Power converter with an adaptive controller and method of operating the same

• US 9,197,132 B2
• Filed: 02/25/2010
• Issued: 11/24/2015
• Est. Priority Date: 12/01/2006
• Status: Active Grant

• Current Assignee: Flextronics International USA Incorporated (Flex, Ltd.)
• Original Assignee: Flextronics International USA Incorporated (Flex, Ltd.)
• Inventors: Artusi, Daniel A., Rozman, Allen F.
• Primary Examiner(s): Laxton, Gary L
• Application Number:
  US12/712,894
• Publication Number:
  US 20110205763A1
• Time in Patent Office: 2,098 Days
• Field of Search: 363/15, 363/16, 363/21, 363/4, 363/21.06, 363/21.09, 363/21.1, 363/21.12, 363/21.14, 363/21.17, 363/97, 323/285
• US Class Current: 1/1
• CPC Class Codes: H02M 1/4225 using a non-isolated boost converter
• 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 3/33592 having a synchronous rectifier circuit or a synchronous freewheeling circuit at the secondary side of an isolation transformer
• 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

Abstract

A controller for a power converter, and method of operating the same. The controller improves power converter operating efficiency by regulating an internal power converter operating characteristic depending on a value of a power converter parameter measured after a manufacturing step, or an environmental parameter, preferably employing a table with entries dependent on the parameter value. The internal operating characteristic may be an internal bus voltage, a voltage level of a drive signal for a power switch, a number of paralleled power switches selectively enabled to conduct, or a basic switching frequency of the power converter. The controller may regulate an internal operating characteristic of the power converter using a functional relationship dependent on the parameter value. The environmental parameter may be received as a signal from an external source. The parameter measured after a manufacturing step may be a parameter measured from representative power converter(s).

Claims

1. A power converter including a power switch configured to conduct for a duty cycle and provide a regulated output characteristic at an output thereof, comprising:

a controller configured to provide a signal to control said duty cycle of said power switch as a function of said output characteristic, said controller configured to regulate an internal operating characteristic of said power converter on a time scale different from a time scale for controlling said duty cycle of said power switch and depending on a value of one of a parameter of said power converter measured after a manufacturing step and an environmental parameter for said power converter.

2. The power converter as recited in claim 1 wherein said controller is configured to regulate said internal operating characteristic of said power converter in accordance with a table with entries dependent on a value of one of said parameter of said power converter measured after said manufacturing step and said environmental parameter for said power converter.

3. The power converter as recited in claim 1 wherein said internal operating characteristic is one of an internal bus voltage, a voltage level of a drive signal for said power switch, a number of paralleled power switches selectively enabled to conduct, a temperature of a component part, or a switching frequency of said power converter.

4. The power converter as recited in claim 1 wherein said controller is configured to regulate said internal operating characteristic of said power converter in accordance with a functional relationship dependent on a value of one of said parameter of said power converter measured after said manufacturing step and said environmental parameter for said power converter.

5. The power converter as recited in claim 1 wherein said environmental parameter is received as a signal from an external source.

6. The power converter as recited in claim 1 wherein said internal operating characteristic is configured to be regulated by said controller on a slower time scale from said time scale for controlling said duty cycle of said power.

7. The power converter as recited in claim 1 wherein said parameter of said power converter measured after said manufacturing step is automatically measured in a test fixture.

8. The power converter as recited in claim 1 wherein said parameter of said power converter measured after said manufacturing step is a parameter measured from a representative power converter.

9. The power converter as recited in claim 1 wherein said controller is configured to regulate said internal operating characteristic of said power converter in a step-by-step manner during an efficiency optimization process.

10. The power converter as recited in claim 1 wherein said controller is configured to regulate said internal operating characteristic of said power converter in a step-by-step manner during an efficiency optimization process on a slower time scale from said time scale for controlling said duty cycle of said power converter.

11. A method of controlling a power converter including a power switch configured to conduct for a duty cycle and provide a regulated output characteristic at an output thereof, comprising:

providing a signal to control said duty cycle of said power switch as a function of said output characteristic, thereby regulating an internal operating characteristic of said power converter on a time scale different from a time scale for controlling said duty cycle of said power switch and depending on a value of one of a parameter of said power converter measured after a manufacturing step and an environmental parameter for said power converter.

12. The method as recited in claim 11 wherein said method regulates said internal operating characteristic of said power converter in accordance with a table with entries dependent on a value of one of said parameter of said power converter measured after said manufacturing step and said environmental parameter for said power converter.

13. The method as recited in claim 11 wherein said internal operating characteristic is one of an internal bus voltage, a voltage level of a drive signal for said power switch, a number of paralleled power switches selectively enabled to conduct, a temperature of a component part, or a switching frequency of said power converter.

14. The method as recited in claim 11 wherein said method regulates said internal operating characteristic of said power converter in accordance with a functional relationship dependent on a value of one of said parameter of said power converter measured after said manufacturing step and said environmental parameter for said power converter.

15. The method as recited in claim 11 wherein said environmental parameter is received as a signal from an external source.

16. The method as recited in claim 11 wherein said internal operating characteristic is regulated on a slower time scale from said time scale for controlling said duty cycle of said power switch.

17. The method as recited in claim 11 wherein said parameter of said power converter measured after said manufacturing step is automatically measured in a test fixture.

18. The method as recited in claim 11 wherein said parameter of said power converter measured after said manufacturing step is a parameter measured from a representative power converter.

19. The method as recited in claim 11 wherein said method regulates said internal operating characteristic of said power converter in a step-by-step manner during an efficiency optimization process.

20. The method as recited in claim 11 wherein said method regulates said internal operating characteristic of said power converter in a step-by-step manner during an efficiency optimization process on a slower time scale from said time scale for controlling said duty cycle of said power converter.