Audio amplifier power supply with inherent power factor correction

• US 9,013,239 B2
• Filed: 05/02/2014
• Issued: 04/21/2015
• Est. Priority Date: 05/15/2012
• Status: Active Grant

• Current Assignee: Crestron Electronics Incorporated
• Original Assignee: Crestron Electronics Incorporated
• Inventors: Buono, Robert
• Primary Examiner(s): NGUYEN, PATRICIA T
• Application Number:
  US14/268,313
• Publication Number:
  US 20140240051A1
• Time in Patent Office: 354 Days
• Field of Search: 330/297, 330/127, 330/165
• US Class Current: 330/297
• CPC Class Codes: H02M 1/4258 using a single converter stage both for correction of AC input power factor and generation of a regulated and galvanically isolated DC output voltage H02M1/4241 takes precedence
• 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: H03F 1/0205 in transistor amplifiers
• CPC Class Codes: H03F 1/0211 with control of the supply voltage or current
• CPC Class Codes: H03F 2200/03 the amplifier being designed for audio applications
• CPC Class Codes: H03F 3/183 with semiconductor devices only
• 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

An audio amplifier is powered by a switch mode power supply optimized for audio applications. The power supply includes a rectifier circuit and a discontinuous mode multiphase isolated flyback power circuit and does not require a separate power factor correction stage. The discontinuous mode multiphase isolated flyback power circuit includes multiple isolated flyback converters operating synchronously to each convert a portion of the power and supply a phase-summed direct current voltage to the audio amplifier.

Claims

1. An audio amplifier power supply with inherent power factor correction, the audio amplifier power supply comprising:

(a) a rectifier circuit configured for rectifying an input voltage from an alternating current (AC) power source;

(b) a discontinuous mode multiphase isolated flyback power circuit configured for receiving the rectified input voltage from the rectifier circuit and supplying a phase-summed direct current (DC) voltage; and

(c) wherein the discontinuous mode multiphase isolated flyback power circuit further comprises a balancing circuit configured for balancing currents across each phase of the multiphase isolated flyback power circuit.

2. The audio amplifier power supply of claim 1 wherein the discontinuous mode multiphase isolated flyback power circuit comprises:

(a) an input rail;

(b) an output rail;

(c) a control circuit further comprising the balancing circuit; and

(d) a plurality of parallel isolated flyback converters coupled in parallel between the input rail and the output rail and configured for being synchronously controlled by the control circuit to supply the phase-summed direct current (DC) voltage.

3. The audio amplifier power supply of claim 2 wherein each one of the plurality of parallel isolated flyback converters further comprises:

(a) a switch configured for being synchronously switched conductive and nonconductive by the control circuit;

(b) a coupled inductor, the coupled inductor comprising

(i) a primary winding coupled in series between the switch and the input rail, and

(ii) a secondary winding inductively coupled to the primary winding;

(c) an output diode coupled in series between the secondary winding and the output rail; and

(d) a current sensing element configured for sensing the current in the switch.

4. The audio amplifier power supply of claim 1 wherein the discontinuous mode multiphase isolated flyback power circuit comprises

(a) an input rail;

(b) a positive output rail;

(c) a negative output rail;

(d) a control circuit; and

(e) a plurality of parallel isolated flyback converters coupled in parallel between the input rail and the positive output rail and negative output rail and wherein the plurality of parallel isolated flyback converters are configured for being synchronously controlled by the control circuit to produce a phase-summed direct current (DC) voltage.

5. The audio amplifier power supply of claim 4 wherein each one of the plurality of parallel isolated flyback converters further comprises:

(a) a switch configured for being synchronously switched conductive and nonconductive by the control circuit;

(b) a coupled inductor, the coupled inductor comprising

(i) a primary winding coupled in series between the switch and the input rail,

(ii) a positive secondary winding inductively coupled to the primary winding, and

(iii) a negative secondary winding inductively coupled to the primary winding;

(c) a first diode coupled in series between the positive secondary winding and the positive output rail;

(d) a second diode coupled in series between the negative secondary winding and the negative output rail; and

(e) a current sensing element configured for sensing the current in the switch.

6. The audio amplifier power supply of claim 5 wherein the control circuit is configured for synchronizing the duty cycles of the switches such that each one of the plurality of parallel isolated flyback converters converts a portion of the input power.

7. The audio amplifier power supply of claim 6 wherein n is the number of parallel isolated flyback converters and the duty cycle of each successive switch is synchronized 360/n degrees out of phase with the previous switch.

8. The audio amplifier power supply of claim 4 further comprising a feedback circuit configured for transmitting a feedback signal to the control circuit wherein the feedback signal is determined from the lower magnitude of the positive output rail and the negative output rail.

9. The audio amplifier power supply of claim 8 wherein the feedback circuit employs overvoltage protection.

10. The audio amplifier power supply of claim 4 further comprising a rectifier control circuit and wherein each one of the plurality of parallel isolated flyback converters further comprises:

(a) a switch configured for being synchronously switched conductive and nonconductive by the control circuit;

(b) a coupled inductor, the coupled inductor comprising

(i) a primary winding coupled in series between the switch and the input rail,

(ii) a positive secondary winding inductively coupled to the primary winding, and

(iii) a negative secondary winding inductively coupled to the primary winding;

(c) a first synchronized rectifier coupled in series between the positive secondary winding and the positive output rail and configured for being synchronously controlled by the rectifier control circuit; and

(d) a second synchronized rectifier coupled in series between the negative secondary winding and the negative output rail and configured for being controlled by the rectifier control circuit.

11. The audio amplifier power supply of claim 5 wherein each switch of the plurality of parallel isolated flyback converters is a plastic insulated power transistor.

12. The audio amplifier power supply of claim 11 wherein each plastic insulated power transistor is thermally coupled to a stamped heat sink soldered to a printed circuit board.

13. The audio amplifier power supply of claim 5 wherein each coupled inductor of the plurality of parallel isolated flyback converters is a ferrite core transformer with an air gap.

14. A method for supplying power inherently corrected for power factor, comprising the steps of:

(a) rectifying an input voltage of an AC power source;

(b) controlling the duty cycle of a switch of a parallel isolated flyback converter to convert a portion of the input power;

(c) repeating the step of controlling the duty cycle of a switch of a parallel isolated flyback converter to convert a portion of the input power for n parallel isolated flyback converters in succession such that the duty cycle of each successive switch of the n parallel isolated flyback converters is 360/n degrees out of phase with the duty cycle of the previous switch;

(d) supplying a phase summed direct current voltage to an audio power amplifier;

(e) determining a current through a switch for each of the n parallel isolated flyback converters;

(f) calculating an average current of each of the n parallel isolated flyback converters as a direct current value;

(g) for each of the n parallel isolated flyback converters, determining a difference between the average current and the current in that phase; and

(h) for each of the n parallel isolated flyback converters, adjusting the duty cycle of that parallel isolated flyback converter according to the determined difference.

15. The method of claim 14 wherein each of the n parallel isolated flyback converters comprises a coupled inductor further comprising a positive secondary winding and a negative secondary winding and wherein the phase summed direct current voltage is a bipolar direct current voltage.

16. The method of claim 15 further comprising the steps of:

(a) determining a lower magnitude of a negative DC voltage and positive DC voltage supplied by the n parallel isolated flyback converters;

(b) generating an error feedback signal according to the difference between the lower magnitude voltage and a desired voltage; and

(c) adjusting the duty cycle of the switch of each of the n parallel isolated flyback converters according to the error feedback signal.