Series interleaved boost converter power factor correcting power supply

• US 7,403,400 B2
• Filed: 07/24/2003
• Issued: 07/22/2008
• Est. Priority Date: 07/24/2003
• Status: Active Grant

• Current Assignee: Harman International Industries Incorporated (Samsung Electronics Co. Ltd.)
• Original Assignee: Harman International Industries Incorporated (Samsung Electronics Co. Ltd.)
• Inventors: Stanley, Gerald R.
• Primary Examiner(s): HAN, YOUNGHUIE JESSICA
• Application Number:
  US10/626,149
• Publication Number:
  US 20050017699A1
• Time in Patent Office: 1,825 Days
• Field of Search: 363/16, 363/17, 363/67, 363/68, 363/71, 363/80, 363/41, 323/222, 323/224, 323/225, 323/284, 323/285
• US Class Current: 363/16
• CPC Class Codes: G05F 1/70 Regulating power factor; Regulating reactive current or power
• CPC Class Codes: H02M 1/4208 Arrangements for improving power factor of AC input
• CPC Class Codes: H02M 7/219 in a bridge configuration
• 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 factor correcting power supply includes an input stage power converter and an output stage power converter. The input stage power converter includes a plurality of series connected boost switches and a power factor correction controller. The power factor correction controller may direct the operation of the boost switches with series interleave phasing to perform power factor correction and voltage regulation. The boost switches are supplied input voltage and input current from a power source. The input voltage is converted to a DC boost voltage by high frequency series interleaved switching of the boost switches. The DC boost voltage is converted to a DC output voltage by the output stage power converter. The DC output voltage is provided on a DC rail for a load of the power factor correcting power supply.

Claims

1. A power factor correcting power supply comprising:

a first boost converter that includes a first boost sub-circuit coupled with a second boost sub-circuit;

a second boost converter coupled in series with the first boost converter, where the second boost converter includes a third boost sub-circuit coupled with a fourth boost sub-circuit, and the first and second boost converters are configured to receive an input voltage and supply a boost voltage that is greater in magnitude than a peak magnitude of the input voltage, where the boost voltage is divided by a factor of at least four with the first, second, third, fourth sub-circuits; and

a power factor correction controller coupled with the first and second boost converters, where the power factor correction controller is configured to control the first and second boost converters with pulse width modulation and series interleave operation with the factor of at least four as a function of the boost voltage.

2. The power factor correcting power supply of claim 1, where the first and second boost sub-circuits are coupled in series and the third and fourth boost sub-circuits are coupled in series.

3. The power factor correcting power supply of claim 1, where the each of the first, second, third and fourth boost sub-circuits include a boost switch, the boost switch of each of the first, second, third and fourth boost sub-circuits coupled in series and configured to be coupled in parallel with an input voltage.

4. The power factor correcting power supply of claim 1, where each of the first, second, third and fourth boost sub-circuits include a respective boost switch and a respective boost capacitor, the respective boost capacitor being chargeable by the respective boost switch to a portion of the boost voltage.

5. The power factor correcting power supply of claim 1, where the first boost converter includes a first boost capacitor and the second boost converter includes a second boost capacitor, the first and second boost sub-circuits configured to charge the first boost capacitor to a portion of the boost voltage and the third and fourth boost sub-circuits configured to charge the second boost capacitor to a portion of the boost voltage.

6. The power factor correcting power supply of claim 1, where each of the first, second, third and fourth boost sub-circuits include respective boost switches, each of the boost switches are independently switchable by the power factor correction controller with a double edge natural pulse width modulated triangle wave that is scaleable by the power factor correction controller based on the boost voltage.

7. The power factor correcting power supply of claim 1, further comprising an output stage power converter coupled with the first boost converter and the second boost converter.

8. The power factor correcting power supply of claim 1, where the boost voltage is a DC voltage.

9. The power factor correcting power supply of claim 1, where first boost converter is configured to supply a first boost voltage and the second boost converter is configured to supply a second boost voltage and the supplied boost voltage includes a summation of the first boost voltage and the second boost voltage.

10. The power factor correcting power supply of claim 1, where each of the first boost voltage and the second boost voltage is greater in magnitude than a peak magnitude of the input voltage.

11. The power factor correcting power supply of claim 1, where the respective first boost sub-circuit, the second boost sub-circuit, the third boost sub-circuit and the fourth boost sub-circuit are configured to receive the input voltage and supply the respective first boost sub-circuit output voltage, the second boost sub-circuit output voltage, the third boost sub-circuit output voltage and the fourth boost sub-circuit output voltage, and the supplied boost voltage is a summation of the first boost sub-circuit output voltage, the second boost sub-circuit output voltage, the third boost sub-circuit output voltage and the fourth boost sub-circuit output voltage.

12. The power factor correcting power supply of claim 11, where each of the first boost sub-circuit output voltage, the second boost sub-circuit output voltage, the third boost sub-circuit output voltage and the fourth boost sub-circuit output voltage is greater in magnitude than the peak magnitude of the input voltage.

13. The power factor correcting power supply of claim 12, where each of the first boost sub-circuit output voltage, the second boost sub-circuit output voltage, the third boost sub-circuit output voltage and the fourth boost sub-circuit output voltage is a DC voltage.

14. The power factor correcting power supply of claim 1, further comprising an output stage power converter coupled with the first boost converter and the second boost converter, where the output stage power converter includes a first output converter, a second output converter, and a switch mode converter, the switch mode converter configured with a predetermined switching duty cycle to substantially balance an output voltage of the first boost converter and the second boost converter.

15. A power factor correcting power supply comprising:

an input stage power converter that includes at least four boost switches coupled in series, the at least four boost switches configured to be coupled in parallel with an input voltage; and

a power factor correction controller coupled with the at least four boost switches, the power factor correction controller configured to direct the at least four boost switches independently with series interleave operation of a factor of at least four to provide a DC boost voltage from the input voltage,

where the power factor correction controller is configured with feedforward control to direct the at least four boost switches as a function of the DC boost voltage.

16. The power factor correcting power supply of claim 15, where the input voltage and the DC boost voltage is divided about equally between each of the at least four boost switches.

17. The power factor correcting power supply of claim 15, further comprising an output stage power converter coupled with the input stage power converter, where the output stage power converter includes a first output converter and a second output converter.

18. The power factor correcting power supply of claim 17, where the first output converter is coupled in parallel with a first pair of the at least four boost switches and the second output converter is coupled in parallel with a second pair of the at least four boost switches.

19. The power factor correcting power supply of claim 18, where the first output stage power converter and the second output stage power converter each comprises a switch mode converter with a predetermined switching duty cycle that substantially balances an output voltage of the first and second pairs of the at least four boost switches.

20. The power factor correcting power supply of claim 17, where each of the first and second output converters includes a switch mode converter, a transformer and a bridge rectifier to convert the DC boost voltage to a DC output voltage that is isolated from the DC boost voltage.

21. The power factor correcting power supply of claim 17, where each of the first and second output converters comprises a fixed frequency non-regulating half-bridge chopper.

22. The power factor correcting power supply of claim 15, where the input stage power converter includes at least four respective boost sub-switches configured to operate in time alternation with the respective at least four boost switches.

23. The power factor correcting power supply of claim 15, where the input voltage is an AC input voltage and two of the at least four boost switches are configured as a first full bridge converter and two of the at least four boost switches are configured as a second full bridge converter.

24. The power factor correcting power supply of claim 15, further comprising a bridge rectifier coupled with the input stage power converter, where the bridge rectifier is configured to provide a rectified AC input voltage as the input voltage to the input stage power converter.

25. The power factor correcting power supply of claim 15, further comprising a synchronous rectifier coupled with the input stage power converter, where the synchronous rectifier is configured to supply a rectified AC input voltage as the input voltage to the input stage power converter and receive an output voltage from the input stage power converter.

26. The power factor correcting power supply of claim 15, further comprising an output stage power converter coupled with the input stage power converter, where the output stage power converter includes a first output converter, a second output converter, and a switch mode converter, the switch mode converter configured with a predetermined switching duty cycle to substantially balance an output voltage of the first and second pairs of the at least four boost switches.

27. A power factor correcting power supply comprising:

an input stage power converter that includes a power factor correction controller and a first boost converter coupled in series with a second boost converter, where the first and second boost converters are controlled with interleave by the power factor correction controller to supply a DC boost voltage and to control a wave shape of an AC input current supplyable to the power factor correcting power supply by a power source; and

an output stage power converter coupled with the first and second boost converters, where the output stage power converter is configured to balance the boost voltage supplied with the first and second boost converters.

28. The power factor correcting power supply of claim 27, where the output stage power converter includes a first output converter and a second output converter, the first output converter coupled with the first boost converter, and the second output converter coupled with the second boost converter.

29. The power factor correcting power supply of claim 28, where the first and second output converters are configured to balance a voltage contribution to the DC boost voltage from each of the first and second boost converters.

30. The power factor correcting power supply of claim 27, where the first and second boost converters each include a plurality of boost sub-circuits coupled in series, where each of the boost sub-circuits include a boost switch.

31. The power factor correcting power supply of claim 27, where the first and second boost converters are controlled by the power factor correction controller with frequency modulation to reduce electromagnetic interference.

32. The power factor correcting power supply of claim 27, where the output stage power converter includes a fixed frequency switch mode power converter and a transformer, the fixed frequency switch mode power converter configured to provide a DC output voltage to a DC rail, and the transformer having galvanic isolation to minimize switching noise of the first and second boost converters.

33. The power factor correcting power supply of claim 27, where the output stage power converter includes an output converter and an output filter configured to convert the DC boost voltage to a DC output voltage supplyable to a load.

34. The power factor correcting power supply of claim 33, where the power factor controller is configured to regulate the DC output voltage as a function of the DC boost voltage and the DC output voltage.

35. The power factor correcting power supply of claim 33, where the power factor correction controller is configured to regulate the DC output voltage as a function of the DC boost voltage, the DC output voltage and the AC input current.

36. The power factor correcting power supply of claim 27, where the output stage power converter includes a switch mode converter configured with a predetermined switching duty cycle to substantially balance the boost voltage supplied with the first and second boost converters.

37. A power factor correcting power supply comprising:

an input stage power converter that includes a first pair of boost switches coupled in series and a second pair of boost switches coupled in series, where the first and the second pair of boost switches are coupled in series;

means for controlling power factor coupled with the first and the second pair of boost switches, the means for controlling power factor configured to control each of the first and the second pair of boost switches with interleave to provide a portion of a DC boost voltage; and

an output stage power converter coupled with the input stage power converter, where the output stage power converter includes a first output converter coupled with the first pair of boost switches and a second output converter coupled with the second pair of boost switches, where the output stage power converter is configured to substantially balance the portion of the DC boost voltage provided by each of the first and the second pair of boost switches.

38. The power factor correcting power supply of claim 37, where the input stage power converter includes an inductor and a plurality of boost capacitors that are coupled with the first and the second pair of boost switches, the first and the second pair of boost switches switchable to magnetize the inductor and charge the boost capacitors.

39. The power factor correcting power supply of claim 38, where the first pair of boost switches are cooperatively switchable to charge a first boost capacitor and the second pair of boost switches are cooperatively switchable to charge a second boost capacitor.

40. The power factor correcting power supply of claim 38, where a first and a second boost switch included in the first pair of boost switches are each switchable to charge a respective first and a second boost capacitor and a third and a fourth boost switch included in the second pair of boost switches are each switchable to charge a respective third and a fourth boost capacitor.

41. The power factor correcting power supply of claim 37, where the input stage power converter includes a first and a second pair of boost sub-switches coupled with the respective first and the second pair of boost switches, the input stage power converter configured to supply power to a power source and consume power from the power source as a function of control by the power factor correction controller.

42. The power factor correcting power supply of claim 37, where the input stage power converter includes a first and a second pair of diodes coupled with the respective first and the second pair of boost switches, the input stage power converter configured to consume power from a power source as a function of control by the power factor correction controller.

43. The power factor correcting power supply of claim 37, where the first output converter and the second output converter each comprises a switch mode converter with a predetermined switching duty cycle that substantially balances the portion of the DC boost voltage provided by each of the first and the second pair of boost switches.

44. A power factor correcting power supply comprising:

a first boost switch and a second boost switch, the first and second boost switches coupled in series and configured to be coupled in parallel with an AC power source;

a first boost sub-switch coupled in series with the first boost switch;

a second boost sub-switch coupled in series with the second boost switch;

a boost capacitor coupled across at least one of the first boost switch coupled in series with the first boost sub-switch and the second boost switch coupled in series with the second boost sub-switch; and

a power factor correction controller coupled with the first and second boost switches and the first and second boost sub-switches, where the first and second boost switches and the first and second boost sub-switches are switchable with pulse width modulation to develop at least a portion of a DC boost voltage on the boost capacitor from an unrectified AC input voltage supplyable from the AC power source, wherein the DC boost voltage is greater in magnitude than a peak magnitude of the AC input voltage.

45. The power factor correcting power supply of claim 44, where the boost capacitor is coupled across both the first boost switch and the first boost sub-switch and the boost capacitor is also coupled across the second boost switch and the second boost sub-switch.

46. The power factor correcting power supply of claim 44, where the boost capacitor comprises a first boost capacitor and a second boost capacitor, the first boost capacitor is coupled across the first boost switch and the first boost sub-switch and the second boost capacitor is coupled across the second boost switch and the second boost sub-switch.

47. The power factor correcting power supply of claim 44, where at least a portion of an output stage power converter is coupled in parallel with the boost capacitor.

48. The power factor correcting power supply of claim 44, further comprising an output stage power converter coupled in parallel with the boost capacitor, where the output stage converter includes a switch mode converter, a transformer and an output filter to convert the DC boost voltage to a DC output voltage that is isolated from the DC boost voltage.

49. The power factor correcting power supply of claim 44, further comprising an output stage power converter that includes a non-resonant fixed frequency switch mode converter and an isolation transformer to galvanically isolate the DC boost voltage.

50. The power factor correcting power supply of claim 44, where the power factor correcting power supply is operable with bilateral energy flow to consume power from the AC power source, and to supply power to the AC power source.

51. A method of performing power factor correction with a power factor correcting power supply, the method comprising:

providing a power source having an input voltage and an input current;

interleave switching at least four boost switches that are coupled in series across the power source to convert the input voltage to a first DC voltage;

converting the first DC voltage to a second DC voltage with an output stage power converter;

switching a switch mode converter included in the output stage power converter with a predetermined duty cycle to substantially balance conversion of the input voltage to the first DC voltage among the at least four boost switches; and

supplying the second DC voltage to a power rail to supply a load.

52. The method of claim 51, where interleave switching comprises regulating the second DC voltage to a desired magnitude as a function of the first DC voltage and the second DC voltage.

53. The method of claim 51, where interleave switching comprises substantially matching a waveform of a pulse width modulation voltage supplied to a boost capacitor by at least one of the at least four boost switches to a waveform of the input voltage.

54. The method of claim 53, where converting the first DC voltage to a second DC voltage comprises substantially balancing division of the first DC voltage between the at least four boost switches.

55. The method of claim 51, where interleave switching comprises dividing the input voltage and the first DC voltage between the at least four boost switches.

56. The method of claim 51, where interleave switching comprises creating a pulse width modulation voltage to charge a boost capacitor to at least a portion of the first DC voltage.

57. The method of claim 51, where converting the first DC voltage to a second DC voltage comprises galvanically isolating the first DC voltage from the second DC voltage.

58. The method of claim 51, where the input voltage is un-rectified AC input voltage, and the input current is un-rectified AC input current.

59. The method of claim 51, where the input voltage is rectified AC input voltage, and the input current is rectified AC input current.

60. The method of claim 51, where interleave switching at least four boost switches comprises series interleave switching with a factor of at least four.