, in a manner similar to that described with regard to ASIC 130. In this case, the interruption of the current flowing in primary winding 142 by second low side driver 190 begins at a voltage level less that nominally required when ASIC 130 is alone.
Further illustrated is a variable resistor 188 for monitoring the voltage at point 125 and providing the monitored voltage to microprocessor 195. In this case, when the monitored voltage remains below a predetermined limit the control signal to the second low side driver 190 is activated and when the monitored voltage exceeds the predetermined limit, the control signal to second low side driver 190 is deactivated. Thereafter, ASIC 130 takes control of the system operation and applies a control frequency and duty cycle sufficient to maintain voltage 170 within a desired range. As an example, the variable resistor 188 may be set such that a voltage of 5 volts applied to port 196 indicates the auxiliary voltage is above a minimum voltage to cause ASIC 130 to be activated. Although a variable resistor 188, it would be recognized by those skilled in the art that any suitable means or circuit for monitoring the voltage may be employed such as a switch, e.g., transistor, that is configured to provide a signal to processor 195 when the voltage at point 125 exceeds a known value.
As would be recognized by those skilled in the art, the frequency and duty cycle of the control signal applied to second low side driver 190 may be similar to, or different from, the control signal applied to low side driver 180. In one aspect, the frequency and duty cycle applied to the second controller may be such to enable voltage 170 to quickly rise to a desired level.
Accordingly, when the ASIC 130 power input is below its minimum operating voltage range, the microprocessor 195 switches the gate of the second driver 190, at a known frequency and duty cycle, until the auxiliary winding voltage 170 achieves a voltage to activate the ASIC 130. Once the auxiliary voltage is above the minimum operating range of the ASIC 130, the ASIC 130 will turn-on and provide a known control signal to first low side driver 180. ASIC 130 will maintain the voltages of the secondary windings 150 and auxiliary windings 170 thereafter.
While there has been shown, described, and pointed out fundamental novel features of the present invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the apparatus described, in the form and details of the devices disclosed, and in their operation, may be made by those skilled in the art without departing from the spirit of the present invention. It is expressly intended that all combinations of those elements that perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Substitutions of elements from one described embodiment to another are also fully intended and contemplated. For example, although the invention has been described with regard to an ASIC and a microprocessor, it would be recognized that other type of control circuit or controller, hardware (e.g., FPGA) or software/hardware elements may be incorporated into the circuit shown in