Voltage regulator including a buck converter pass switch

• US 10,404,167 B2
• Filed: 10/03/2018
• Issued: 09/03/2019
• Est. Priority Date: 03/26/2015
• Status: Active Grant

• Current Assignee: Hamilton Sundstrand Corporation (Rtx Corporation)
• Original Assignee: Hamilton Sundstrand Corporation (Rtx Corporation)
• Inventors: Fox, Brennan, Thornton, Christopher Derek, Peterson, Kevin C., Vandergrift, Adrian E.
• Primary Examiner(s): Laxton, Gary L
• Application Number:
  US16/150,417
• Publication Number:
  US 20190036451A1
• Time in Patent Office: 335 Days
• CPC Class Codes: H02H 3/025 Disconnection after limiting, e.g. when limiting is not sufficient or for facilitating disconnection
• CPC Class Codes: H02H 9/025 Current limitation using field effect transistors
• CPC Class Codes: H02H 9/04 responsive to excess voltage lightning arrestors H01C7/12, H01C8/04, H01G9/18, H01T
• CPC Class Codes: H02M 1/0045 Converters combining the concepts of switch-mode regulation and linear regulation, e.g. linear pre-regulator to switching converter, linear and switching converter in parallel, same converter or same transistor operating either in linear or switching mode
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• CPC Class Codes: H02M 3/156 with automatic control of output voltage or current, e.g. switching regulators
• CPC Class Codes: H02M 3/157 with digital control

Abstract

A voltage driver includes a voltage input, a voltage regulation controller including an on/off input. The voltage regulation controller is configured to control a switching converter in a first mode, a second mode, and at least one additional mode. The switching converter is configured to operate as an open pass switch in the first mode, is configured to operate as a closed pass switch in the second mode, and is configured to operate as an overcurrent and overvoltage protection switch in the at least one additional mode. A discrete output driver control and monitoring circuit can be used to control the switching converter. The output driver control and monitoring circuit includes a controller coupled to a communication bus and is configured to provide high level control instructions to the communication bus.

Claims

1. A discrete output driver control and monitoring circuit comprising:

a microprocessor controller coupled to a communication bus and configured to provide high level control instructions to the communication bus;

a programmable circuit coupled to the communications bus and configured to convert a high level control instruction received from the communications bus to at least one control signal;

a voltage driver connected to said programmable circuit such that said at least one control signal sets an operational mode of at least one component of the voltage driver; and

wherein the voltage driver includes a voltage input, a voltage regulation controller including an on/off input, the voltage regulation controller configured to control a switching converter in a first mode, a second mode, and at least one additional mode;

the switching converter being configured to operate as an open pass switch in the first mode, configured to operate as a closed pass switch in the second mode, and configured to operate as an overcurrent and overvoltage protection switch in the at least one additional mode, wherein the first mode is a 0% duty cycle, the second mode is a 100% duty cycle, and the at least one additional mode is greater than 0% duty cycle and less than 100% duty cycle, and wherein the at least one additional mode is mutually exclusive with the first mode and the second mode.

2. The discrete output driver control and monitoring circuit of claim 1, further comprising:

at least one sensor module connected to said voltage driver such that a voltage sensor of said sensor module is configured to sense an output voltage of said voltage driver and a current sensor of said sensor module is configured to sense an output current of said sensor module; and

each of said voltage sensor and said current sensor being connected to said controller through said communications bus, such that said output voltage and said output current are communicated to said controller through said bus.

3. The discrete output driver control and monitoring circuit of claim 1, wherein the communications bus is one of an I2C bus and a SPI bus.

4. The discrete output driver control and monitoring circuit of claim 1, wherein an overvoltage threshold of the voltage driver in said at least one additional mode is dependent on a duty cycle of the switching converter in the at least one additional mode.

5. The discrete output driver control and monitoring circuit of claim 1, further comprising an isolation and decoupling module connecting said controller to said communications bus, wherein said isolation and decoupling module is configured to isolate said communications bus from said controller.

6. The discrete output driver of claim 1, wherein the switching converter is configured as a fully open switch in the first mode and a fully closed switch in the second mode, and wherein an overvoltage threshold of the voltage driver in said at least one additional mode is dependent on a duty cycle of the switching converter in the at least one additional mode.

7. The discrete output driver of claim 1, wherein the microprocessor controller is configured to output control signals at a first power level, the switching converter is configured to receive control signals at a second power level, the second power level being higher than the first power level;

and

the voltage driver further includes an isolation module connecting said controller to said programmable circuit such that the microprocessor controller is isolated from the converter.

8. The discrete output driver of claim 1, wherein said microprocessor controller is configured to set an overvoltage limit at a first level during power on and at a second level, lower than the first level, during continued operations in at least one additional mode.

9. A method of operating a voltage driver comprising:

placing the voltage driver in a first mode where a switching converter is a fully open switch by operating the switching converter at a 0% duty cycle;

placing the voltage driver in a second mode where the switching converter is a fully closed switch by operating the switching converter at a 100% duty cycle; and

placing the voltage driver in a third mode where the switching converter is an overcurrent and overvoltage protection, where the switching converter is a voltage limiter by operating the switching converter at a duty cycle greater than 0% and less than 100%, wherein operating the switching converter at a duty cycle greater than 0% and less than 100% comprises operating the switching converter at a first duty cycle when a first overcurrent and overvoltage control level is required and at a second duty cycle with a second overcurrent and overvoltage control level is required.