Universal power module

• US 5,661,643 A
• Filed: 02/20/1996
• Issued: 08/26/1997
• Est. Priority Date: 02/20/1996
• Status: Expired due to Term

• Current Assignee: Eaton Corp. (Wisconsin) (Eaton Corporation PLC.)
• Original Assignee: Eaton Corp. (Wisconsin) (Eaton Corporation PLC.)
• Inventors: Elms, Robert T., Blakely, John H.
• Primary Examiner(s): Krishnan, Aditya
• Application Number:
  US08/603,826
• Time in Patent Office: 553 Days
• Field of Search: 363/20.21, 363/130-131, 363/22-25, 323/266, 323/282, 323/284, 323/407
• US Class Current: 363/21.16
• CPC Class Codes: H02M 1/10 Arrangements incorporating converting means for enabling loads to be operated at will from different kinds of power supplies, e.g. from ac or dc
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• 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

Abstract

A power supply for converting a plurality of alternating current (AC) and direct current (DC) input line voltages to a DC output voltage includes a converter for converting the input voltages to an intermediate voltage at a first node; a switching regulator having a power voltage at a second node for providing a reference voltage therefrom, and for providing a switching signal at a third node from the reference voltage and a feedback voltage; a circuit for electrically interconnecting the first node to the second node whenever the intermediate voltage exceeds a predetermined voltage; a transformer including a primary winding electrically interconnected with the first node, and a secondary winding having a secondary voltage; a feedback circuit cooperating with the transformer for providing the feedback voltage therefrom; a switching circuit responsive to the switching signal at the third node for switching an electrical current from the first node through the primary winding; and a circuit electrically interconnected with the secondary winding for converting the secondary voltage to the output voltage.

Claims

1. A power supply apparatus for converting at least one input line voltage to an output voltage, said power supply apparatus comprising:

converting means for converting said at least one input line voltage to an intermediate voltage at a first node, with said at least one input line voltage having a voltage range including a maximum voltage and a minimum voltage, and with a ratio of the maximum voltage to the minimum voltage being about 10;

1;

switching regulator means having a power voltage at a second node for providing a reference voltage therefrom, and for providing a switching signal at a third node from the reference voltage and a feedback voltage;

means for electrically interconnecting the first node to the second node whenever the intermediate voltage exceeds a predetermined voltage;

transformer means including at least a primary winding electrically interconnected with the first node, and a secondary winding having a secondary voltage;

feedback means cooperating with said transformer means for providing the feedback voltage therefrom;

switching means responsive to the switching signal at the third node for switching an electrical current from the first node through the primary winding; and

means electrically interconnected with the secondary winding for converting the secondary voltage to the output voltage.

2. The power supply apparatus as recited in claim 1 wherein said at least one input line voltage is an alternating current (AC) line voltage;

wherein said voltage range is about 60 VAC to about 632 VAC; and

wherein said converting means includes full wave rectification means for rectifying the AC line voltage to provide the intermediate voltage therefrom.

3. The power supply apparatus as recited in claim 1 wherein said at least one input line voltage is a direct current (DC) voltage, wherein said voltage;

range is about 85 VDC to about 900 VDC; and

wherein said converting means includes means for sourcing the DC voltage to the intermediate voltage.

4. The power supply apparatus as recited in claim 1 wherein said at least one input line voltage includes at least one of an alternating current (AC) line voltage having a voltage range of about 60 VAC to about 632 VAC and a direct current (DC) voltage having a voltage range of about 85 VDC to about 900 VDC.

5. The power supply apparatus as recited in claim 1 wherein said at least one input line voltage includes an alternating current (AC) line voltage;

and wherein said means for electrically interconnecting the first node to the second node includes means for electrically disconnecting the first node from the second node in response to an undervoltage condition of the AC line voltage and for electrically reconnecting the first node to the second node in order to recover from the undervoltage condition.

6. The power supply apparatus as recited in claim 1 wherein said at least one input voltages include a surge waveform;

and wherein said converting means includes surge suppression means for suppressing the surge waveform from the intermediate voltage.

7. The power supply apparatus as recited in claim 6 wherein said at least one input line voltage is a plurality of input line voltage;

wherein said converting means includes a plurality of diode pairs for converting the input line voltages to the intermediate voltage; and

wherein the surge suppression means includes a series resistor for each of the diode pairs, a capacitor for shaping the surge waveform at the first node and varistor means for clamping the voltage of the surge waveform at the first node.

8. The power supply apparatus as recited in claim 7 wherein said switching means includes a switching transistor interconnected with the primary winding and zener diode means for limiting the voltage of the switching transistor at the primary winding.

9. A power supply apparatus for converting at least one input line voltage to an output voltage, said power supply apparatus comprising:

first converting means for converting said at least one input line voltage to a first intermediate voltage at a first node, with said at least one input line voltage having a voltage range including a maximum voltage and a minimum voltage, and with a ratio of the maximum voltage to the minimum voltage being about 10;

1;

second converting means for converting the first intermediate voltage to a second intermediate voltage at a second node;

switching regulator means having a power voltage at a third node for providing a reference voltage therefrom, and for providing a switching signal at a fourth node from the reference voltage and a feedback voltage;

means for electrically interconnecting the second node to the third node whenever the second intermediate voltage exceeds a predetermined voltage;

transformer means including at least a primary winding electrically interconnected with the first node, and a secondary winding having a secondary voltage;

feedback means cooperating with said transformer means for providing the feedback voltage therefrom;

switching means responsive to the switching signal at the fourth node for switching an electrical current from the first node through the primary winding; and

means electrically interconnected with the secondary winding for converting the secondary voltage to the output voltage.

10. The power supply apparatus as recited in claim 9 wherein said at least one input line voltage includes an alternating current (AC) line voltage;

and wherein said first converting means includes full wave rectification means for rectifying the AC line voltage to provide the first intermediate voltage therefrom.

11. The power supply apparatus as recited in claim 10 wherein the AC line voltage includes a voltage range of about 60 VAC to about 632 VAC.

12. The power supply apparatus as recited in claim 9 wherein said at least one input line voltage includes a plurality of alternating current (AC) line voltages;

and wherein said first converting means includes full wave rectification means for rectifying the AC line voltages to provide the first intermediate voltage therefrom.

13. The power supply apparatus as recited in claim 12 wherein the input AC line voltages include at least two phases;

having a voltage range of about 60 VAC to about 632 VAC between the phases.

14. The power supply apparatus as recited in claim 9 wherein said at least one input line voltage includes a direct current (DC) voltage;

and wherein said first converting means includes means for sourcing the DC voltage to the first intermediate voltage.

15. The power supply apparatus as recited in claim 14 wherein the DC voltage includes a voltage range of about 85 VDC to about 900 VDC.

16. The power supply apparatus as recited in claim 9 wherein said second converting means includes a capacitor, a resistor and detecting means for detecting the predetermined voltage at the capacitor;

wherein the capacitor is charged from the first intermediate voltage through the resistor; and

wherein said means for electrically interconnecting the second node to the third node includes a series pass transistor responsive to the detecting means for sourcing the second intermediate voltage to the power voltage.

17. The power supply apparatus as recited in claim 16 wherein the capacitor has a voltage;

and wherein said means for electrically interconnecting the second node to the third node includes latching means having a first state whenever the voltage of the capacitor exceeds a first predetermined voltage and a second state whenever the voltage of the capacitor falls below a second predetermined voltage.

18. The power supply apparatus as recited in claim 17 wherein the second node is electrically interconnected with the third node in the first state and is electrically disconnected from the third node in the second state.

19. The power supply apparatus as recited in claim 9 wherein said means for electrically interconnecting the second node to the third node includes first diode means for electrically interconnecting the second intermediate voltage to the power voltage;

wherein said transformer means further includes a tertiary winding having a tertiary voltage; and

wherein said feedback means includes rectification means for rectifying the tertiary voltage and producing the feedback voltage therefrom, and second diode means for electrically interconnecting the tertiary voltage to the power voltage.

20. The power supply apparatus as recited in claim 9 wherein the primary winding has a first capacitor associated therewith;

and wherein said means for converting the secondary voltage to the output voltage includes a second capacitor and flyback means for rectifying the secondary voltage, with the capacitance of the second capacitor being greater than the capacitance of the first capacitor.

21. The power supply apparatus as recited in claim 9 wherein said second converting means includes a capacitor, a resistor and detecting means for detecting the predetermined voltage at the capacitor;

wherein the capacitor is charged from the first intermediate voltage through the resistor; and

wherein said means for electrically interconnecting the second node to the third node includes first transistor means and second transistor means;

wherein the first transistor means is turned on about when said detecting means detects the predetermined voltage; and

wherein the second transistor means is turned on by the first transistor means.

22. The power supply apparatus as recited in claim 21 wherein said means for electrically interconnecting the second node to the third node further includes feedback means between the second transistor means and the first transistor means in order that the second transistor means electrically interconnects the second intermediate voltage to the power voltage whenever the second intermediate voltage exceeds a first predetermined voltage and electrically disconnects the second intermediate voltage from the power voltage whenever the second intermediate voltage falls below a second predetermined voltage.

23. The power supply apparatus as recited in claim 9 wherein said at least one input line voltage includes a plurality of alternating current (AC) line voltages each of which includes an ANSI C62.41 surge waveform;

and wherein said first converting means includes full wave rectification means for converting the AC line voltages to the first intermediate voltage, and surge suppression means for suppressing the ANSI C62.41 surge waveform from the first intermediate voltage.

24. The power supply apparatus as recited in claim 23 wherein the second converting means includes low-pass filter means for shaping the surge waveform at the second node and inductor means for limiting the current from the first node to said switching means.

25. The power supply apparatus as recited in claim 9 wherein the switching signal of said switching regulator means has a switching frequency;

and wherein said switching regulator means includes modulation means for modulating the switching frequency about when said at least one input line voltage exceeds a predetermined value.

26. The power supply apparatus as recited in claim 25 wherein said modulation means includes detecting means for detecting about when said at least one input line voltage exceeds the predetermined value, and means responsive to said detecting means for decreasing the switching frequency about when said at least one input line voltage exceeds the predetermined value.