Hold-up time enhancement circuit for LLC resonant converter

• US 9,143,040 B2
• Filed: 03/03/2014
• Issued: 09/22/2015
• Est. Priority Date: 04/11/2012
• Status: Active Grant

• Current Assignee: Astec International Limited (Emerson Electric Company)
• Original Assignee: Tai Keung Lee
• Inventors: Lee, Tai Keung
• Primary Examiner(s): Behm, Harry
• Application Number:
  US14/195,506
• Publication Number:
  US 20140247626A1
• Time in Patent Office: 568 Days
• Field of Search: 363/16
• US Class Current: 1/1
• CPC Class Codes: H02M 1/0096 Means for increasing hold-up time, i.e. the duration of time that a converter's output will remain within regulated limits following a loss of input power
• 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 3/33523 with galvanic isolation between input and output of both the power stage and the feedback loop
• CPC Class Codes: H02M 3/3353 having at least two simultaneously operating switches on the input side, e.g. "double forward" or "double (switched) flyback" converter
• 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
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier

Abstract

An open loop half-bridge LLC power converter includes circuitry to reliably increase hold-up time without sacrificing efficiency. An LLC resonant circuit includes resonant inductance, a primary transformer winding, and resonant capacitance. An auxiliary circuit includes an auxiliary transformer winding, an inductor, and a third switching element coupled in series. A controller is coupled across a voltage sensor and effective thereby to determine a holdup time condition. In a “normal” operating condition the controller generates switch driver signals to turn OFF the third switching element and disable the auxiliary circuit, and in a hold-up time condition the controller turns ON the third switching element and enables the auxiliary circuit wherein the output voltage is increased via current supplied from the auxiliary winding. In various embodiments the auxiliary winding may be an auxiliary primary or secondary, or a secondary to an auxiliary primary winding of a second transformer.

Claims

1. A power conversion system comprising:

first and second switching elements coupled in series across first and second power input terminals;

an LLC resonant circuit coupled between the first and second switching elements and comprising a first inductor, a primary winding of a transformer, and one or more resonant capacitors;

an output circuit comprising one or more secondary transformer windings and a bulk capacitor coupled across first and second output terminals;

a voltage sensor;

a hold-up time enhancement circuit comprising an auxiliary primary winding of the transformer, a second inductor coupled on a first end to the auxiliary primary winding, and a third switching element coupled to a second end of the second inductor;

a controller coupled to the voltage sensor and effective to determine a hold-up time condition based on a voltage across the voltage sensor;

wherein the controller is further effective in a first operating mode associated with a normal condition to generate switch driver signals to turn OFF the third switching element and disable the hold-up time enhancement circuit; and

the controller is further effective in a second operating mode associated with a hold-up time condition to generate switch driver signals to turn ON the third switching element and enable the hold-up time enhancement circuit wherein an output voltage across the first and second output terminals is increased via current supplied from the auxiliary primary winding.

2. The system of claim 1, wherein the auxiliary primary winding is coupled on a second end to circuit ground, and wherein the third switching element is coupled on a first end to the second inductor and on a second end to circuit ground.

3. The system of claim 2, further comprising a fourth switching element coupled between the second end of the auxiliary primary winding and circuit ground.

4. The system of claim 2, the hold-up time enhancement circuit further comprising a diode having an anode coupled to the second end of the second inductor and a cathode coupled to the first end of the third switching element.

5. The system of claim 1, the hold-up time enhancement circuit further comprising first and second diodes in each of first and second branches of a diode bridge, wherein the anodes of each of the first diodes are coupled to circuit ground, the cathodes of each of the second diodes are coupled to the first end of the second inductor, and opposing ends of the auxiliary primary winding are coupled between the first and second diodes of the first and second branches, respectively.

6. The system of claim 1, the output circuit comprising first and second secondary windings coupled in series, opposing ends of the secondary windings coupled to the first output terminal, and a center tap between the secondary windings coupled to the second output terminal.

7. A power conversion system comprising:

first and second switching elements coupled in series across first and second power input terminals;

an LLC resonant circuit coupled between the first and second switching elements and comprising a first inductor, a primary winding of a transformer, and one or more resonant capacitors;

an output circuit comprising one or more secondary transformer windings, and a bulk capacitor coupled across first and second output terminals;

a voltage sensor;

a hold-up time enhancement circuit comprising an auxiliary secondary winding of the transformer coupled in series with a second inductor and a third switching element; and

a controller coupled to the voltage sensor and effective to determine a hold-up time condition based on a voltage across the voltage sensor, wherein the controller is further effective in a first operating mode associated with a normal condition to generate switch driver signals to turn OFF the third switching element and disable the hold-up time enhancement circuit, the controller is further effective in a second operating mode associated with a hold-up time condition to generate switch driver signals to turn ON the third switching element and enable the hold-up time enhancement circuit to maintain an output voltage across the first and second output terminals at or above a threshold for a period of time during the hold-up time condition, and the hold-up time enhancement circuit is not coupled across the first and second output terminals.

8. The system of claim 7, wherein the auxiliary secondary winding is coupled on a first end to the second inductor and on a second end to the second output terminal, further wherein the third switching element is coupled on a first end to the second inductor and on a second end to the second output terminal.

9. The system of claim 7, further comprising a fourth switching element coupled to the auxiliary secondary winding.

10. The system of claim 7, the hold-up time enhancement circuit further comprising a diode having an anode coupled to the second end of the second inductor and a cathode coupled to the first end of the third switching element.

11. The system of claim 7, the hold-up time enhancement circuit further comprising first and second diodes in each of first and second branches of a diode bridge, wherein the anodes of each of the first diodes are coupled to the second output terminal, the cathodes of each of the second diodes are coupled to the first end of the second inductor, and opposing ends of the auxiliary secondary winding are coupled between the first and second diodes of the first and second branches, respectively.

12. The system of claim 7, the output circuit comprising first and second secondary windings coupled in series, opposing ends of the secondary windings coupled to the first output terminal, and a center tap between the secondary windings coupled to the second output terminal.

13. A power conversion system comprising:

first and second switching elements coupled in series across first and second power input terminals;

an LLC resonant circuit coupled between the first and second switching elements and comprising a first inductor, a primary winding of a first transformer, and one or more resonant capacitors;

a primary winding of a second transformer coupled in parallel with the primary winding of the first transformer;

an output circuit comprising one or more secondary transformer windings of the first transformer and a bulk capacitor coupled across first and second output terminals;

a voltage sensor;

a hold-up time enhancement circuit further comprising a secondary winding of the second transformer as an auxiliary winding, a second inductor coupled on a first end to the auxiliary winding, and a third switching element coupled to a second end of the second inductor; and

a controller coupled to the voltage sensor and effective to determine a hold-up time condition based on a voltage across the voltage sensor, wherein the controller is further effective in a first operating mode associated with a normal condition to generate switch driver signals to turn OFF the third switching element and disable the hold-up time enhancement circuit, and the controller is further effective in a second operating mode associated with a hold-up time condition to generate switch driver signals to turn ON the third switching element and enable the hold-up time enhancement circuit to maintain an output voltage across the first and second output terminals at or above a threshold for a period of time during the hold-up time condition.

14. The system of claim 13, wherein the auxiliary winding is coupled on a first end to the second inductor and on a second end to circuit ground, further wherein the third switching element is coupled on a first end to the second inductor and on a second end to circuit ground.

15. The system of claim 14, the hold-up time enhancement circuit further comprising a diode having an anode coupled to the second end of the second inductor and a cathode coupled to the first end of the third switching element.

16. The system of claim 15, the output circuit comprising first and second secondary windings coupled in series, opposing ends of the secondary windings coupled to the first output terminal, and a center tap between the secondary windings coupled to the second output terminal.

17. The system of claim 16, wherein the auxiliary winding is coupled on a first end to the second inductor and on a second end to the first output terminal, further wherein the third switching element is coupled on a first end to the second inductor and on a second end to circuit ground.

18. The system of claim 13, wherein the auxiliary winding is coupled on a first end to the second inductor and on a second end to the first output terminal.

19. The system of claim 13, the hold-up time enhancement circuit further comprising first and second diodes in each of first and second branches of a diode bridge, the anodes of each of the first diodes coupled to circuit ground, the cathodes of each of the second diodes coupled to the first end of the second inductor, and opposing ends of the auxiliary winding coupled between the first and second diodes of the first and second branches, respectively.

20. A power conversion system comprising:

first and second switching elements coupled in series across first and second power input terminals;

an LLC resonant circuit coupled between the first and second switching elements and comprising a first inductor, a primary winding of a transformer, and one or more resonant capacitors;

an output circuit comprising one or more secondary transformer windings and a bulk capacitor coupled across a first output terminal and a second output terminal;

a voltage sensor;

a hold-up time enhancement circuit comprising a second inductor, an auxiliary secondary winding of the transformer coupled in series with the second inductor, a third switching element, and first and second diodes in each of first and second branches of a diode bridge, anodes of each of the first diodes coupled to the second output terminal, cathodes of each of the second diodes coupled to the second inductor, opposing ends of the auxiliary secondary winding coupled between the first and second diodes of the first and second branches, respectively; and

a controller coupled to the voltage sensor and effective to determine a hold-up time condition based on a voltage across the voltage sensor, wherein the controller is further effective in a first operating mode associated with a normal condition to generate switch driver signals to turn OFF the third switching element and disable the hold-up time enhancement circuit, and the controller is further effective in a second operating mode associated with a hold-up time condition to generate switch driver signals to turn ON the third switching element and enable the hold-up time enhancement circuit to maintain an output voltage across the first and second output terminals at or above a threshold for a period of time during the hold-up time condition.

21. A power conversion system comprising:

first and second switching elements coupled in series across first and second power input terminals;

an LLC resonant circuit coupled between the first and second switching elements and comprising a first inductor, a primary winding of a transformer, and one or more resonant capacitors;

an output circuit comprising first and second secondary transformer windings coupled in series and a bulk capacitor coupled across a first output terminal and a second output terminal, opposing ends of the secondary transformer windings coupled to the first output terminal, the secondary transformer windings including a center tap coupled to the second output terminal;

a voltage sensor;

a hold-up time enhancement circuit comprising a second inductor, an auxiliary secondary winding of the transformer coupled in series with the second inductor and a third switching element, the auxiliary secondary winding coupled on a first end to the second inductor and on a second end to the first output terminal, the third switching element coupled on a first end to the second inductor and on a second end to the second output terminal; and

a controller coupled to the voltage sensor and effective to determine a hold-up time condition based on a voltage across the voltage sensor, wherein the controller is further effective in a first operating mode associated with a normal condition to generate switch driver signals to turn OFF the third switching element and disable the hold-up time enhancement circuit, and the controller is further effective in a second operating mode associated with a hold-up time condition to generate switch driver signals to turn ON the third switching element and enable the hold-up time enhancement circuit to maintain an output voltage across the first and second output terminals at or above a threshold for a period of time during the hold-up time condition.