Current controlled switch mode power supply

• US 20060152947A1
• Filed: 01/04/2006
• Published: 07/13/2006
• Est. Priority Date: 01/07/2005
• Status: Active Grant

• Current Assignee: Harman International Industries Incorporated (Samsung Electronics Co. Ltd.)
• Original Assignee: Harman International Industries Incorporated (Samsung Electronics Co. Ltd.)
• Inventors: Stanley, Gerald R., Baker, Eric Matthew, Busquets-Monge, Sergio
• Granted Patent: US 7,283,379 B2
• Time in Patent Office: Days
• US Class Current: 363/16
• CPC Class Codes: H02M 1/009 having two or more independently controlled outputs for DC-DC converter with intermediate AC H02M3/33561
• CPC Class Codes: H02M 1/4241 using a resonant converter
• CPC Class Codes: H02M 1/425 using a single converter stage both for correction of AC input power factor and generation of a high frequency AC output voltage
• CPC Class Codes: H02M 3/33507 with automatic control of the output voltage or current, e.g. flyback converters H02M3/33561, H02M3/33569 take precedence
• CPC Class Codes: H02M 7/4815 Resonant converters H02M7/4811 and H02M7/4826 take precedence
• CPC Class Codes: H02M 7/5387 in a bridge configuration
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

A single stage switch mode power converter receives a supply line voltage and a supply line current from a power supply line, and provides one or more regulated output voltages for a load, such as an amplifier. The power converter is operable to regulate the output voltage(s) using a controller that includes a voltage controlled current loop. The controller can enable substantially constant supply line current to be drawn from the power supply line by selectively allowing conduction of the supply line current through the power converter. A power factor of the supply line voltage and the supply line current may be optimized by the controller at medium to high power levels thereby maximizing the power provided to the switch mode power converter from the power supply line. Due to the adaptive nature of the controller, the power converter can operate over a wide range of supply line voltage.

Claims

1. A power converter comprising:

a single stage switching stage suppliable with a supply line current and a supply line voltage from a power source;

a controller coupled with the single stage switching stage, where the controller is operable to control the switching frequency of the switching stage to generate a switch generated voltage; and

a transformer having a primary winding and a secondary winding, where the transformer is wound to have a predetermined reflected voltage and is operable to receive the switch generated voltage at the primary winding; and

where the controller is operable to direct the single stage switching stage to vary the switch generated voltage as a function of the predetermined reflected voltage, and to selectively conduct the line current to the primary winding to create a substantially constant line current flow.

2. The power converter of claim 1, where the controller comprises an average line current circuit that is operable to determine the supply line current suppliable to the single stage switching stage, and the controller is operable to control the single stage switching stage as a function of the determined supply line current.

3. The power converter of claim 2, further comprising an inductor included in the single stage switching stage, where the average line current circuit is operable to sense a voltage across at least a portion of the inductor, and determine the supply line current therefrom.

4. The power converter of claim 3, where the average line current circuit is operable to integrate the voltage sensed across the at least a portion of the inductor to determine a switch generated current, and the average line current circuit is further operable to integrate the switch generated current only during the time when the supply line current is being supplied to the single stage switching stage to determine the supply line current.

5. The power converter of claim 1, where the predetermined reflected voltage is a minimum alternating current line voltage, and the line current only flows when a peak of the alternating current line voltage is greater than the minimum alternating current line voltage.

6. The power converter of claim 1, where the controller is operable to control the wave shape of the supply line current suppliable to the single stage switching stage by variation of the switch generated voltage to create a fundamental voltage that is equal to or greater than the predetermined reflected voltage.

7. The power converter of claim 1, where the controller is operable to control the switch generated voltage to clip a peak of the supply line current suppliable to the single stage switching stage.

8. The power converter of claim 1, where the controller is further operable to control switching of the single stage switching stage to optimize a power factor by control of the shape of a waveform of the supply line current.

9. The power converter of claim 8, where the controller is further operable to control switching of the single stage switching stage to regulate an output voltage suppliable with the secondary winding.

10. A power converter comprising:

a switching stage that includes a first set of switches and a second set of switches;

a controller coupled with the switching stage, where the controller is operable to control switching of the first set of switches and the second set of switches to enable the output of a first time variable voltage from the first set of switches and a second time variable voltage from the second set of switches; and

a transformer having a primary and a secondary, the transformer operable to receive a primary voltage representative of the combination of the first and second time variable voltages,

where the controller is operable to control the primary voltage by variation of a relative phase difference between the first time variable voltage and the second time variable voltage based on a primary current suppliable to the transformer.

11. The power converter of claim 10, where the controller is operable to control the primary voltage to a conduction voltage of the transformer.

12. The power converter of claim 10, where the first set of switches comprises a first half bridge and the second set of switches comprises a second half bridge.

13. The power converter of claim 10, where an alternating current voltage is suppliable from a power supply line to the switching stage, and the first set of switches and the second set of switches are selectively controllable to conduct a line current suppliable from the power supply line only during a determined time within each half cycle of the alternating current voltage.

14. The power converter of claim 10, where the first set of switches and the second set of switches are exchangeable by the controller between operation in a leading mode and a lagging mode with respect to each other.

15. The power converter of claim 10, where the power converter is operable to supply power to a power supply rail of an audio amplifier.

16. The power converter of claim 10, where the controller is operable to control the primary voltage as a function of a primary current suppliable to the primary of the transformer and a load suppliable by the power converter.

17. The power converter of claim 10, further comprising an inductor, where the controller is operable to determine the primary current by integration of a voltage drop across the inductor.

18. The power converter of claim 17, where the controller is further operable to determine an average line current by integration of the primary current only during times when the first time variable voltage and the second time variable voltage have a relative phase difference.

19. A method of manufacture of a power converter, the method comprising:

providing a transformer having a primary winding and a secondary winding;

selecting a conduction voltage that is a lowest expected operating voltage;

designing a turns ratio of the primary winding and the secondary winding so that a reflected voltage of the secondary winding is about equal to the conduction voltage;

connecting an average line current circuit to measure a voltage across an inductor, where the measured voltage is useable to derive a supply line current that is shaped by a waveform of a primary voltage suppliable to the primary winding; and

configuring a plurality of switch position scenarios of a first set of switches and a second set of switches that are switchable to control the primary voltage to the selected conduction voltage so that the supply line current only flows to the primary winding during some of the switch position scenarios.

20. The method of claim 19, where configuring a plurality of switch position scenarios comprises configuring at least one first switch position scenario to allow the supply line current to flow to the primary winding and configuring at least one second switch position scenario to allow current to flow from one of the first or second set of switches to the other of the first or second set of switches.

21. The method of claim 19, further comprising combining a first voltage output of the first set of switches with a second voltage output of the second set of switches so that a relative phase difference between the first voltage output and the second voltage output is controllable to control the primary voltage to the selected conduction voltage.

22. The method of claim 19, where connecting an average line current circuit comprises configuring the average line circuit to perform integration of the measured voltage across the inductor to derive an inductor current, and to perform integration of the inductor current to derive the supply line current.

23. The method of claim 22, where configuring the average line circuit to perform integration of the inductor current comprises limiting the performance of the integration to only when the supply line current flows to the primary winding.

24. The method of claim 19, where providing a transformer comprises winding the transformer as a parallel interleave wound transformer to lower leakage flux.

25. A method of converting power with a power converter, the method comprising:

providing a supply line voltage and a supply line current to a first set of switches and a second set of switches;

switching the first set of switches with a controller to control a first voltage output of the first set of switches and to selectively conduct the supply line current through a switch included in the first set of switches;

switching the second set of switches with the controller to control a second voltage output of the second set of switches and to selectively conduct the supply line current through a switch included in the second set of switches;

combining the first voltage output with the second voltage output to form a primary voltage that is provided to a transformer having a predetermined conduction voltage;

calculating a magnitude of the supply line current supplied to the power converter as a function of a voltage across an inductor and a period of time when the supply line current is conducted through the first set of switches and the second set of switches; and

varying the relative phase of the first voltage output with respect to the second voltage output to control the primary voltage to the predetermined conduction voltage as a function of the calculated magnitude of the supply line current.

26. The method of claim 25, where calculating a magnitude of the supply line current comprises measuring a voltage across a winding of the inductor.

27. The method of claim 26, where calculating a magnitude of the supply line current comprises integrating the measured voltage over time to obtain an inductor current.

28. The method of claim 27, where calculating a magnitude of the supply line current comprises integrating the inductor current over the time when the supply line current is being conducted through a switch in each of the first set of switches and the second set of switches to obtain the supply line current.

29. The method of claim 25, where varying the relative phase comprises adjusting a duty cycle of the first and second sets of switches to be more or less overlapped.

30. The method of claim 25, where the supply line voltage is an alternating current voltage and switching the first and second sets of switches comprises providing a current path for the supply line current through the first and second sets of switches during only a portion of each half cycle of the supply line voltage.

31. The method of claim 25, where switching the first and second sets of switches comprises conducting the supply line current to the transformer with the first and second sets of switches at a time other than a peak in a waveform of the supply line voltage.

32. The method of claim 25, where the supply line current is conducted through the first set of switches and the second set of switches when a switch is closed in both of the first set of switches and the second set of switches.

33. A power converter comprising:

a first set of switches coupled in parallel with a second set of switches, and configured to be coupled in parallel with a source of line voltage and line current; and

a controller coupled with the first and second sets of switches, where the controller is operable to output a first control signal to control the relative phase of a first voltage output from the first set of switches, and output a second control signal to control the relative phase of a second voltage output from the second set of switches such that the first voltage output is selectively lagging with respect to the second voltage output;

where the controller is operable to exchange the first control signal with the second control signal so that the second voltage output of the second set of switches becomes selectively lagging with respect to the first voltage output of the first set of switches.

34. The power converter of claim 33, where the controller is further operable to exchange the first control signal and the second control signal in response to a predetermined event.

35. The power converter of claim 33, where the controller is further operable to exchange the first control signal and the second control signal in response to a temperature of at least one switch included in the first set of switches or the second set of switches.

36. The power converter of claim 33, where the line voltage is an alternating current line voltage, and where the controller is further operable to exchange the first control signal and the second control signal in response to completion of a half cycle of the alternating current line voltage.

37. The power converter of claim 33, where the controller is further operable to exchange the first control signal and the second control signal when current being conducted by the power converter is at or below a predetermined level.

38. The power converter of claim 33, where the controller is further operable to exchange the first control signal and the second control signal when at least one of the line voltage or the line current, or the combination thereof, are in an exchange opportunity window.

39. The power converter of claim 33, where the controller comprises a detector to detect a determined condition, a register, and an exchange circuit, where the exchange circuit is operable to exchange the first and second control signals in response to an update to the register.

40. A method of controlling a power converter, the method comprising:

switching a first set of switches with a first switching signal to control a first voltage output with the first set of switches;

switching a second set of switches with a second switching signal to control a second voltage output with the second set of switches;

selectively adjusting a relative phase of the first voltage with respect to the second voltage so that the first voltage lags the second voltage; and

exchanging the first switching signal with the second switching signal so that the second voltage lags the first voltage.

41. The method of claim 40, where exchanging comprises switching the first set of switches with the second switching signal and switching the second set of switches with the first switching signal.

42. The method of claim 40, where selectively adjusting a relative phase comprises controlling the relative phase so that a differential voltage of the first and second voltage outputs will be controlled to a predetermined fundamental voltage.

43. The method of claim 40, where selectively adjusting a relative phase comprises monitoring a supply line current and adjusting the relative phase based on the monitored supply line current.

44. The method of claim 40, where exchanging the first switching signal with the second switching signal comprises exchanging the first switching signal with the second switching signal in responses to a predetermined event.