Full range soft-switching DC-DC converter

• US 5,875,103 A
• Filed: 12/22/1995
• Issued: 02/23/1999
• Est. Priority Date: 12/22/1995
• Status: Expired due to Fees

• Current Assignee: Lambda EMI Incorporated
• Original Assignee: Electronic Measurements, Inc.
• Inventors: Prasad, Atluri Rama, Bhagwat, Pradeep Madhay, Britton, Harry J., Justo, Chadd Dial, Kashani, Hamid
• Primary Examiner(s): Sterrett, Jeffrey L.
• Application Number:
  US08/577,628
• Time in Patent Office: 1,159 Days
• Field of Search: 363/170, 363/24, 363/25, 363/26, 363/65, 363/71, 363/97, 363/98, 363/132, 363/134
• US Class Current: 363/17
• CPC Class Codes: H02M 3/3376 with automatic control of output voltage or current

Abstract

A soft-switching DC to DC power converter which minimizes switching losses from a no load condition to a full load condition while operating at fixed frequency. Output voltage control is achieved by controlling the phase angle between the two switching networks. High frequency transformer primaries are always excited with a square wave input voltage equal to ##EQU1## The power converter can be implemented with a single transformer. Moreover, the switch voltage never increases the input DC voltage from no load to full load. The power converter can be used in both low voltage high current applications and high voltage low current applications.

Claims

1. An apparatus for converting an input DC voltage from an input DC voltage source to a DC output voltage supplied to a load, the apparatus comprising:

a divider circuit comprising two capacitors connected in series thereby defining a node therebetween, the divider circuit being coupled in parallel with the input DC voltage source;

first and second switching networks, each switching network having an output junction, a first path for carrying load current and arranged between the output it junction and a positive side of the input DC voltage source, a second path for carrying load current and arranged between the output junction and a negative side of the input DC voltage source, the first and second paths each having a blocking state and a conducting state and each having a control input, wherein the respective states of the first and second paths are selected based on a control signal applied to the respective control inputs;

a first and second power transformer, each transformer having at least one primary winding and at least one secondary winding, each winding having a polarity, the primary winding of the first transformer connected between the output junction of the first switching network and the node of the divider circuit, the primary winding of the second transformer connected between the output junction of the second switching network and the node of the divider circuit, the secondary windings of the first and second transformers connected in series with each other thereby forming a transformer secondary circuit having two end terminals;

a voltage rectifier coupled with the two end terminals of the transformer secondary circuit and providing the output DC voltage; and

a controller coupled between the voltage rectifier and the control inputs of the first and second devices of the first switching network and the third and fourth devices of the second switching network, wherein the controller responsively shifts a phase relationship of the first and second switching networks to maintain the output voltage of the output DC voltage source at a selected level,

wherein, a relative phase between a current induced on the secondary winding of the first transformer and a current induced on the secondary winding of the second transformer affects the DC output voltage such that the DC output voltage varies with respect to a fixed voltage of the node of the divider circuit when the relative phase is varied.

2. The apparatus of claim 1 wherein the controller includes a voltage sensor for sensing the output DC voltage provided by the rectifier.

3. An apparatus for converting an input DC voltage from an input DC voltage source to a DC output voltage supplied to a load, the apparatus comprising:

a divider circuit comprising two capacitors connected in series thereby defining a node therebetween, the divider circuit being coupled in parallel with the input DC voltage source;

first and second switching networks, each switching network having an output junction, a first path for carrying load current and arranged between the output junction and a positive side of the input DC voltage source, a second path for carrying load current and arranged between the output junction and a negative side of the input DC voltage source, the first and second paths each having a blocking state and a conducting state and each having a control input, wherein the respective states of the first and second paths are selected based on a control signal applied to the respective control inputs;

a first and second power transformer, each transformer having at least one primary winding and at least one secondary winding, each winding having a polarity, the primary winding of the first transformer connected between the output junction of the first switching network and the node of the divider circuit, the primary winding of the second transformer connected between the output junction of the second switching network and the node of the divider circuit, the secondary windings of the first and second transformers connected in series with each other thereby forming a transformer secondary circuit having two end terminals;

a voltage rectifier coupled with the two end terminals of the transformer secondary circuit and providing the output DC voltage;

a controller coupled between the voltage rectifier and the control inputs of the first and second devices of the first switching network and the third and fourth devices of the second switching network, wherein the controller responsively shifts a phase relationship of the first and second switching networks to maintain the output voltage of the output DC voltage source at a selected level; and

a first inductor coupled between the output junction of the first switching network and the node of the divider circuit and a second inductor coupled between the output junction of the second switching network and the node of the divider circuit.

4. An apparatus for converting an input DC voltage from an input DC voltage source having a first terminal and a second terminal, to an output voltage, the apparatus comprising:

a) a divider circuit, the divider circuit

i) including a first capacitor and a second capacitor coupled in series thereby defining a node therebetween, and

ii) coupled across the first and second terminals of the input DC voltage source;

b) a first switching network, the first switching network

i) coupled across the first and second terminals of the input DC voltage source,

ii) having an output node,

iii) having a first device having a conducting state for creating a current path between the first terminal of the input voltage source and the output node, and a blocking state, the first device having an input terminal for receiving a first control signal which determines whether the first device is in its conducting state or its blocking state, and

iv) having a second device having a conducting state for creating a current path between the second terminal of the input voltage source and the output node and a blocking state, the second device having an input terminal for receiving a second control signal which determines whether the second device is in its conducting state or its blocking state;

c) a second switching network, the second switching network

i) coupled across the first and second terminals of the input DC voltage source,

ii) having an output node,

iii) having a third device having a conducting state for creating a current path between the first terminal of the input voltage source and the output node of the second switching network, and a blocking state, the third device of the second switching network having an input terminal for receiving a third control signal which determines whether the third device of the second switching network is in its conducting state or its blocking state, and

iv) having a fourth device having a conducting state for creating a current path between the second terminal of the input voltage source and the output node of the second switching network, and a blocking state, the fourth device of the second switching network having an input terminal for receiving a fourth control signal which determines whether the fourth device of the second switching network is in its conducting state or its blocking state;

d) a transformer, the transformer

i) having a primary winding coupled between the output node of the first switching network and the output node of the second switching network, and

ii) having a secondary winding inductively coupled with the primary winding, the secondary winding having a first terminal node and a second terminal node;

e) a first inductor coupled between the output node of the first switching network and the node of the divider circuit; and

f) a second inductor coupled between the output node of the second switching network and the node of the divider circuit,

wherein the output voltage appears across the first and second terminal nodes.

5. The apparatus of claim 4 further comprising:

f) a rectifier coupled with the first terminal node and the second terminal node of the secondary winding and providing an output DC voltage; and

g) a controller, the controller

i) having an input coupled with the output DC voltage, and

ii) providing the first, second, third, and fourth control signals to the input terminals of the first and second devices of the first switching network and the third and fourth devices of the second switching network, respectively, based on a comparison of the output DC voltage with a setpoint DC output voltage.

6. An apparatus for converting an input DC voltage from an input DC voltage source having a first terminal and a second terminal, to an output voltage, the apparatus comprising:

a) a divider circuit, the divider circuit

i) including a first capacitor and a second capacitor coupled in series thereby defining a node therebetween, and

ii) coupled across the first and second terminals of the input DC voltage source;

b) a first switching network, the first switching network

i) coupled across the first and second terminals of the input DC voltage source,

ii) having an output node,

iii) having a first device having a conducting state for creating a current path between the first terminal of the input voltage source and the output node, and a blocking state, the first device having an input terminal for receiving a first control signal which determines whether the first device is in its conducting state or its blocking state, and

iv) having a second device having a conducting state for creating a current path between the second terminal of the input voltage source and the output node and a blocking state, the second device having an input terminal for receiving a second control signal which determines whether the second device is in its conducting state or its blocking state;

c) a second switching network, the second switching network

i ) coupled across the first and second terminals of the input DC voltage source,

ii) having an output node,

iii) having a third device having a conducting state for creating a current path between the first terminal of the input voltage source and the output node of the second switching network, and a blocking state, the third device of the second switching network having an input terminal for receiving a third control signal which determines whether the third device of the second switching network is in its conducting state or its blocking state, and

iv) having a fourth device having a conducting state for creating a current path between the second terminal of the input voltage source and the output node of the source switching network, and a blocking state, the fourth device of the second switching network having an input terminal for receiving a fourth control signal which determines whether the fourth device of the second switching network is in its conducting state or its blocking state;

d) a first transformer, the first transformer

i) having a primary winding coupled between the output node of the first switching network and the node of the divider circuit, and

ii) having a secondary winding inductively coupled with the primary winding;

e) a second transformer, the second transformer

i) having a primary winding coupled between the output node of the second switching network and the node of the divider circuit, and

ii) having a secondary winding inductively coupled with the primary winding of the second transformer, the secondary winding of the second transformer connected in series with the secondary winding of the first transformer thereby forming a series connection of secondary windings having a first terminal node and a second terminal node,

wherein the output voltage appears across the first and second terminal nodes; and

f) a first inductor coupled between the output node of the first switching network and the node of the divider circuit and a second inductor coupled between the output node of the second switching network and the node of the divider circuit.

7. An apparatus for converting an input DC voltage from an input DC, voltage source having a first terminal and a second terminal, to an output voltage, the apparatus comprising:

a) a divider circuit, the divider circuit

i) including a first capacitor and a second capacitor coupled in series thereby defining a node therebetween, and

ii) coupled across the first and second terminals of the input DC voltage source;

b) a first switching network, the first switching network

i) coupled across the first and second terminals of the input DC voltage source,

ii) having an output node,

iii) having a first device having a conducting state for creating a current path between the is first terminal of the input voltage source and the output node, and a blocking state, the first device having an input terminal for receiving a first control signal which determines whether the first device is in its conducting state or its blocking state, and

iv) having a second device having a conducting state for creating a current path between the second terminal of the input voltage source and the output node and a blocking state, the second device having an input terminal for receiving a second control signal which determines whether the second device is in its conducting state or its blocking state;

c) a second switching network, the second switching network

i) coupled across the first and second terminals of the input DC voltage source,

ii) having an output node,

iii) having a third device having a conducting state for creating a current path between the first terminal of the input voltage source and the output node of the second switching network, and a blocking state, the third device of the second switching network having an input terminal for receiving a third control signal which determines whether the third device of the second switching network is in its conducting state or its blocking state, and

iv) having a fourth device having a conducting state for creating a current path between the second terminal of the input voltage source and the output node of the second switching network, and a blocking state, the fourth device of the second switching network having an input terminal for receiving a fourth control signal which determines whether the fourth device of the second switching network is in its conducting state or its blocking state;

d) a first transformer, the first transformer

i) having a primary winding coupled between the output node of the first switching network and the node of the divider circuit, and

ii) having a secondary winding inductively coupled with the primary winding;

e) a second transformer, the second transformer

i) having a primary winding coupled between the output node of the second switching network and the node of the divider circuit, and

ii) having a secondary winding inductively coupled with the primary winding of the second transformer, the secondary winding of the second transformer connected in series with the secondary winding of the first transformer thereby forming a series connection of secondary windings having a first terminal node and a second terminal node,

wherein the output voltage appears across the first and second terminal nodes, and

wherein a relative phase between a current induced on the secondary winding of the first transformer and a current induced on the secondary winding of the second transformer affects the output voltage appearing across the first and second terminal nodes such that the output voltage varies with respect to a fixed voltage of the node of the divider circuit when the relative phase is varied.

8. The apparatus of claim 7 wherein each of the first and second devices of the of the first switching network and the third and fourth devices of the second switching network includes a controllable switch and wherein the output node of the first switching network is formed between the first and second devices of the first switching network and the output node of the second switching network is formed between the third and fourth devices of the second switching network.

9. The apparatus of claim 8 wherein each of the controllable switches includes a MOSFET having a gate serving as the input terminal.

10. The apparatus of claim 8 wherein each of the first and second devices of the first switching network and the third and fourth devices of the second switching network include a resonant tank circuit connected across its controllable switch.

11. The apparatus of claim 10 wherein each of the resonant tank circuits includes a capacitor with an anti-parallel diode.

12. The apparatus of claim 7 further comprising:

f) a rectifier coupled with the first terminal node and the second terminal node of the series connection of the secondary windings and providing an output DC voltage; and

g) a controller, the controller

i) having an input coupled with the output DC voltage, and

ii) providing the first, second, third, and fourth control signals to the input terminals of the first and second devices of the first switching network and the third and fourth devices of the second switching network, respectively, based on a comparison of the output DC voltage with a setpoint DC output voltage.

13. The apparatus of claim 12 wherein the rectifier includes a filtering device.

14. The apparatus of claim 12 wherein the controller provides the first, second, third, and fourth control signals in a sequence of eight states wherein,

in a first of the eight states, each of the first device of the first switching network and the fourth device of the second switching network is in its conducting state and each of the second device of the first switching network and the third device of the second switching network is in its blocking state,

in a second of the eight states, the first device of the first switching network is in its conducting state and each of the second device of the first switching network and the third and fourth devices of the second switching network is in its blocking state,

in a third of the eight states, each of the first device of the first switching network and the third device of the second switching network is in its conducting state and each of the second device of the first network and the third and fourth devices of the second network is in its blocking state,

in a fourth of the eight states, each of the first and second devices of the first switching network and the fourth device of the second switching network is in its blocking state and the third device of the second switching network is in its conducting state,

in a fifth of the eight states, each of the first device of the first switching network and fourth device of the second switching network is in its blocking state and each of the second device of the first switching network and the third device of the second switching network is in its conducting state,

in a sixth of the eight states, the second device of the first switching network is in its conducting state and each of the first device of the first switching network and the third and fourth devices of the second switching network is in its blocking state,

in a seventh of the eight states, each of the first device of the first network and the third device of the second network is in its blocking state and each of the second device of the first network and the fourth device of the second network is in its conducing state, and

in an eighth of the eight states, each of the first and second devices of the first switching network and the third device of the second switching network is in its blocking state and the fourth device of the second switching network is in its conducting state.

15. The apparatus of claim 12 wherein the first, second, third and fourth control signals are square waves having a duty cycle of less than 50%, wherein the first control signal is approximately 180°

out of phase with the second control signal whereby the first and second devices of the first switching network cannot be in their conducting states simultaneously and wherein the third control signal is approximately 180°

out of phase with the fourth control signal, whereby the third and fourth devices of the second switching network cannot be in their conducting states simultaneously.

16. The apparatus of claim 15 wherein the first, second, third and fourth control signals are provided at a fixed frequency.

17. The apparatus of claim 16 wherein the controller adjusts the first, second, third and fourth control signals based on the comparison of the output DC voltage with the setpoint DC output voltage by shifting the phases of the first and second signals with respect to the phases of the third and fourth signals, respectively.

18. The apparatus of claim 12 wherein the first and second switching networks are of a type selected from a group consisting of half-bridge inverters, full-bridge inverters, and push-pull inverters.