Peak power control technique for primary side controller operation in continuous conduction mode

• US 9,621,053 B1
• Filed: 08/05/2014
• Issued: 04/11/2017
• Est. Priority Date: 08/05/2014
• Status: Active Grant

• Current Assignee: Flextronics America LLC (Flextronics International Limited)
• Original Assignee: Flextronics America LLC (Flextronics International Limited)
• Inventors: Telefus, Mark
• Primary Examiner(s): Benitez, Gustavo Rosario
• Application Number:
  US14/452,443
• Time in Patent Office: 980 Days
• CPC Class Codes: H02M 1/0025 Arrangements for modifying reference values, feedback values or error values in the control loop of a converter
• CPC Class Codes: H02M 1/0032 Control circuits allowing low power mode operation, e.g. in standby mode
• 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: 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 power converter includes a primary side controller configured to operate the power converter in the discontinuous conduction mode during low to mid-power requirements and to operate the power converter in the continuous conduction mode during high or peak power requirements. The power converter includes a primary side auxiliary winding that provides a feedback signal to the primary side controller, and an adjusted resistor and diode circuit which is coupled to a multi-function feedback (FB) pin of the primary side controller. The primary side controller monitors for a peak power demand, upon detection of which a negative supply rail is enabled, which is used to compensate for voltage losses due to non-zero current while operating in the CCM, thereby enabling output voltage regulation while operating in the CCM during peak power demand.

Claims

1. A power converter for providing a regulated output voltage, the power converter comprising:

a. an isolation transformer comprising a primary side, a secondary side, and an auxiliary winding on the primary side;

b. a main switch coupled to the primary side;

c. an output rectifier coupled the secondary side to output the regulated output voltage; and

d. a control module coupled to the primary side for determining a period of nominal power use and a period of high power use and configuring the power converter to operate in a discontinuous conduction mode during the period of nominal power use and to operate in a continuous conduction mode during the period of high power use, wherein the control module comprises a gate driver circuit, a first switch and a second switch, wherein the gate driver circuit is configured to drive the main switch, further wherein the first switch is ON and the second switch is OFF during the period of nominal power use thereby enabling a first signal generation path to the gate driver circuit and disabling a second signal generation path to the gate driver circuit, further wherein the first switch is OFF and the second switch is ON during the period of high power use thereby enabling the second signal generation path and disabling the first signal generation path, wherein the second signal generation path includes connection to a negative power supply.

2. The power converter of claim 1 wherein the power converter is a flyback converter.

3. The power converter of claim 1 wherein the power converter further comprises a first voltage divider coupled to the auxiliary winding, having a first divided output voltage, and the control module comprises:

a. the gate driver circuit configured to drive the main switch,

b. a second voltage divider coupled to the first voltage divider, wherein the second voltage divider has a second voltage divider output voltage;

c. the first switch coupled between the first voltage divider and the gate driver circuit, wherein the first switch is configured to couple the first voltage divider to the gate driver circuit during the period of nominal power use;

d. the second switch coupled to the second voltage divider, wherein the second switch is configured to couple the second voltage divider to the negative power supply during the period of high power use; and

e. a comparator coupled to the second voltage divider, wherein the comparator is configured to compare the second voltage divider output voltage to a reference signal, wherein an output of the comparator is coupled to the gate driver circuit.

4. The power converter of claim 3 further comprising a pulse width modulator coupled to the comparator, wherein the pulse width modulator is configured to modulate the output of the comparator.

5. The power converter of claim 4 further comprising a level shifter coupled to an output of the pulse width modulator, wherein the level shifter is configured to level shift the modulated output of the pulse width modulator.

6. The power converter of claim 4 further comprising an oscillator coupled to the pulse width modulator, wherein the oscillator is configured to increase a frequency of the pulse width modulator during the period of high power use.

7. The power converter of claim 3 further comprising an adjusted resistor coupled between ground and a common node between the first voltage divider and the second voltage divider, wherein during the period of high power use current flows from ground through the adjusted resistor, the second voltage divider, the second switch and to the negative power supply.

8. The power converter of claim 7 wherein a resistance value of the adjusted resistor is set to a value such that during the period of high power use the second voltage divider output voltage has a voltage that results in regulating the output voltage.

9. A method of controlling a power converter comprising:

a. configuring the power converter with an isolation transformer having a primary side, a secondary side, and an auxiliary winding on the primary side, wherein a regulated output voltage is provided on the secondary side;

b. determining a period of nominal power use and a period of high power use; and

c. operating the power converter in a discontinuous conduction mode during the period of nominal power use and enabling a first signal generation path to generate a first driving signal for driving the power converter during the period of nominal use, and operating the power converter in a continuous conduction mode during the period of high power use and enabling a second signal generation path to generate a second driving signal for driving the power converter during the period of high power use, wherein enabling the first signal generation path comprises turning ON a first switch and turning OFF a second switch during the period of nominal use, and enabling the second signal generation path comprises turning OFF the first switch and turning ON the second switch during the period of high power use, wherein the second signal generation path includes connection to a negative power supply.

10. The method of claim 9 wherein determining the period of nominal use and the period of high power use comprises monitoring a feedback voltage that is a function of an auxiliary winding voltage.

11. The method of claim 10 wherein determining the period of nominal use and the period of high power use further comprises comparing the feedback voltage to a threshold voltage, wherein if the feedback voltage is equal to or greater than the threshold voltage then it is determined to be the period of nominal use and if the feedback voltage is less than the threshold voltage then it is determined to be the period of high power use.

12. The method of claim 9 wherein when the second signal generation path is enabled the method further comprises comparing a feedback signal to a negative reference value to generate a difference value.

13. The method of claim 12 wherein when the second signal generation path is enabled the method further comprises using a pulse width modulator to modulate the output of the difference value.

14. The method of claim 13 wherein when the second signal generation path is enabled the method further comprises level shifting a modulated output of the pulse width modulator.

15. The method of claim 14 wherein when the second signal generation path is enabled the method further comprises increasing a frequency of the pulse width modulator.

16. The method of claim 12 wherein the second signal generation path comprises an adjusted resistor, and the feedback signal comprises a feedback voltage that is a function of a resistance value of the adjusted resistor.

17. The method of claim 16 wherein the resistance value of the adjusted resistor is set so that the output voltage is regulated when the power converter is operating in the continuous conduction mode.

18. The method of claim 9 wherein when the first signal generation path is enabled the method further comprises using a feedback voltage that is a function of an auxiliary winding voltage to regulate the output voltage.

19. The method of claim 9 wherein when the second signal generation path is enabled the second signal generation path is connected to the negative power supply.