DC-DC switching cell modules for on-board power systems

• US 8,004,111 B2
• Filed: 01/22/2008
• Issued: 08/23/2011
• Est. Priority Date: 01/19/2007
• Status: Expired due to Fees

• Current Assignee: Astec International Limited (Emerson Electric Company)
• Original Assignee: Astec International Limited (Emerson Electric Company)
• Inventors: Mao, Hong, Potter, Geoffrey
• Primary Examiner(s): Fureman; Jared J
• Assistant Examiner(s): Amrany; Adi
• Application Number:
  US12/009,827
• Publication Number:
  US 20080238208A1
• Time in Patent Office: 1,309 Days
• Field of Search: 307 18- 20
• US Class Current: 307/20
• CPC Class Codes: G06F 1/26 Power supply means, e.g. regulation thereof for memories G11C
• CPC Class Codes: H02J 1/08 Three-wire systems; Systems having more than three wires
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 1/008 Plural converter units for generating at two or more independent and non-parallel outputs, e.g. systems with plural point of load switching regulators
• CPC Class Codes: H02M 3/157 with digital control

Abstract

A DC-DC switching cell module includes a switch, a rectifier, an output filter coupled to the rectifier, and an input port for receiving an external PWM control signal from a controller. The switching cell module is configured to control the switch in response to the external PWM control signal to generate a DC output voltage from a DC input voltage. The switching cell module is configured for attachment to a circuit board as a discrete component.

Claims

1. A distributed power system comprising a centralized controller, a multiplexer, a plurality of DC-DC switching cell modules, and a plurality of loads, each DC-DC switching cell module adapted to generate a DC output voltage from a DC input voltage, each DC-DC switching cell module including at least one switch, an output filter, an inductor coupled to the output filter, and an input port for receiving a PWM control signal from the centralized controller, a first DC-DC switching cell module of the plurality of DC-DC switching cell modules coupled to provide power to a first one of the plurality of loads, a second DC-DC switching cell module of the plurality of DC-DC switching cell modules coupled to provide power to a second one of the plurality of loads, the centralized controller configured to output a first PWM control signal to the input port of the first DC-DC switching cell module and a second PWM control signal to the input port of the second DC-DC switching cell module to thereby control the power provided to the first one and the second one of the plurality of loads, the multiplexer coupled to receive a plurality of output voltages from the plurality of switching cell modules, the centralized controller configured to sample the plurality of output voltages one at a time via the multiplexer, and the multiplexer coupled to receive output voltages from less than all of the plurality of switching cell modules.

2. The distributed power system of claim 1 wherein the centralized controller comprises a digital controller.

3. The distributed power system of claim 1 wherein each DC-DC switching cell module includes an output port for providing a feedback signal to the centralized controller and the centralized controller includes at least one input port to receive the feedback signals.

4. The distributed power system of claim 3 wherein the centralized controller is configured to regulate the DC output voltages of the plurality of switching cell modules in response to the feedback signals.

5. The distributed power system of claim 1 wherein each DC-DC switching cell module includes a driver configured to control its at least one switch in response to its PWM control signal from the centralized controller to generate a DC output voltage from a DC input voltage.

6. The distributed power system of claim 1 wherein at least one of the plurality of switching cell modules is configured to generate a different DC output voltage than another one of the plurality of switching cell modules.

7. The distributed power system of claim 1 wherein the centralized controller includes the multiplexer.

8. The distributed power system of claim 1 wherein the centralized controller includes an input port and wherein at least one of the output voltages not sampled via the multiplexer is sampled by the centralized controller via the input port.

9. The distributed power system of claim 1 wherein the plurality of output voltages are sampled in a sequence via the multiplexer.

10. The distributed power system of claim 1 wherein at least one of the plurality of switching cell modules is configured to provide a DC output voltage to a voltage bus.

11. The distributed power system of claim 10 wherein the DC output voltage for the voltage bus is a regulated DC voltage.

12. The distributed power system of claim 10 wherein one of the plurality of switching cell modules includes a DC voltage input port connected to the voltage bus.

13. The distributed power system of claim 1 wherein at least two of the plurality of switching cell modules have voltage output ports connected in parallel.

14. The distributed power system of claim 1 wherein at least one of the plurality of switching cell modules is an isolated DC-DC converter.

15. The distributed power system of claim 1 further comprising an additional DC-DC switching cell module, the additional DC-DC switching cell module including a switch, an output filter, and an input port for receiving an unmodulated control signal from the centralized controller, and wherein the centralized controller is configured to provide the unmodulated control signal to the input port of the additional switching cell module, the unmodulated control signal having a fixed pulse width.

16. A distributed power system comprising an external controller, a first DC-DC switching cell module for supplying a DC output voltage to a first load, and a second DC-DC switching cell module for supplying a DC output voltage to a second load, the first and second DC-DC switching cell modules each including a switch, an output filter, an inductor coupled to the output filter, and an input port for receiving a PWM control signal from the external controller, the external controller configured to provide a first PWM control signal to the input port of the first DC-DC switching cell module and a second PWM control signal to the input port of the second DC-DC switching cell module, the first DC-DC switching cell module configured to generate a first DC output voltage from a DC input voltage in response to the first PWM control signal from the external controller, the second DC-DC switching cell module configured to generate a second DC output voltage from a DC input voltage in response to the second PWM control signal from the external controller, the first DC-DC switching cell module coupled to output the first DC output voltage to a voltage bus, and the second DC-DC switching cell module including a DC voltage input port connected to the voltage bus.

17. The distributed power system of claim 16 wherein the external controller comprises a digital controller.

18. The distributed power system of claim 16 wherein the first and second DC-DC switching cell modules each includes an output port for providing a feedback signal to the external controller and the external controller includes at least one input port to receive the feedback signals.

19. The distributed power system of claim 18 wherein the external controller is configured to regulate the first and second DC output voltages in response to the feedback signals.

20. The distributed power system of claim 16 wherein the first DC-DC switching cell module includes a driver configured to control its at least one switch in response to the first PWM control signal from the external controller to generate the first DC output voltage.

21. The distributed power system of claim 16 wherein the first DC-DC switching cell module is configured to generate a different DC output voltage than the second DC-DC switching cell module.

22. The distributed power system of claim 16 further comprising a multiplexer, the multiplexer coupled to receive the first DC output voltage from the first DC-DC switching cell module and the second DC output voltage from the second DC-DC switching cell module, the controller configured to sample the first and second DC output voltages one at a time via the multiplexer.

23. The distributed power system of claim 22 wherein the external controller includes the multiplexer.

24. The distributed power system of claim 22 further comprising a third DC-DC switching cell module, the third DC-DC switching cell module including a switch, an output filter, and an input port for receiving a PWM control signal from the external controller, wherein the external controller is configured to provide a third PWM control signal to the input port of the third DC-DC switching cell module, and the third DC-DC switching cell module is configured to generate a third DC output voltage from a DC input voltage in response to the third PWM control signal from the external controller.

25. The distributed power system of claim 24 wherein the external controller includes an input port and wherein the third DC output voltage is sampled by the external controller via the input port.

26. The distributed power system of claim 24 wherein the multiplexer is coupled to receive the third output voltage from the third DC-DC switching cell module, and the controller is configured to sample the first, second, and third DC output voltages one at a time via the multiplexer.

27. The distributed power system of claim 26 wherein the first, second, and third DC output voltages are sampled in a sequence via the multiplexer.

28. The distributed power system of claim 24 wherein the second and third DC-DC switching cell modules have voltage output ports connected in parallel.

29. The distributed power system of claim 24 wherein at least one of the first, second and third DC-DC switching cell modules is an isolated DC-DC converter.

30. The distributed power system of claim 16 further comprising a third DC-DC switching cell module, the third DC-DC switching cell module including a switch, an output filter, and an input port for receiving a control signal from the external controller, wherein the external controller is configured to provide a control signal having a fixed duty cycle to the input port of the third DC-DC switching cell module, and the third DC-DC switching cell module is configured to generate a third DC output voltage from a DC input voltage in response to the control signal from the external controller.

31. A distributed power system comprising a centralized controller, a plurality of DC-DC switching cell modules, and a plurality of loads, each DC-DC switching cell module adapted to generate a DC output voltage from a DC input voltage, each DC-DC switching cell module including at least one switch, an output filter, an inductor coupled to the output filter, and an input port for receiving a PWM control signal from the centralized controller, a first DC-DC switching cell module of the plurality of DC-DC switching cell modules coupled to provide power to a first one of the plurality of loads, a second DC-DC switching cell module of the plurality of DC-DC switching cell modules coupled to provide power to a second one of the plurality of loads, the centralized controller configured to output a first PWM control signal to the input port of the first DC-DC switching cell module and a second PWM control signal to the input port of the second DC-DC switching cell module to thereby control the power provided to the first one and the second one of the plurality of loads, at least one of the plurality of switching cell modules configured to provide a DC output voltage to a voltage bus, and at least one of the plurality of switching cell modules including a DC voltage input port connected to the voltage bus.

32. The distributed power system of claim 31 wherein each DC-DC switching cell module includes an output port for providing a feedback signal to the centralized controller and the centralized controller includes at least one input port to receive the feedback signals.

33. The distributed power system of claim 32 wherein the centralized controller is configured to regulate the DC output voltages of the plurality of switching cell modules in response to the feedback signals.

34. The distributed power system of claim 31 wherein each DC-DC switching cell module includes a driver configured to control its at least one switch in response to its PWM control signal from the centralized controller to generate a DC output voltage from a DC input voltage.

35. The distributed power system of claim 31 wherein at least two of the plurality of switching cell modules have voltage output ports connected in parallel.

36. The distributed power system of claim 31 wherein at least one of the plurality of switching cell modules is configured to generate a different DC output voltage than another one of the plurality of switching cell modules.

37. The distributed power system of claim 31 wherein the DC output voltage for the voltage bus is a regulated DC voltage.

38. The distributed power system of claim 31 wherein at least one of the plurality of switching cell modules is an isolated DC-DC converter.

39. The distributed power system of claim 31 further comprising an additional DC-DC switching cell module, the additional DC-DC switching cell module including a switch, an output filter, and an input port for receiving an unmodulated control signal from the centralized controller, and wherein the centralized controller is configured to provide the unmodulated control signal to the input port of the additional switching cell module, the unmodulated control signal having a fixed pulse width.