Circuits and methods for synchronous rectification in resonant converters

• US 9,887,634 B2
• Filed: 07/23/2015
• Issued: 02/06/2018
• Est. Priority Date: 07/23/2015
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Ramabhadran, Ramanujam, Levy, Yehuda Daniel, She, Xu
• Primary Examiner(s): NASH, GARY A
• Application Number:
  US14/806,793
• Publication Number:
  US 20170025965A1
• Time in Patent Office: 929 Days
• Field of Search: 363 2102, 363 2103, 363 78, 363 79, 363 88
• 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 3/33546 with automatic control of the output voltage or current H02M3/33561 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
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier

Abstract

A resonant converter includes a primary stage having first and second switches coupled in series, a controller coupled to the first switch and the second switch to control operation thereof, a first transformer comprising a primary coil coupled to a node between the first and second switches, and a resonant inductor coupled to the primary coil of the first transformer. The resonant converter also includes a secondary stage having a second transformer formed of a primary coil coupled to the resonant inductor and a secondary coil comprising first and second coil sections, a third switch coupled to the first coil section of the secondary coil, and a fourth switch coupled to the second coil section of the secondary coil. A switch drive circuit is provided to drive the third and fourth switches for synchronous rectification, with the switch drive circuit comprising a secondary coil of the first transformer.

Claims

1. A resonant converter comprising:

a resonant converter primary stage including;

a first switch;

a second switch coupled in series with the first switch;

a controller coupled to the first switch and the second switch and programmed to control operation of the first switch and the second switch;

a first transformer comprising a primary coil coupled to a node between the first switch and the second switch; and

a resonant inductor coupled to the primary coil of the first transformer;

a resonant converter secondary stage including;

a second transformer comprising;

a primary coil coupled to the resonant inductor; and

a secondary coil comprising a first coil section and a second coil section coupled to the first coil section;

a third switch coupled to the first coil section of the secondary coil of the second transformer; and

a fourth switch coupled to the second coil section of the secondary coil of the second transformer; and

a switch drive circuit configured to drive the third switch and the fourth switch for synchronous rectification, wherein the switch drive circuit comprises a secondary coil of the first transformer.

2. The resonant converter of claim 1 wherein the primary coil of the first transformer is integrated with the resonant inductor.

3. The resonant converter of claim 2 wherein the primary coil of the first transformer is integrated with the resonant inductor in a split bobbin arrangement.

4. The resonant converter of claim 1 wherein the switch drive circuit further comprises:

a voltage follower circuit including an input coupled to the secondary coil of the first transformer and an output;

an inverting amplifier circuit including an input coupled to the output of the voltage follower circuit and an output;

a first comparator circuit for driving the third switch, wherein the first comparator circuit is coupled to the output of the inverting amplifier circuit; and

a second comparator circuit for driving the fourth switch, wherein the second comparator circuit is coupled to the output of the inverting amplifier circuit.

5. The resonant converter of claim 4 wherein the first comparator circuit of the switch drive circuit comprises an operational amplifier and the second comparator circuit of the switch drive circuit comprises an operational amplifier, with each operational amplifier comprising a non-inverting input and an inverting input.

6. The resonant converter of claim 5 wherein the non-inverting input of the operational amplifier of the first comparator circuit is coupled to the output of the inverting amplifier circuit;

and

wherein the inverting input of the operational amplifier of the second comparator circuit is coupled to the output of the inverting amplifier circuit.

7. The resonant converter of claim 1 wherein the first transformer is an air core transformer.

8. The resonant converter of claim 1 wherein the first transformer is a current transformer.

9. The resonant converter of claim 1 further comprising:

a first diode coupled in parallel with the first switch and a second diode coupled in parallel with the second switch and in series with the first switch; and

a capacitor coupled in parallel with the second diode.

10. A method for synchronous rectification in a resonant converter, the method comprising:

providing a resonant converter primary stage comprising;

providing a primary pair of switches;

coupling a controller to the primary pair of switches, the controller configured to control operation of the primary pair of switches;

coupling a primary coil of a current transformer to the primary pair of switches; and

coupling a primary coil of a voltage transformer to the current transformer;

providing a resonant converter secondary stage comprising;

providing a secondary coil of the voltage transformer; and

coupling a pair of secondary switches to the secondary coil of the voltage transformer;

coupling a switch drive circuit to the pair of secondary switches, the switch drive circuit comprising a secondary coil of the current transformer;

providing power to the resonant converter primary stage; and

controlling the primary pair of switches with the controller to direct power through the primary coil of the current transformer and the primary coil of the voltage transformer;

wherein the power flowing through the primary coil of the voltage transformer causes power to flow through the secondary coil of the voltage transformer;

wherein the power flowing through the primary coil of the current transformer causes power to flow through the secondary coil of the current transformer; and

wherein the power flowing through the secondary coil of the current transformer causes the switch drive circuit to drive the pair of secondary switches to direct the power flowing through the secondary coil of the voltage transformer to a load.

11. The method of claim 10 wherein coupling a switch drive circuit to the pair of secondary switches comprises:

coupling the secondary coil of the current transformer to an input of a voltage follower circuit;

coupling an output of the voltage follower circuit to an input of an inverting amplifier circuit;

coupling an output of the inverting amplifier circuit to an input of a first comparator circuit; and

coupling the output of the inverting amplifier circuit to an input of a second comparator circuit.

12. The method of claim 11 wherein coupling the output of the inverting amplifier circuit to the input of the first comparator circuit comprises coupling the output of the inverting amplifier circuit to an operational amplifier of the first comparator circuit;

and

wherein coupling the output of the inverting amplifier circuit to the input of the second comparator circuit comprises coupling the output of the inverting amplifier circuit to an operational amplifier of the second comparator circuit.

13. The method of claim 12 wherein coupling the output of the inverting amplifier circuit to the operational amplifier of the first comparator circuit comprises coupling the output of the inverting amplifier circuit to a non-inverting input of the operational amplifier of the first comparator circuit;

and

wherein coupling the output of the inverting amplifier circuit to an operational amplifier of the second comparator circuit comprises coupling the output of the inverting amplifier circuit to an inverting input of the operational amplifier of the second comparator circuit.

14. The method of claim 10 wherein providing the resonant converter primary stage further comprises coupling an inductor between the primary coil of the current transformer and the primary coil of the voltage transformer.

15. The method of claim 14 wherein providing the resonant converter primary stage further comprises integrating the primary coil of the current transformer with the inductor in a split bobbin arrangement.

16. The method of claim 10 further comprising isolating the resonant converter primary stage from the resonant converter secondary stage and the switch drive circuit.

17. A clamped series resonant converter comprising:

a half bridge circuit comprising a first switch and a second switch coupled in series with the first switch;

a first controller coupled to the half bridge circuit and programmed to control the half bridge circuit;

a pair of diodes coupled in parallel with the half bridge circuit, the pair of diodes comprising a first diode in series with a second diode;

a first capacitor coupled in parallel with the second diode of the pair of diodes;

an inductor coupled to a node between the first switch of the half bridge circuit and the second switch of the half bridge circuit;

a transformer comprising;

a primary coil coupled to the inductor and to a node between the first diode and the second diode; and

a secondary coil comprising a first coil section and a second coil section coupled to the first coil section;

a pair of switches including a third switch coupled to the first coil section of the secondary coil of the transformer and a fourth switch coupled to the second coil section of the secondary coil of the transformer;

a first current sensor coupled to the third switch for sensing the current through the third switch;

a second current sensor coupled to the fourth switch for sensing the current through the fourth switch; and

a second controller coupled to the first current sensor, the second current sensor, and the pair of switches and programmed to control the pair of switches synchronously with the half bridge circuit based on the current sensed by the first current sensor and the second current sensor.

18. The clamped series resonant converter of claim 17 wherein the third switch of the pair of switches comprises a first metal-oxide-semiconductor field-effect transistor (MOSFET) and the fourth switch of the pair of switches comprises a second MOSFET;

and

wherein the first current sensor senses the drain to source current for the first MOSFET and the second current sensor senses the drain to source current for the second MOSFET.

19. The clamped series resonant converter of claim 17 wherein the second controller is programmed to turn the pair of switches on and off based on zero current transitions sensed by the first current sensor and the second current sensor.

20. The clamped series resonant converter of claim 17 wherein the second controller is an integrated circuit.

21. The clamped series resonant converter of claim 17 further comprising a second capacitor coupled in parallel with the first diode of the pair of diodes so that the first capacitor and the second capacitor are in a split arrangement.

22. The clamped series resonant converter of claim 17 wherein the primary coil is coupled between the inductor and the node between the first diode and the second diode.