Centralized controller and power manager for on-board power systems

• US 7,847,532 B2
• Filed: 01/22/2008
• Issued: 12/07/2010
• Est. Priority Date: 01/19/2007
• Status: Active Grant

• Current Assignee: Astec International Limited (Emerson Electric Company)
• Original Assignee: Astec International Limited (Emerson Electric Company)
• Inventors: Mao, Hong, Potter, Geoffrey
• Primary Examiner(s): Patel; Rajnikant B
• Application Number:
  US12/009,837
• Publication Number:
  US 20080238393A1
• Time in Patent Office: 1,050 Days
• Field of Search: 323282-289, 323/239, 323/267, 323/272, 363/89, 363/95, 363/97, 363/98, 363/132, 307/75, 307/82, 307/66
• US Class Current: 323/283
• CPC Class Codes: G06F 1/26 Power supply means, e.g. regulation thereof for memories G11C
• CPC Class Codes: H02J 1/08 Three-wire systems; Systems having more than three wires
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 1/008 Plural converter units for generating at two or more independent and non-parallel outputs, e.g. systems with plural point of load switching regulators
• CPC Class Codes: H02M 3/157 with digital control

Abstract

A controller for controlling a plurality of DC-DC switching cells each configured to generate an output voltage in response to receiving a PWM control signal from the controller. The controller includes a plurality of output ports for outputting a plurality of PWM control signals, and at least one input port for receiving a plurality of output voltages from the plurality of switching cells. The controller is configured to sample the plurality of output voltages one at a time via a multiplexer and to regulate the output voltages in response to the sampling.

Claims

1. A controller for controlling a plurality of DC-DC switching cells, each switching cell configured to generate an output voltage in response to receiving a PWM control signal from the controller, the controller comprising a plurality of output ports for outputting a plurality of PWM control signals, and at least one input port for receiving a plurality of output voltages from the plurality of switching cells, the controller configured to sample the plurality of output voltages one at a time via a multiplexer and to regulate the output voltages in response to the sampling.

2. The controller of claim 1 further configured to sample the plurality of output voltages in a sequence.

3. The controller of claim 1 further configured to regulate the output voltages by adjusting the PWM control signals in response to the sampling.

4. The controller of claim 1 further comprising at least one additional input port for receiving an output voltage from one of the plurality of switching cells.

5. The controller of claim 4 wherein the controller is configured to sample the output voltage received at said additional input port substantially continuously.

6. The controller of claim 4 further comprising a digital filter to determine an adjustment to the output voltage received by the additional input port.

7. The controller of claim 1 wherein the at least one input port includes a plurality of input ports, wherein the controller comprises the multiplexer, and wherein the multiplexer includes a plurality of inputs coupled to the plurality of input ports.

8. The controller of claim 7 further comprising an analog to digital converter having an input coupled to an output of the multiplexer.

9. The controller of claim 1 further comprising a firmware-based filter algorithm to determine an adjustment to the output voltage.

10. The controller of claim 1 further configured to perform monitoring, sequencing and margining functions for the plurality of switching cells.

11. The controller of claim 1 further comprising at least one operating parameter input port for receiving a plurality of operating parameter signals from the plurality of switching cells.

12. The controller of claim 11 further configured to sample the plurality of operating parameter signals one at a time via a multiplexer.

13. The controller of claim 1 wherein the controller comprises a digital controller.

14. The controller of claim 1 wherein the controller is configured as a controller module for attachment to a circuit board.

28. The controller of claim 14 further comprising at least one operating parameter input port for receiving a plurality of operating parameter signals from the plurality of switching cells, and a multiplexer coupled to the at least one operating parameter input port, the controller configured to sample the plurality of operating parameter signals one at a time via the multiplexer coupled to the at least one operating parameter input port.

29. The controller of claim 28 further configured to sample the plurality of output voltages in a sequence and configured to regulate the output voltages by adjusting the PWM control signals in response to the sampling.

30. The controller of claim 29 further comprising at least one additional input port for receiving an output voltage from one of the plurality of switching cells, and wherein the controller is further configured to sample the output voltage received at said additional input port substantially continuously.

31. The controller of claim 30 further configured to perform monitoring, sequencing and margining functions for the plurality of switching cells.

32. The controller of claim 31 further configured to sample the plurality of output voltages in a sequence and configured to regulate the output voltages by adjusting the PWM control signals in response to the sampling.

15. A controller for controlling a plurality of DC-DC switching cells, each switching cell configured to generate an output voltage in response to receiving a PWM control signal from the controller, the controller comprising a plurality of output ports for outputting a plurality of PWM control signals to the plurality of switching cells, and at least one input port for receiving one or more output voltages from the plurality of switching cells, the controller configured to configured to perform monitoring, sequencing and/or margining functions for the plurality of switching cells.

33. The controller of claim 15 wherein the controller is configured as a controller module for attachment to a circuit board.

34. The controller of claim 33 further comprising at least one operating parameter input port for receiving a plurality of operating parameter signals from the plurality of switching cells.

35. The controller of claim 34 further configured to sample the plurality of operating parameter signals one at a time via a multiplexer.

36. The controller of claim 34 further configured to sample the one or more output voltages one at a time via a multiplexer and to regulate the output voltages in response to the sampling.

37. The controller of claim 36 further comprising at least one additional input port for receiving an output voltage from one of the plurality of switching cells, and wherein the controller is further configured to sample the output voltage received at said additional input port substantially continuously.

16. A DC-DC power converter comprising a switch, a rectifier, and an output filter coupled to the rectifier for generating a DC output voltage from a DC input voltage, a first output port for outputting the DC output voltage, a second output port for outputting a first PWM control signal to a first switching cell, and a controller for controlling said switch and generating said first PWM control signal.

38. The DC-DC power converter of claim 16 further comprising an input port for receiving an output voltage of the switching cell.

39. The DC-DC power converter of claim 38 wherein the controller is further configured to regulate the output voltage of the switching cell by adjusting the PWM control signal.

40. The DC-DC power converter of claim 16 further comprising a third output port for outputting a second PWM control signal to a second switching cell, the controller further configured for generating the second PWM control signal.

41. The DC-DC power converter of claim 40 further comprising at least one input port for receiving an output voltage of the first switching cell and an output voltage of the second switching cell, the controller further configured to regulate the output voltage of the first switching cell and the output voltage of the second switching cell by adjusting the first PWM control signal and the second PWM control signal.

17. A method of using a single controller to control a plurality of DC-DC switching cells each configured to generate an output voltage in response to a PWM control signal from the controller, the method comprising providing a PWM control signal to each of the switching cells, receiving via a multiplexer a plurality of output voltages from the plurality of switching cells, sampling the received plurality of output voltages one at a time, and adjusting the PWM control signal for one of said switching cells in response to its sampled output voltage.

18. The method of claim 17 wherein the switching cells are switching cell modules.

19. The method of claim 17 wherein the controller is a controller module.

20. The method of claim 17 wherein the controller comprises a digital controller.

21. The method of claim 17 wherein sampling the plurality of output voltages includes sampling the plurality of output voltages in a sequence.

22. The method of claim 17 wherein adjusting one of said PWM control signals includes adjusting the duty cycle of the PWM control signal by a predetermined amount.

23. The method of claim 17 wherein adjusting includes adjusting said PWM control signal for one of said switching cells when its sampled output voltage is outside a predetermined range.

24. The method of claim 23 wherein adjusting further includes adjusting the duty cycle of said PWM control signal for one of said switching cells by a predetermined amount when its sampled output voltage is outside the predetermined range.

25. The method of claim 24 wherein the predetermined amount is an amount calculated to change the sampled output voltage by approximately half of the predetermined range.

26. The method of claim 17 wherein the controller includes the multiplexer.

27. The method of claim 17 wherein the multiplexer is external to the controller.

42. The method of claim 18 wherein the controller is a controller module.

43. The method of claim 42 wherein adjusting includes adjusting the duty cycle of said PWM control signal for one of said switching cells by a predetermined amount when its sampled output voltage is outside a predetermined range.

44. The method of claim 24 wherein the predetermined amount is an amount calculated to change the sampled output voltage by approximately half of the predetermined range.