Apparatus, system and method for cascaded power conversion

• US 7,952,294 B2
• Filed: 04/06/2008
• Issued: 05/31/2011
• Est. Priority Date: 04/06/2008
• Status: Active Grant

• Current Assignee: Chemtron Research LLC (Intellectual Ventures LLC)
• Original Assignee: Exclara, Inc. (Million Star Technology Ltd.)
• Inventors: Lehman, Bradley M., Rodriguez, Harry, Shteynberg, Anatoly
• Primary Examiner(s): Vu; David Hung
• Application Number:
  US12/098,443
• Publication Number:
  US 20090251934A1
• Time in Patent Office: 1,150 Days
• Field of Search: 315/307, 315/308, 315/291, 315/224, 315/227.R, 315/240, 315/242, 315/241.R, 315/243, 315/244, 323/282, 323/285, 323/284, 323/234, 323/265
• US Class Current: 315/224
• CPC Class Codes: H02M 3/155 using semiconductor devices only
• CPC Class Codes: H02M 3/157 with digital control
• CPC Class Codes: H05B 45/3725 Switched mode power supply [SMPS]

Abstract

An apparatus method and system are provided for power conversion, to supply power to a nonlinear load such as a plurality of light emitting diodes. An exemplary apparatus comprises a first power converter stage, a second power converter stage, a plurality of sensors such as first and second sensors, and a controller. The first power converter stage includes a power switch and a first inductor having a first inductance. The first and second sensors are both coupled to a common reference node, with the first sensor adapted to sense a first parameter of the first power converter stage, and the second sensor adapted to sense the output current level. The second power converter stage includes a second inductor having a second inductance, and is couplable to provide an output current to the nonlinear load such as LEDs. The controller is coupled to the power switch, the first sensor and the second sensor, and the controller is adapted to turn the power switch into an on state for an on-time duration substantially proportional to a ratio of the second inductance to the first inductance.

Claims

1. An apparatus for power conversion, the apparatus couplable to a nonlinear load, the apparatus comprising:

a first power converter stage comprising a power switch and a first inductor, the first inductor having a first inductance;

a first sensor coupled to the first power converter stage and coupled to a common reference node, the first sensor adapted to sense a first parameter of the first power converter stage;

a second power converter stage coupled to the first power converter stage, the second power converter stage comprising a second inductor, the second inductor having a second inductance, the second power converter stage couplable to provide an output current to the nonlinear load;

a second sensor coupled to the common reference node and couplable to the nonlinear load, the second sensor adapted to sense the output current level; and

a controller coupled to the power switch, the first sensor and the second sensor, the controller adapted to turn the power switch into an on state for an on-time duration substantially proportional to a ratio of the second inductance to the first inductance.

2. The apparatus of claim 1, wherein the on-time duration is substantially proportional to either a square root of the ratio of the second inductance to the first inductance or to a square root of one-half of the ratio of the second inductance to the first inductance.

3. The apparatus of claim 1, wherein a ratio of the on-time duration to an off-time duration is substantially constant and substantially proportional to either a square root of the ratio of the second inductance to the first inductance or a square root of one-half of the ratio of the second inductance to the first inductance.

4. The apparatus of claim 1, wherein the first parameter is an input voltage level.

5. The apparatus of claim 4, wherein the first power converter stage further comprises a first capacitor, and wherein the apparatus further comprises a third sensor coupled to the first power converter stage and adapted to sense a first capacitor voltage level, and wherein the controller is further adapted to determine a first error substantially as a difference between the input voltage level and the first capacitor voltage level, and to use the first error to adjust the on-time duration of a next switching cycle.

6. The apparatus of claim 5, wherein the controller is further adapted to determine a second error substantially as a difference between the output current level and a predetermined output current level and to use the second error to adjust the on-time duration of the next switching cycle.

7. The apparatus of claim 6, wherein the first error is determined in a comparatively fast feedback loop of the controller and the second error is determined in a comparatively slow feedback loop of the controller.

8. The apparatus of claim 4, wherein the first power converter stage further comprises a first capacitor, wherein the apparatus further comprises a third sensor coupled to the first power converter stage and adapted to sense a first capacitor voltage level, and wherein the controller is further adapted to determine a voltage ratio of the input voltage level and the first capacitor voltage level, to determine a first error substantially as a difference between the voltage ratio and a predetermined ratio substantially proportional to the first and second inductance, and to use the first error to adjust the on-time duration of a next switching cycle.

9. The apparatus of claim 4, wherein the first power converter stage further comprises a first capacitor, wherein the apparatus further comprises a third sensor coupled to the first power converter stage and adapted to sense a first capacitor voltage level, and wherein the controller is further adapted to determine a voltage ratio of the input voltage level and the first capacitor voltage level, to determine a first error substantially as a difference between the voltage ratio and a predetermined ratio, and to use the first error to adjust the on-time duration of a next switching cycle, wherein the predetermined ratio is substantially proportional to either a square root of the ratio of the second inductance to the first inductance or a square root of one-half of the ratio of the second inductance to the first inductance.

10. The apparatus of claim 4, wherein the controller is further adapted to integrate the input voltage level, and when the integrated voltage level is substantially equal to a difference between the sensed output current level and a predetermined output current level, to turn the power switch into an off state for an off-time duration proportional to a difference between the switching cycle time and the on-time duration.

11. The apparatus of claim 1, wherein the controller is coupled to the power switch through a buffer circuit.

12. The apparatus of claim 1, wherein a switching cycle time is substantially constant and substantially proportional to a minimum input voltage substantially sufficient for both the first power converter stage and the second power converter stage to operate in a critical conduction mode.

13. The apparatus of claim 1, wherein the controller is further adapted to maintain the output current provided by the second power converter stage between a first threshold and a second threshold by incrementing or decrementing a next on-time duration by an amount Δ

t_on, wherein Δ

t_on is substantially proportional to

14. The apparatus of claim 1, wherein the apparatus further comprises a third sensor coupled to the second power converter stage and adapted to sense a second stage output current level, and wherein the controller is further adapted to turn the power switch into an off state when the sensed second stage output current level has reached substantially a predetermined peak current level, to determine an actual on-time duration of the current cycle, and when the sensed second stage output current level has decreased substantially to zero, to determine an actual switching time period and reset time period of the current switching cycle.

15. The apparatus of claim 14, wherein the controller is further adapted to determine the on-time duration t_on0 for a next switching cycle, wherein t_on0 is substantially proportional to

16. The apparatus of claim 1, wherein the first sensor is a first resistor and wherein the second sensor is a second resistor, and wherein the first and second resistors are coupled to the common reference node having a ground potential.

17. The apparatus of claim 16, wherein the first power converter stage further comprises:

a first diode couplable to an input voltage and coupled to the first inductor;

a first capacitor coupled to the power switch; and

wherein the power switch is coupled to the first inductor, the first capacitor, and the first resistor.

18. The apparatus of claim 17, wherein the second power converter stage is coupled to the power switch through the first resistor.

19. The apparatus of claim 18, wherein the second power converter stage further comprises:

a second diode coupled to the second inductor;

a second capacitor coupled to the second diode and couplable to the nonlinear load; and

wherein the second resistor is coupled to the first resistor at the common reference node.

20. The apparatus of claim 19, wherein the first power converter stage further comprises a third diode coupled between the first capacitor and the first inductor, and wherein the second power converter stage further comprises a fourth diode coupled between the second inductor and the first capacitor.

21. The apparatus of claim 17, further comprising a rectifier coupled to the first diode, coupled to the common reference node, and couplable to receive an AC input voltage.

22. The apparatus of claim 1, further comprising:

a fourth sensor coupled to the power switch and adapted to sense a first stage current level.

23. The apparatus of claim 1, wherein the first parameter is at least one of the following parameters:

an input voltage level, a first capacitor voltage level, or a first stage current level.

24. The apparatus of claim 1, further comprising:

a fifth sensor coupled to the second inductor and adapted to sense a second stage current level.

25. The apparatus of claim 1, wherein the nonlinear load is a plurality of light emitting diodes.

26. The apparatus of claim 1, wherein the controller is adapted to vary the on-time duration comparatively slowly over a plurality of switching cycles to provide a power factor substantially close to one.

27. A method of providing power conversion for a nonlinear load using a power converter comprising a power switch and a first power converter stage coupled to a second power converter stage, the first power converter stage comprising a first inductor having a first inductance and the second power converter stage comprising a second inductor having a second inductance, the method comprising:

sensing a first parameter of the first power converter stage with reference to a common potential;

turning on the power switch for an on-time duration of a switching cycle and providing an output current to the nonlinear load, the on-time duration substantially proportional to a ratio of the second inductance to the first inductance; and

sensing the output current level with reference to the common potential.

28. The method of claim 27, wherein the on-time duration is substantially proportional to either a square root of the ratio of the second inductance to the first inductance or to a square root of one-half of the ratio of the second inductance to the first inductance.

29. The method of claim 27, wherein a ratio of the on-time duration to an off-time duration is substantially constant and substantially proportional to either a square root of the ratio of the second inductance to the first inductance or a square root of one-half of the ratio of the second inductance to the first inductance.

30. The method of claim 27, wherein the first parameter is an input voltage level.

31. The method of claim 30, further comprising:

sensing a first capacitor voltage level of the first power converter stage;

determining a first error substantially as a difference between the input voltage level and the first capacitor voltage level; and

using the first error, adjusting the on-time duration of a next switching cycle.

32. The method of claim 31, further comprising:

determining a second error substantially as a difference between the output current level and a predetermined output current level; and

using the second error, adjusting the on-time duration of the next switching cycle.

33. The method of claim 30, further comprising:

sensing a first capacitor voltage level of the first power converter stage;

determining a voltage ratio of the input voltage level and the first capacitor voltage level;

determining a first error substantially as a difference between the voltage ratio and a predetermined ratio proportional to the first and second inductance; and

using the first error, adjusting the on-time duration of a next switching cycle.

34. The method of claim 30, further comprising:

sensing a first capacitor voltage level of the first power converter stage;

determining a voltage ratio of the input voltage level and the first capacitor voltage level;

determining a first error substantially as a difference between the voltage ratio and a predetermined ratio, the predetermined ratio proportional to either a square root of the ratio of the second inductance to the first inductance or a square root of one-half of the ratio of the second inductance to the first inductance; and

using the first error, adjusting the on-time duration of a next switching cycle.

35. The method of claim 30, further comprising:

integrating the input voltage level; and

when the integrated voltage level is substantially equal to a difference between the sensed output current level and a predetermined output current level, turning the power switch into an off state for an off-time duration substantially proportional to a difference between a switching cycle time and the on-time duration.

36. The method of claim 27, further comprising:

maintaining a switching cycle time substantially constant and substantially proportional to a minimum input voltage, wherein the minimum input voltage is substantially sufficient for both the first power converter stage and the second power converter stage to operate in a critical conduction mode.

37. The method of claim 27, further comprising:

maintaining the output current provided by the second power converter stage between a first threshold and a second threshold by incrementing or decrementing a next on-time duration by an amount Δ

t_on, wherein Δ

t_on is substantially proportional to

38. The method of claim 27, further comprising:

sensing a second stage output current;

turning the power switch into an off state when the sensed second stage output current level has reached substantially a predetermined peak current level;

determining an actual on-time duration of a current switching cycle; and

when the sensed second stage output current level has decreased substantially to zero, determining an actual switching time period and reset time period of the current switching cycle.

39. The method of claim 38, further comprising:

determining the on-time duration t_on0 for a next switching cycle as substantially proportional to

40. The method of claim 27, further comprising:

rectifying an AC input voltage.

41. The method of claim 27, further comprising:

sensing a first stage current level with reference to the common potential.

42. The method of claim 27, wherein the first parameter is at least one of the following parameters:

an input voltage level, a first capacitor voltage level, or a first stage current level.

43. The method of claim 27, further comprising:

sensing a second stage current level with reference to the common potential.

44. The method of claim 27, wherein the nonlinear load is a plurality of light emitting diodes.

45. The method of claim 27, further comprising:

varying the on-time duration comparatively slowly over a plurality of switching cycles to provide a power factor substantially close to one.

46. A system for power conversion, the system couplable to receive an input voltage, the system comprising:

a plurality of light emitting diodes;

a first power converter stage comprising a power switch, a first capacitor, and a first inductor, the first inductor having a first inductance;

a first sensor coupled to the first power converter stage and coupled to a common reference node, the first sensor adapted to sense a first parameter of the first power converter stage;

a second power converter stage coupled to the first power converter stage, the second power converter stage comprising a second inductor and a second capacitor, the second inductor having a second inductance, the second power converter stage coupled to the plurality of light emitting diodes to provide an output current to the plurality of light emitting diodes;

a second sensor coupled to the common reference node and to the plurality of light emitting diodes, the second sensor adapted to sense the output current level; and

a controller coupled to the power switch, the first sensor and the second sensor, the controller adapted to turn the power switch into an on state for an on-time duration substantially proportional to a ratio of the second inductance to the first inductance.

47. The system of claim 46, wherein the on-time duration is substantially proportional to either a square root of the ratio of the second inductance to the first inductance or to a square root of one-half of the ratio of the second inductance to the first inductance.

48. The system of claim 46, wherein a ratio of the on-time duration to an off-time duration is substantially constant and substantially proportional to either a square root of the ratio of the second inductance to the first inductance or a square root of one-half of the ratio of the second inductance to the first inductance.

49. The system of claim 46, wherein the first parameter is an input voltage level.

50. The apparatus of claim 49, wherein the system further comprises a third sensor coupled to the first power converter stage and adapted to sense a first capacitor voltage level, and wherein the controller is further adapted to determine a first error substantially as a difference between the input voltage level and the first capacitor voltage level, and to use the first error to adjust the on-time duration of a next switching cycle.

51. The system of claim 50, wherein the controller is further adapted to determine a second error substantially as a difference between the output current level and a predetermined output current level and to use the second error to adjust the on-time duration of the next switching cycle.

52. The system of claim 51, wherein the first error is determined in a comparatively fast feedback loop of the controller and the second error is determined in a comparatively slow feedback loop of the controller.

53. The system of claim 49, wherein the system further comprises a third sensor coupled to the first power converter stage and adapted to sense a first capacitor voltage level, and wherein the controller is further adapted to determine a voltage ratio of the input voltage level and the first capacitor voltage level, to determine a first error substantially as a difference between the voltage ratio and a predetermined ratio proportional to the first and second inductance, and to use the first error to adjust the on-time duration of a next switching cycle.

54. The apparatus of claim 49, wherein system further comprises a third sensor coupled to the first power converter stage and adapted to sense a first capacitor voltage level, and wherein the controller is further adapted to determine a voltage ratio of the input voltage level and the first capacitor voltage level, to determine a first error substantially as a difference between the voltage ratio and a predetermined ratio, and to use the first error to adjust the on-time duration of a next switching cycle, wherein the predetermined ratio is proportional to either a square root of the ratio of the second inductance to the first inductance or a square root of one-half of the ratio of the second inductance to the first inductance.

55. The system of claim 49, wherein the controller is further adapted to integrate the input voltage level, and when the integrated voltage level is substantially equal to a difference between the sensed output current level and a predetermined output current level, to turn the power switch into an off state for an off-time duration substantially proportional to a difference between the switching cycle time and the on-time duration.

56. The system of claim 46, wherein the controller is coupled to the power switch through a buffer circuit.

57. The system of claim 46, wherein a switching cycle time is substantially constant and substantially proportional to a minimum input voltage, wherein the minimum input voltage is substantially sufficient for both the first power converter stage and the second power converter stage to operate in a critical conduction mode.

58. The system of claim 46, wherein the controller is further adapted to maintain the output current provided by the second power converter stage between a first threshold and a second threshold by incrementing or decrementing a next on-time duration by an amount Δ

t_on, wherein Δ

t_on is substantially proportional to

59. The system of claim 46, wherein the apparatus further comprises a third sensor coupled to the second power converter stage and adapted to sense a second stage output current level, and wherein the controller is further adapted to turn the power switch into an off state when the sensed output current level has reached substantially a predetermined peak current level, to determine an actual on-time duration of the current cycle, and when the sensed second stage output current level has decreased substantially to zero, to determine an actual switching time period and reset time period of the current switching cycle.

60. The system of claim 46, wherein the controller is further adapted to determine the on-time duration t_on0 for a next switching cycle as substantially proportional to

61. The system of claim 46, wherein the first sensor is a first resistor and wherein the second sensor is a second resistor, and wherein the first and second resistors are coupled to the common reference node having a ground potential.

62. The system of claim 61, wherein the first power converter stage further comprises:

a first diode couplable to an input voltage and coupled to the first inductor;

a first capacitor coupled to the power switch; and

wherein the power switch is coupled to the first inductor, the first capacitor, and the first resistor.

63. The system of claim 62, wherein the second power converter stage is coupled to the power switch through the first resistor.

64. The system of claim 63, wherein the second power converter stage further comprises:

a second diode coupled to the second inductor;

a second capacitor coupled to the second diode and couplable to the nonlinear load; and

wherein the second resistor is coupled to the first resistor at the common reference node.

65. The system of claim 64, wherein the first power converter stage further comprises a third diode coupled between the first capacitor and the first inductor, and wherein the second power converter stage further comprises a fourth diode coupled between the second inductor and the first capacitor.

66. The system of claim 62, further comprising a rectifier coupled to the first diode, coupled to the common reference node, and couplable to receive an AC input voltage.

67. The system of claim 46, further comprising:

a fourth sensor coupled to the power switch and adapted to sense a first stage current level.

68. The system of claim 46, wherein the first parameter is at least one of the following parameters:

an input voltage level, a first capacitor voltage level, or a first stage current level.

69. The system of claim 46, further comprising:

a fifth sensor coupled to the second inductor and adapted to sense a second stage current level.

70. An apparatus for power conversion, the apparatus couplable to a plurality of light emitting diodes and couplable to receive an input voltage, the apparatus comprising:

a first power converter stage comprising;

a power switch;

a first capacitor coupled to the power switch;

a first inductor coupled to the power switch, the first inductor having a first inductance; and

a first diode couplable to the input voltage and coupled to the first inductor;

a first resistor coupled to the power switch and coupled to a common reference node couplable to a ground potential;

a second power converter stage coupled to the first power converter stage, the second power converter stage couplable to provide an output current to the plurality of light emitting diodes, the second power converter stage comprising;

a second inductor having a second inductance;

a second diode coupled to the second inductor and couplable to the plurality of light emitting diodes; and

a second capacitor coupled to the second diode and couplable to the plurality of light emitting diodes;

a second resistor coupled to the common reference node and couplable to the plurality of light emitting diodes; and

a controller coupled to the power switch, the first resistor and the second resistor, the controller adapted to turn the power switch into an on state for an on-time duration substantially proportional to a ratio of the second inductance to the first inductance.