LLC converter and loss of inductive mode detection circuit

• US 9,257,913 B1
• Filed: 09/06/2014
• Issued: 02/09/2016
• Est. Priority Date: 09/06/2014
• Status: Active Grant

• Current Assignee: Texas Instruments, Inc.
• Original Assignee: Texas Instruments, Inc.
• Inventors: McDonald, Brent Alan
• Primary Examiner(s): Berhane, Adolf
• Assistant Examiner(s): Quddus, Nusrat
• Application Number:
  US14/479,279
• Time in Patent Office: 521 Days
• Field of Search: 323/282, 323/284, 363 15- 17, 363/21.02, 363/21.03, 363 39- 41, 363 97- 98, 363131-132, 363/127
• US Class Current: 1/1
• CPC Class Codes: H02M 1/0058 by employing soft switching techniques, i.e. commutation of transistors when applied voltage is zero or when current flow is zero using an auxiliary actively switched resonant commutation circuit connected to an intermediate DC voltage or between two push-pull branches of an inverter bridge H02M7/4811; in resonant inverters H02M7/4815; in inverters operating from a resonant DC source H02M7/4826
• CPC Class Codes: H02M 3/01 Resonant DC/DC converters
• CPC Class Codes: H02M 3/33571 Half-bridge at primary side of an isolation transformer
• CPC Class Codes: H02M 3/3376 with automatic control of output voltage or current
• 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

Methods, control apparatus and series resonant or LLC power conversion systems are presented in which a resonant series circuit current is compared with a threshold during a portion of a modulation switching cycle following turn on of a corresponding switching device and one or more indications or remedial actions are undertaken to modify modulation control of a switching circuit in response to a determination that the resonant current is below the threshold to facilitate our promote zero voltage switching or near-zero voltage switching and provide current reversal protection.

Claims

1. A power conversion system, comprising:

a resonant circuit, comprising;

a series circuit including at least one inductance, a transformer primary winding, and at least one capacitance coupled in series with one another between a switching node and a constant voltage node, and

a switching circuit including first and second switching devices coupled with one another between an input voltage node and the circuit ground node, the first switching device coupled between the input voltage node and the switching node and operative in a first state to selectively couple the switching node with the input voltage node and in a second state to decouple the switching node from the input voltage node according to a first switching control signal, the second switching device coupled between the switching node and the constant voltage node and operative in a first state to selectively couple the switching node with the constant voltage node and in a second state to decouple the switching node from the constant voltage node according to a second switching control signal;

a controller operatively coupled to provide the first and second switching control signals as modulated signals to the switching circuit in each of a plurality of switching cycles to modify a voltage at the switching node to control a converter output voltage;

a sensing circuit operatively coupled with the series circuit to provide a sense signal representing a resonant current flowing in the series circuit; and

a detection circuit operatively coupled with the sensing circuit to receive the sense signal and operative to selectively provide a detection signal or value to the controller in a first state if an amplitude of the sense signal is below a predetermined threshold in a predetermined portion of a given half cycle of a given one of the plurality of switching cycles and to provide the detection signal or value in a different second state if the amplitude of the sense signal is greater than or equal to the predetermined threshold in the predetermined portion of the given half cycle;

wherein the controller is operative to selectively modify the first and second switching control signals responsive to receiving the detection signal or value in the first state.

2. The power conversion system of claim 1, wherein the predetermined portion of the given half cycle begins a non-zero predetermined time after a given one of the first and second switching devices is turned on and ends before the given one of the first and second switching devices is turned off.

3. The power conversion system of claim 2, wherein the detection circuit comprises:

a comparator including a first input coupled to receive the sense signal from the sensing circuit, a second input coupled to a voltage reference representing the predetermined threshold, and a comparator output providing a comparator output signal in a first state if the amplitude of the sense signal is below an amplitude of the voltage reference and in a different second state if the amplitude of the sense signal is greater than or equal to the amplitude of the voltage reference; and

a timing circuit operatively coupled to receive the first and second switching control signals from the controller and to receive the comparator output signal from the comparator, the timing circuit operative to provide the detection signal or value in the second state for the non-zero predetermined time after the given one of the first and second switching devices is turned on, and to selectively provide the detection signal or value in the first state if the comparator output signal is in the first state after the non-zero predetermined time and before the given one of the first and second switching devices is turned off.

4. The power conversion system of claim 3, wherein the controller is operative to selectively increase a modulation switching frequency in providing the first and second switching control signals responsive to receiving the detection signal or value in the first state.

5. The power conversion system of claim 2, comprising:

an analog to digital converter receiving the sense signal and providing a sense value representing resonant current flowing in the series circuit;

at least one processor programmed to;

implement the controller by providing the first and second switching control signals as modulated signals to the switching circuit, and

implement the detection circuit by comparing the sense value with the predetermined threshold, and selectively modifying the first and second switching control signals responsive to the sense value being less than the predetermined threshold in the predetermined portion of the given half cycle.

6. The power conversion system of claim 5, wherein the predetermined threshold is an adjustable value stored in an electronic memory operatively coupled with the at least one processor.

7. The power conversion system of claim 2, wherein the controller is operative to selectively increase a modulation switching frequency in providing the first and second switching control signals responsive to receiving the detection signal or value in the first state.

8. The power conversion system of claim 2, comprising:

a second detection circuit operatively coupled with the sensing circuit to receive the sense signal and operative to selectively provide a second detection signal or value to the controller in a first state if the amplitude of the sense signal is below a second predetermined threshold a second non-zero predetermined time after the given one of the first and second switching devices is turned on, and to provide the second detection signal or value in a different second state if the amplitude of the sense signal is greater than or equal to the second predetermined threshold the second non-zero predetermined time after the given one of the first and second switching devices is turned on;

wherein the controller is operative to selectively increase a dead time value during which the first and second switching devices are both off responsive to receiving the second detection signal or value in the first state.

9. The power conversion system of claim 8, wherein the second detection circuit comprises:

a comparator including a first input coupled to receive the sense signal from the sensing circuit, a second input coupled to a voltage reference representing the second predetermined threshold, and a comparator output providing a comparator output signal in a first state if the amplitude of the sense signal is below an amplitude of the voltage reference, and in a different second state if the amplitude of the sense signal is greater than or equal to the amplitude of the voltage reference; and

a timing circuit operatively coupled to receive the first and second switching control signals from the controller and to receive the comparator output signal from the comparator, the timing circuit operative to provide the second detection signal or value in the second state for the second non-zero predetermined time after the given one of the first and second switching devices is turned on, and to selectively provide the second detection signal in the first state if the comparator output signal is in the first state the second non-zero predetermined time after the given one of the first and second switching devices is turned on.

10. The power conversion system of claim 8, comprising:

an analog to digital converter receiving the sense signal and providing a sense value representing resonant current flowing in the series circuit;

at least one processor programmed to;

implement the controller by providing the first and second switching control signals as modulated signals to the switching circuit, and

implement the second detection circuit by comparing the sense value with the second predetermined threshold, and selectively modifying the first and second switching control signals to increase the dead time value responsive to the sense value being less than the second predetermined threshold the second non-zero predetermined time after the given one of the first and second switching devices is turned on.

11. The power conversion system of claim 1, comprising:

a second detection circuit operatively coupled with the sensing circuit to receive the sense signal and operative to selectively provide a second detection signal or value to the controller in a first state if the amplitude of the sense signal is below a second predetermined threshold a second non-zero predetermined time after the given one of the first and second switching devices is turned on, and to provide the second detection signal or value in a different second state if the amplitude of the sense signal is greater than or equal to the second predetermined threshold the second non-zero predetermined time after the given one of the first and second switching devices is turned on;

wherein the controller is operative to selectively increase a dead time value during which the first and second switching devices are both off responsive to receiving the second detection signal or value in the first state.

12. The power conversion system of claim 11, wherein the second detection circuit comprises:

a comparator including a first input coupled to receive the sense signal from the sensing circuit, a second input coupled to a voltage reference representing the second predetermined threshold, and a comparator output providing a comparator output signal in a first state if the amplitude of the sense signal is below an amplitude of the voltage reference, and in a different second state if the amplitude of the sense signal is greater than or equal to the amplitude of the voltage reference; and

a timing circuit operatively coupled to receive the first and second switching control signals from the controller and to receive the comparator output signal from the comparator, the timing circuit operative to provide the second detection signal or value in the second state for the second non-zero predetermined time after the given one of the first and second switching devices is turned on, and to selectively provide the second detection signal in the first state if the comparator output signal is in the first state the second non-zero predetermined time after the given one of the first and second switching devices is turned on.

13. The power conversion system of claim 11, comprising:

an analog to digital converter receiving the sense signal and providing a sense value representing resonant current flowing in the series circuit;

at least one processor programmed to;

implement the controller by providing the first and second switching control signals as modulated signals to the switching circuit, and

implement the second detection circuit by comparing the sense value with the second predetermined threshold, and selectively modifying the first and second switching control signals to increase the dead time value responsive to the sense value being less than the second predetermined threshold the second non-zero predetermined time after the given one of the first and second switching devices is turned on.

14. The power conversion system of claim 1, wherein the controller is operative to selectively increase a modulation switching frequency in providing the first and second switching control signals responsive to receiving the detection signal or value in the first state.

15. The power conversion system of claim 1, wherein the series circuit further comprises a second inductance connected in parallel with the transformer primary winding;

and wherein the sensing circuit comprises;

a current transformer having a primary winding connected in the series circuit to sense the resonant current flowing in the series circuit, and a secondary winding, and

a rectifier circuit operatively coupled to rectify a signal from the secondary winding and to provide the sense signal representing an absolute value of the resonant current flowing in the series circuit.

16. A control apparatus for operating a series resonant or LLC power conversion system with a series circuit and a switching circuit, the control apparatus comprising:

a modulation controller operatively coupled to provide first and second switching control signals as alternating modulated signals to corresponding first and second switching devices of the power conversion system in each of a plurality of switching cycles to modify a voltage at a switching node to control a converter output voltage; and

a detection circuit comprising an input for receiving a sense signal representing a resonant current flowing in the series circuit, and an output providing a detection signal or value to the controller in a first state if an amplitude of the sense signal is below a predetermined threshold in a predetermined portion of a given half cycle of a given one of the plurality of switching cycles and to provide the detection signal or value in a different second state if the amplitude of the sense signal is greater than or equal to the predetermined threshold in the predetermined portion of the given half cycle;

wherein the controller is operative to selectively modify the first and second switching control signals to promote zero voltage switching or near-zero voltage switching operation of the first and second switching devices in response to receiving the detection signal or value in the first state.

17. The control apparatus of claim 16, wherein the controller is operative to selectively increase a modulation switching frequency in providing the first and second switching control signals in response to receiving the detection signal or value in the first state.

18. The control apparatus of claim 16, comprising:

a second detection circuit comprising an input for receiving a sense signal to receive the sense signal, and an output providing a second detection signal or value to the controller in a first state if the amplitude of the sense signal is below a second predetermined threshold a second non-zero predetermined time after the given one of the first and second switching devices is turned on, and to provide the second detection signal or value in a different second state if the amplitude of the sense signal is greater than or equal to the second predetermined threshold the second non-zero predetermined time after the given one of the first and second switching devices is turned on;

wherein the controller is operative to selectively increase a dead time value during which the first and second switching devices are both off in response to receiving the second detection signal or value in the first state.

19. The control apparatus of claim 16, comprising an integrated circuit including:

an analog to digital converter receiving the sense signal and providing a sense value representing resonant current flowing in the series circuit;

at least one processor operatively coupled to receive the sense signal from the analog to digital converter and having outputs operatively coupled to provide the first and second switching control signals to the first and second switching devices, the at least one processor programmed to implement the modulation controller and to implement the detection circuit.

20. A method for controlling a resonant power conversion system, the method comprising:

sensing a resonant current flowing in a series circuit of the power conversion system;

determining whether the resonant current is below a predetermined threshold in a predetermined portion of a given modulation half cycle, the predetermined portion beginning a non-zero predetermined time after a switching device of the power conversion system is turned on and ending before the switching device is turned off; and

in response to determining that the resonant current is below the predetermined threshold in the predetermined portion of the given modulation half cycle, selectively modifying at least one modulation switching control signal provided to the power conversion system to promote zero voltage switching or near-zero voltage switching operation of the switching device.

21. The method of claim 20, comprising:

in response to determining that the resonant current is below the predetermined threshold in the predetermined portion of the given modulation half cycle, selectively shutting down and restarting the power conversion system.

22. The method of claim 20, comprising:

in response to determining that the resonant current is below the predetermined threshold in the predetermined portion of the given modulation half cycle, selectively turning off an active MOSFET and delaying turn on of a next MOSFET in a primary side bridge of the power conversion system.