Power conversion regulator with predictive energy balancing

• US 7,642,758 B2
• Filed: 11/06/2006
• Issued: 01/05/2010
• Est. Priority Date: 11/07/2005
• Status: Active Grant

• Current Assignee: CogniPower, LLC
• Original Assignee: Lawson Labs, Inc.
• Inventors: Morong, William H., Lawson, Thomas E.
• Primary Examiner(s): HAN, YOUNGHUIE JESSICA
• Application Number:
  US11/593,702
• Publication Number:
  US 20070103122A1
• Time in Patent Office: 1,156 Days
• Field of Search: 363/13, 363/15, 363/16, 363/21.01, 363/131, 323205-211, 323282-285, 323/286, 323/287, 323/290, 324/207.16, 324/207.25, 173/1, 173/2, 173/217, 318/254, 318/701
• US Class Current: 323/206
• CPC Class Codes: G05F 1/46 wherein the variable actually regulated by the final control device is dc G05F1/625 takes precedence
• 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
• CPC Class Codes: H03F 1/083 in transistor amplifiers H03F1/10 - H03F1/22 take precedence
• CPC Class Codes: H03F 1/14 by use of neutralising means
• CPC Class Codes: H03F 1/26 Modifications of amplifiers to reduce influence of noise generated by amplifying elements
• CPC Class Codes: H03F 1/342 in field-effect transistor amplifiers
• CPC Class Codes: H03F 2200/114 the amplifier comprising means for electro-magnetic interference [EMI] protection
• CPC Class Codes: H03F 2200/153 Feedback used to stabilise the amplifier
• CPC Class Codes: H03F 2200/459 Ripple reduction circuitry being used in an amplifying circuit
• CPC Class Codes: H03F 2200/534 Transformer coupled at the input of an amplifier
• CPC Class Codes: H03F 3/45475 using IC blocks as the active amplifying circuit
• CPC Class Codes: H03F 3/50 Amplifiers in which input is applied to, or output is derived from, an impedance common to input and output circuits of the amplifying element, e.g. cathode follower

Abstract

A power-conversion regulator comprising an inductive reactor, an output filter reactor, and a switch for admitting energy to the inductive reactor, additionally comprises computation circuitry responsive to the flux in the inductive reactor, to a reference signal, to an output voltage, and sometimes to an output load current, for computing the quantity of energy that must be supplied to a load and to the output filter reactor to regulate the output voltage or current to a desired relationship with the reference signal during each chopping waveform cycle driving the switch. As the inductive reactor is charged from an input energy source, the computation circuitry predicts whether the energy in the inductive reactor has become adequate for the regulation.

Claims

1. A power-conversion regulator comprising;

an input adapted to receive energy from an energy source;

an inductive reactor for temporary energy storage;

an output reactor for output filtration;

an output adapted to supply energy to a load;

a reference signal to which the output is compared to provide a desired output;

control circuitry for controlling the charging of the inductive reactor so that the amount of energy placed into the inductive reactor during inductive reactor charging is based approximately upon a per-chopping-cycle load energy requirement; and

turn-around circuitry is provided to terminate charging of the inductive reactor when the time available for inductive discharge decreases such that additional charge time yields a decrease in the amount of inductive energy that may be withdrawn within the chopping cycle.

2. The regulator of claim 1 wherein the per-chopping-cycle load energy requirement is based upon prediction of said requirement.

3. The regulator of claim 1 wherein the amount of energy placed into the inductor to satisfy the per-chopping-cycle load energy requirement is controlled in response to measured inductive reactor magnetic flux, predicted inductive reactor magnetic flux, measured inductive reactor current, or predicted inductive reactor current.

4. The regulator of claim 1 further comprising flux-determining circuitry to produce a flux signal having a known mathematical relationship to the energy held in the inductive reactor'"'"'s magnetic field.

5. The regulator of claim 4 further comprising output signal-conditioning circuitry to produce an output signal having a known mathematical relationship to the voltage or current at said regulator'"'"'s output.

6. The regulator of claim 4 wherein the flux-determining circuitry comprises a Hall-effect sensor, a GMR sensor, or a circuit to sense current in the inductive reactor.

7. The regulator of claim 6, wherein the flux-determining circuitry is a circuit to sense current in the inductive reactor which is further comprised of a sampling resistor in series with the inductive reactor, a current transformer having one winding in series with the inductive reactor, or a current mirror.

8. The regulator of claim 1, wherein said regulator comprises flux-determining circuitry that computes the field of said inductive reactor based on the voltage-time product having been applied to the inductive reactor.

9. The regulator of claim 8, wherein said flux-determining circuitry is used to adjust the time duration of application of an input voltage to correct the amount of energy being placed into the inductive reactor.

10. The regulator of claim 1, wherein said regulator is a DC-to-DC power converter, an AC-to-AC power converter, an AC-to-DC power converter, or a DC-to-AC power converter.

11. The regulator of claim 1, wherein said regulator is synchronous or asynchronous.

12. The regulator of claim 1, wherein said regulator regulates a flyback, buck, boost or sepic type power converter.

13. The regulator of claim 1 wherein the inductive reactor is an inductor, transformer, motor or flywheel.

14. The regulator of claim 1 wherein the regulator is a single-phase or multiphase power converter.

15. The regulator of claim 1, wherein the control circuitry is digital or analog.

16. The regulator of claim 1, comprising circuitry for determining total output capacitance, said circuitry being an explicit capacitance meter or implicitly calculating capacitance based on other measured values in the regulator.

17. The regulator of claim 1, comprising circuitry for determining its internal inductance, said internal inductance being determined by an explicit inductance meter or implicitly calculated based on other measured values in the regulator.

18. The regulator of claim 1, comprising circuitry for determining its load current, in the presence or absence of load reactance.

19. The regulator of claim 18 comprising at least one current transformer.

20. The regulator of claim 1, comprising circuitry for predicting energy to be consumed by a load during any fraction of a chopping period.

21. The regulator of claim 1 wherein the control circuit includes computational circuitry driving at least one switch, the switch controlling charging of the inductive reactor.

22. The regulator of claim 21 wherein the switch is a MOSFET, IGBT, BJT, thyristor, or saturable reactor.

23. The regulator of claim 20 wherein the switches are optically, electromagnetically, or galvanically isolated from the computational circuitry.

24. The regulator of claim 1 wherein the output reactor is substantially capacitive or inductive.

25. A method of regulating a power converter comprising the steps of:

at a point in a chopping cycle of said regulator estimating the amount of load energy required to maintain the output of a regulator at a desired voltage or current for the cycle;

charging an inductive reactor with energy;

determining or estimating the amount of stored energy contained within the field of the inductive reactor;

comparing the amount of load energy with the amount of stored energy;

controlling the charging of the inductive reactor to cause the stored energy to be sufficient to provide the load energy; and

delivering to said output at least a portion of the stored energy in the field of the inductive reactor.

26. The method of claim 25 wherein the stored energy contained within the field of the inductive reactor is approximately calculated as:

KE=(L*I²)/2

where;

KE is the stored energy in the inductive reactor

I is current in amperes in the inductive reactor

L is inductance stored of the inductive reactor.

27. The method of claim 25 wherein the load energy required for the remainder of the cycle is calculated as the sum of the energy supplied or used by a filter capacitor and the energy required by the load, wherein the filter capacitor is the sum of the internal capacitance of the regulator and external capacitance of the load.