Method and apparatus for sequencing outputs in a multi-output power converter system

• US 10,218,282 B1
• Filed: 05/31/2018
• Issued: 02/26/2019
• Est. Priority Date: 05/31/2018
• Status: Active Grant

• Current Assignee: Power Integrations Incorporated
• Original Assignee: Power Integrations Incorporated
• Inventors: Moore, Karl, Waterson, Matthew David, Werner, Antonius Jacobus Johannes
• Primary Examiner(s): Berhane, Adolf
• Assistant Examiner(s): Quddus, Nusrat
• Application Number:
  US15/994,888
• Time in Patent Office: 271 Days
• Field of Search: 363 13, 363 15- 20, 363 49- 53, 363 55- 5602, 363 97, 363 98, 363125-127, 363131-132
• CPC Class Codes: H02M 1/0083 Converters characterised by their input or output configuration
• CPC Class Codes: H02M 1/08 Circuits specially adapted for the generation of control voltages for semiconductor devices incorporated in static converters
• CPC Class Codes: H02M 1/36 Means for starting or stopping converters
• CPC Class Codes: H02M 3/33561 having more than one ouput with independent control
• CPC Class Codes: H02M 3/33576 having at least one active switching element at the secondary side of an isolation transformer
• CPC Class Codes: H05B 45/34 Voltage stabilisation; Maintaining constant voltage
• CPC Class Codes: H05B 45/385 using flyback topology
• CPC Class Codes: H05B 45/46 having LEDs disposed in parallel lines

Abstract

Apparatus and methods for sequencing outputs in a multi-output power converter system are disclosed herein. During start-up multiple CC/CV outputs may be sequenced so that energy is first provided to a highest voltage secondary output and subsequently provided to a lowest voltage secondary output. Additionally, control may be exerted so as to concurrently and monotonically increase voltages during at least part of the start-up transient; and concurrent control may be further implemented using control circuitry and a variable reference generator. In some embodiments a variable reference may be generated from a capacitor voltage.

Claims

1. A method of sequencing output voltages in a multi-output switch-mode converter system comprising:

providing a power source to a primary of the multi-output switch-mode converter system;

transferring energy from the primary to a highest voltage secondary output so as to increase a voltage of the highest voltage secondary output;

transferring energy from the primary to a lowest voltage secondary output so as to concurrently increase a voltage of the lowest voltage secondary output while regulating the voltage of the highest voltage secondary output, the voltage of the highest voltage secondary output greater than the voltage of the lowest voltage secondary output; and

transferring energy from the primary to the highest voltage secondary output and the lowest voltage secondary output so as to concurrently increase the voltage of the highest voltage secondary output and the voltage of the lowest voltage secondary output.

2. The method of claim 1, wherein transferring energy from the primary to the highest voltage secondary output so as to increase the voltage of the highest voltage secondary output comprises:

transferring energy from the primary to the highest voltage secondary output at a first switching rate.

3. The method of claim 2, wherein transferring energy from the primary to the highest voltage secondary output and the lowest voltage secondary output so as to concurrently increase the voltage of the highest voltage secondary output and the voltage of the lowest voltage secondary output further comprises:

transferring energy from the primary to the highest voltage secondary output and the lowest voltage secondary output at a second switching rate.

4. The method of claim 3, wherein the second switching rate is greater than the first switching rate.

5. The method of claim 1, wherein transferring energy from the primary to the highest voltage secondary output so as to increase the voltage of the highest voltage secondary output comprises:

transferring energy from the primary to the highest voltage secondary output so as to increase the voltage of the highest voltage secondary output to a first high voltage regulation value.

6. The method of claim 5, wherein the first high voltage regulation value is twenty percent of a final target value of the voltage of the highest voltage secondary output.

7. The method of claim 5, wherein transferring energy from the primary to the lowest voltage secondary output so as to concurrently increase the voltage of the lowest voltage secondary output while regulating the voltage of the highest voltage secondary output comprises:

regulating the voltage of the highest voltage secondary output to the first high voltage regulation value.

8. The method of claim 1, wherein transferring energy from the primary to the highest voltage secondary output and the lowest voltage secondary output so as to concurrently increase the voltage of the highest voltage secondary output and the voltage of the lowest voltage secondary output further comprises:

controlling the voltage of the highest voltage secondary output and the voltage of the lowest voltage secondary output relative to a common reference voltage.

9. The method of claim 8, further comprising:

transferring energy from the primary to the highest voltage secondary output and the lowest voltage secondary output at a variable switching rate so as to concurrently increase the voltage of the highest voltage secondary output and the voltage of the lowest voltage secondary output by monotonically increasing the common reference voltage.

10. The method of claim 8, further comprising:

providing the common reference voltage using a capacitor.

11. The method of claim 10, further comprising:

regulating the voltage of the lowest voltage secondary output relative to a low voltage reference when the voltage of the lowest voltage secondary output reaches a final target value;

using the capacitor to provide an integrated value of a sampled voltage; and

regulating a load current of the highest voltage secondary output relative to the integrated value of the sampled voltage.

12. The method of claim 10, further comprising:

regulating the voltage of the lowest voltage secondary output relative to a low voltage reference when the voltage of the lowest voltage secondary output reaches a final target value; and

regulating the voltage of the highest voltage secondary output relative to a high voltage reference.

13. The method of claim 1, further comprising:

transferring energy from the primary to an intermediate voltage secondary output so as to concurrently increase a voltage of the intermediate voltage secondary output to a first intermediate voltage regulation value while regulating the voltage of the highest voltage secondary output, the voltage of the highest voltage secondary output greater than the voltage of the intermediate voltage secondary output, and the voltage of the intermediate voltage secondary output greater than the voltage of the lowest voltage secondary output.

14. The method of claim 13, wherein transferring energy from the primary to the highest voltage secondary output and the lowest voltage secondary output so as to concurrently increase the voltage of the highest voltage secondary output and the voltage of the lowest voltage secondary output further comprises:

transferring energy from the primary to the highest voltage secondary output, the intermediate voltage secondary output, and the lowest voltage secondary output so as to concurrently increase the voltage of the highest voltage secondary output, the voltage of intermediate voltage secondary output, and the voltage of the lowest voltage secondary output.

15. The method of claim 1, wherein the multi-output switch-mode converter system is configured as a multi-output flyback converter system.

16. A multi-output power converter configured to provide power to multiple loads, the multi-output power converter comprising:

a system control module;

a transformer comprising a primary coil and a stacked secondary coil having a plurality of stacked secondary outputs, the primary coil electrically coupled to receive energy from a first power supply; and

a secondary switches block electrically coupled to the plurality of stacked secondary outputs and comprising a plurality of outputs, the plurality of outputs comprising a highest voltage output and a lowest voltage output;

wherein during a start-up transient prior to reaching a steady state, the system control module is configured to control a transference of energy from the primary coil to the plurality of outputs such that during an initial soft-start phase, a voltage of the highest voltage output increases monotonically before a voltage of the lowest voltage output increases, and during a subsequent ramping phase, the voltage of the highest voltage output rises concurrently with the voltage of the lowest voltage output.

17. The multi-output power converter of claim 16, further comprising:

a primary switch electrically coupled to the primary coil,

wherein the system control module is configured to provide control signals to the primary switch and to the secondary switches block to control the transference of energy from the primary coil to the plurality of outputs; and

wherein during the subsequent ramping phase, the system control module is configured to provide control signals to regulate the voltage of the highest voltage output and the voltage of the lowest voltage output relative to a common reference voltage.

18. The multi-output power converter of claim 17, wherein a capacitor is configured to provide the common reference voltage.

19. The multi-output power converter of claim 18, wherein the capacitor is configured to receive a current so as to monotonically increase the common reference voltage during the subsequent ramping phase.

20. The multi-output power converter of claim 19, wherein in the steady state the capacitor is configured to provide an integrated value of a sampled voltage and the control signals control a current of the highest voltage output in relation to the integrated value.

21. The multi-output power converter of claim 17, wherein the control signals regulate the voltage of the highest voltage output relative to a high voltage reference in the steady state.

22. The multi-output power converter of claim 17, wherein the control signals regulate the voltage of the lowest voltage output relative to a low voltage reference in the steady state.

23. The multi-output power converter of claim 17, wherein the primary switch is configured to switch at a first frequency in the initial soft-start phase and to switch at a second frequency in the subsequent ramping phase.

24. The multi-output power converter of claim 23, wherein the second frequency is greater than the first frequency.

25. The multi-output power converter of claim 23, wherein the second frequency is varied so as to monotonically increase the common reference voltage during the subsequent ramping phase.

26. The multi-output power converter of claim 16, wherein the plurality of outputs further comprises an intermediate voltage output.

27. The multi-output power converter of claim 26, wherein during the initial soft-start phase, a voltage of the intermediate voltage output increases monotonically before a voltage of the lowest voltage output increases, and during the subsequent ramping phase, the voltage of the highest voltage output rises concurrently with the voltage of the intermediate voltage output and the voltage of the lowest voltage output.

28. The multi-output power converter of claim 26, wherein the voltage of the highest voltage output is greater than the voltage of the intermediate voltage output, and wherein the voltage of the intermediate voltage output is greater than the voltage of the lowest voltage output.

29. The multi-output power converter of claim 28, wherein the multiple loads comprise:

a light emitting diode (LED) string configured to receive power from the highest voltage output; and

an audio amplifier configured to receive power from the intermediate voltage output.

30. The multi-output power converter of claim 29, wherein the system control module is configured to receive power from at least one of the highest voltage output, the intermediate voltage output, and the lowest voltage output.

31. The multi-output power converter of claim 16, wherein the multi-output power converter is configured as a multi-output flyback converter.

32. A method of sequencing a plurality of output voltages from an off-state to an operational steady-state in a multi-output power converter system, wherein the plurality of output voltages comprise a lowest voltage output and a highest voltage output, the method comprising:

providing a power source to a primary of the multi-output power converter system;

starting the multi-output power converter system in a soft-start mode, wherein starting the multi-output system converter system in the soft-start mode comprises;

increasing a voltage of the highest voltage output in the soft-start mode;

regulating the voltage of the highest voltage output in the soft-start mode;

increasing a voltage of the lowest voltage output in the soft-start mode; and

controlling the plurality of output voltages in a ramping mode, wherein controlling the plurality of output voltages in the ramping mode comprises;

concurrently increasing the voltage of the lowest voltage output with the voltage of the highest voltage output.

33. The method of claim 32, wherein regulating the voltage of the highest voltage output in the soft-start mode comprises:

regulating the voltage of the highest voltage output to a first high voltage regulation value.

34. The method of claim 32, wherein the first high voltage regulation value is twenty percent of a final target value of the voltage of the highest voltage output.

35. The method of claim 32, wherein the voltage of the highest voltage output is greater than the voltage of the lowest voltage output.

36. The method of claim 32, wherein concurrently increasing the voltage of the lowest voltage output with the voltage of the high voltage output comprises:

controlling the voltage of the highest voltage output and the voltage of the lowest voltage output relative to a common reference voltage.

37. The method of claim 36, wherein the common reference voltage is a capacitor voltage, and the capacitor voltage increases monotonically.

38. The method of claim 36, further comprising:

regulating a current of the highest voltage output relative to the common reference voltage during the operational steady state.

39. The method of claim 36, further comprising:

regulating the voltage of the highest voltage output relative to a high voltage reference during the operational steady state.

40. The method of claim 36, further comprising:

regulating the voltage of the lowest voltage output relative to a low voltage reference during the operational steady state.