Dynamic sharing average current mode control for active-reset and self-driven synchronous rectification for power converters

• US 9,780,635 B1
• Filed: 06/10/2016
• Issued: 10/03/2017
• Est. Priority Date: 06/10/2016
• Status: Active Grant

• Current Assignee: Crane Electronics, Inc. (Crane Company)
• Original Assignee: Crane Electronics, Inc. (Crane Company)
• Inventors: Lam, Cuon, Nguyen, Hach, Nguyen, Khoa, Odell, Peter, Song, Sovann
• Primary Examiner(s): Dole, Timothy J
• Assistant Examiner(s): Andino, Ivan Laboy
• Application Number:
  US15/178,968
• Time in Patent Office: 480 Days
• Field of Search: 363 2101- 2118, 363 65, 323271, 323272, 323282-285, 323351
• CPC Class Codes: H02M 1/0009 Devices or circuits for detecting current in a converter
• 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 1/342 Active non-dissipative snubbers
• CPC Class Codes: H02M 1/36 Means for starting or stopping converters
• CPC Class Codes: H02M 3/285 Single converters with a plurality of output stages connected in parallel parallel operation of a plurality of converters in dc distribution networks H02J1/10
• CPC Class Codes: H02M 3/33538 of the forward type H02M3/3353, H02M3/33569 take precedence
• CPC Class Codes: H02M 3/33546 with automatic control of the output voltage or current H02M3/33561 takes precedence
• CPC Class Codes: H02M 3/33553 with galvanic isolation between input and output of both the power stage and the feedback loop
• CPC Class Codes: H02M 3/33569 having several active switching elements H02M3/3353 takes 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 circuit for providing dynamic output current sharing using average current mode control for active-reset and self-driven synchronous rectification with pre-bias startup and redundancy capabilities for power converters. The circuit communicates a secondary side feedback signal to a primary side via a bidirectional magnetic communicator that also provides a secondary voltage supply. Pre-bias startup is achieved by detection of the output current direction and controlling the gate signals of synchronous rectifiers. The circuit permits dynamic current sharing via a single-control signal and automatic master converter selection and promotion.

Claims

1. An average current mode control (ACMC) controller for a power converter, the power converter comprising a power transformer having a primary winding electrically coupleable to an input voltage node and a secondary winding electrically coupleable to an output voltage node, a primary control circuit electrically coupled to the primary winding, a secondary control circuit electrically coupled to the secondary winding, the secondary control circuit comprising first and second synchronous rectifying elements comprising respective first and second control nodes, the average current mode control (ACMC) controller comprising:

a magnetic communicator circuit comprising;

a selectively controllable switch; and

a coupling transformer comprising a first primary winding, a second primary winding, and a secondary winding, the secondary winding electrically coupled to a secondary side DC voltage supply circuit comprising a DC supply rectifier and a DC supply capacitor which provides a secondary side DC voltage supply on the DC supply capacitor of the secondary side DC voltage supply circuit, the first and second primary windings selectively coupled to a primary side DC voltage supply via the controllable switch whereby the secondary side DC voltage supply is developed on the DC supply capacitor of the secondary side DC voltage supply circuit by selectively controlling the controllable switch into conduction, the secondary winding electrically coupled to a secondary side feedback signal node, and the second primary winding electrically coupled to a sampling circuit comprising a sampling rectifier and a sampling capacitor whereby a secondary side feedback signal at the secondary side feedback signal node is transferred to the second primary winding by the selective controlling of the controllable switch into conduction, whereby a primary side feedback voltage is developed on the sampling capacitor of the sampling circuit by the selective controlling of the controllable switch into conduction, the primary side feedback voltage electrically coupleable to the primary control circuit of the power converter.

2. The average current mode control (ACMC) controller of claim 1, further comprising:

a voltage error amplifier circuit comprising an input node and an output node, the input node electrically coupled to the output voltage node of the power converter; and

a current error amplifier circuit comprising an input node and an output node, the input node of the current error amplifier circuit electrically coupled to the output node of the voltage error amplifier circuit, and the output node of the current error amplifier electrically coupled to the secondary side feedback signal node.

3. The average current mode control (ACMC) controller of claim 2 wherein the voltage error amplifier circuit comprises an operational amplifier which includes a supply input node electrically coupled to the secondary side DC voltage supply to receive power therefrom.

4. The average current mode control (ACMC) controller of claim 2 wherein the current error amplifier circuit comprises an operational amplifier which includes a supply input node electrically coupled to the secondary side DC voltage supply to receive power therefrom.

5. The average current mode control (ACMC) controller of claim 2, further comprising:

a common control node which is representative of an output signal of the voltage error amplifier circuit, the common control node coupleable to a common control node of another power converter to provide current sharing operation between the power converter and the other power converter.

6. The average current mode control (ACMC) controller of claim 1, further comprising:

a current direction detector circuit operatively coupled to sense a direction of an output current of the power converter and, responsive to detecting output current flows into the power converter, the current direction detector circuit causes the first and second control nodes of the respective first and second synchronous rectifying elements to control the first and second synchronous rectifying elements to be in an non-conduction state.

7. The average current mode control (ACMC) controller of claim 6 wherein the current direction detector circuit comprises a comparator which includes a supply input node electrically coupled to the secondary side DC voltage supply to receive power therefrom.

8. The average current mode control (ACMC) controller of claim 6 wherein the current direction detector circuit comprises a control switch electrically coupled to each of the first and second control nodes of the respective first and second synchronous rectifying elements, the control switch comprising a control switch control node electrically coupled to the output voltage node of the power converter.

9. The average current mode control (ACMC) controller of claim 6 wherein the current direction detector comprises a control switch electrically coupled to each of the first and second control nodes of the respective first and second synchronous rectifying elements via respective first and second diodes, the control switch comprising a control switch control node electrically coupled to the output voltage node of the power converter via a resistor.

10. An active-clamp forward converter, comprising:

a transformer having a primary winding and a secondary winding, the secondary winding electrically coupleable to an output voltage node;

a primary control circuit electrically coupled to the primary winding, the primary winding electrically coupleable to an input voltage node;

a secondary control circuit electrically coupled to the secondary winding, the secondary control circuit comprising first and second synchronous rectifying elements comprising respective first and second control nodes; and

an average current mode control (ACMC) converter, comprising;

a magnetic communicator circuit comprising;

a selectively controllable switch; and

a coupling transformer comprising a first primary winding, a second primary winding, and a secondary winding, the secondary winding electrically coupled to a secondary side DC voltage supply circuit comprising a DC supply rectifier and a DC supply capacitor which provides a secondary side DC voltage supply on the DC supply capacitor of the secondary side DC voltage supply circuit, the first and second primary windings selectively coupled to a primary side DC voltage supply via the controllable switch whereby the secondary side DC voltage supply is developed on the DC supply capacitor of the secondary side DC voltage supply circuit by selectively controlling the controllable switch into conduction, the secondary winding electrically coupled to a secondary side feedback signal node, and the second primary winding electrically coupled to a sampling circuit comprising a sampling rectifier and a sampling capacitor whereby a secondary side feedback signal at the secondary side feedback signal node is transferred to the second primary winding by the selective controlling of the controllable switch into conduction, whereby a primary side feedback voltage is developed on the sampling capacitor of the sampling circuit by the selective controlling of the controllable switch into conduction, the primary side feedback voltage electrically coupleable to the primary control circuit of the active-clamp forward converter.

11. The active-clamp forward converter of claim 10, further comprising:

a voltage error amplifier circuit comprising an input node and an output node, the input node electrically coupled to the output voltage node of the active-clamp forward converter; and

a current error amplifier circuit comprising an input node and an output node, the input node of the current error amplifier electrically coupled to the output node of the voltage error amplifier circuit, and the output node of the current error amplifier electrically coupled to the secondary side feedback signal node.

12. The active-clamp forward converter of claim 11 wherein the voltage error amplifier circuit comprises an operational amplifier which includes a supply input node electrically coupled to the secondary side DC voltage supply to receive power therefrom.

13. The active-clamp forward converter of claim 11 wherein the current error amplifier circuit comprises an operational amplifier which includes a supply input node electrically coupled to the secondary side DC voltage supply to receive power therefrom.

14. The active-clamp forward converter of claim 11, further comprising:

a common control node which is representative of an output signal of the voltage error amplifier circuit, the common control node coupleable to a common control node of another active-clamp forward converter to provide current sharing operation between the active-clamp forward converter and the other active-clamp forward converter.

15. The active-clamp forward converter of claim 10, further comprising:

a current direction detector circuit operatively coupled to sense a direction of an output current of the active-clamp forward converter and, responsive to detecting output current flows into the active-clamp forward converter, the current direction detector circuit causes the first and second control nodes of the respective first and second synchronous rectifying elements to control the first and second synchronous rectifying elements to be in an non-conduction state.

16. The active-clamp forward converter of claim 15 wherein the current direction detector circuit comprises a comparator which includes a supply input node electrically coupled to the secondary side DC voltage supply to receive power therefrom.

17. The active-clamp forward converter of claim 15 wherein the current direction detector comprises a control switch electrically coupled to each of the first and second control nodes of the respective first and second synchronous rectifying elements, the control switch comprising a control switch control node electrically coupled to the output voltage node of the active-clamp forward converter.

18. The active-clamp forward converter of claim 15 wherein the current direction detector comprises a control switch electrically coupled to each of the first and second control nodes of the respective first and second synchronous rectifying elements via respective first and second diodes, the control switch comprising a control switch control node electrically coupled to the output voltage node of the active-clamp forward converter via a resistor.

19. An average current mode control (ACMC) controller for a power converter, the power converter comprising a power transformer having a primary winding electrically coupleable to an input voltage node and a secondary winding electrically coupleable to an output voltage node, a primary control circuit electrically coupled to the primary winding, a secondary control circuit electrically coupled to the secondary winding, the secondary control circuit comprising first and second synchronous rectifying elements comprising respective first and second control nodes, the average current mode control (ACMC) controller comprising:

a voltage error amplifier circuit comprising an input node and an output node, the input node electrically coupled to the output voltage node of the power converter;

a current error amplifier circuit comprising an input node and an output node, the input node of the current error amplifier electrically coupled to the output node of the voltage error amplifier circuit, and the output node of the current error amplifier electrically coupled to a secondary side feedback signal node;

a current direction detector circuit operatively coupled to sense a direction of an output current of the power converter and, responsive to detecting output current flows into the power converter, the current direction detector circuit causes the first and second control nodes of the respective first and second synchronous rectifying elements to control the first and second synchronous rectifying elements to be in an non-conduction state; and

a magnetic communicator circuit comprising;

a selectively controllable switch; and

a coupling transformer comprising a first primary winding, a second primary winding, and a secondary winding, the secondary winding electrically coupled to a secondary side DC voltage supply circuit comprising a DC supply rectifier and a DC supply capacitor which provides a secondary side DC voltage supply on the DC supply capacitor of the secondary side DC voltage supply circuit, the first and second primary windings selectively coupled to a primary side DC voltage supply via the controllable switch whereby the secondary side DC voltage supply is developed on the DC supply capacitor of the secondary side DC voltage supply circuit by selectively controlling the controllable switch into conduction, the secondary winding electrically coupled to the secondary side feedback signal node, and the second primary winding electrically coupled to a sampling circuit comprising a sampling rectifier and a sampling capacitor whereby a secondary side feedback signal at the secondary side feedback signal node is transferred to the second primary winding by the selective controlling of the controllable switch into conduction, whereby a primary side feedback voltage is developed on the sampling capacitor of the sampling circuit by the selective controlling of the controllable switch into conduction, the primary side feedback voltage electrically coupleable to the primary control circuit of the power converter.