Systems and methods for protecting power conversion systems from thermal runaway

• US 9,906,144 B2
• Filed: 02/10/2016
• Issued: 02/27/2018
• Est. Priority Date: 12/06/2013
• Status: Active Grant

• Current Assignee: On-Bright Electronics (Shanghai) Co., Ltd. (Orthosie Investment Holdings Ltd.)
• Original Assignee: On-Bright Electronics (Shanghai) Co., Ltd. (Orthosie Investment Holdings Ltd.)
• Inventors: Zhang, Yunchao, Zhang, Xiuhong, Fang, Lieyi
• Primary Examiner(s): Berhane, Adolf
• Assistant Examiner(s): DEMISSE, AFEWORK S
• Application Number:
  US15/040,674
• Publication Number:
  US 20160218631A1
• Time in Patent Office: 748 Days
• Field of Search: 363 2101, 363 2116, 363 50, 363 55, 363 56, 363 5609- 5611
• CPC Class Codes: H02M 1/0009 Devices or circuits for detecting current in a converter
• CPC Class Codes: H02M 1/08 Circuits specially adapted for the generation of control voltages for semiconductor devices incorporated in static converters
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• CPC Class Codes: H02M 1/327 against abnormal temperatures
• 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
• CPC Class Codes: H02M 3/33515 with digital control

Abstract

System and method for protecting a power conversion system. An example system controller includes a protection component and a driving component. The protection component is configured to receive a feedback signal, a reference signal, and a demagnetization signal generated based on at least information associated with the feedback signal, process information associated with the feedback signal, the reference signal, and the demagnetization signal, and generate a protection signal based on at least information associated with the feedback signal, the reference signal, and the demagnetization signal. The demagnetization signal is related to multiple demagnetization periods of the power conversion system, the multiple demagnetization periods including a first demagnetization period and a second demagnetization period. The driving component is configured to receive the protection signal and output a drive signal to a switch configured to affect a current flowing through a primary winding of the power conversion system.

Claims

1. A system controller for protecting a power conversion system, the system controller comprising:

a protection component configured to receive a feedback signal, a reference signal, and a demagnetization signal generated based at least in part on the feedback signal and to generate a protection signal based at least in part on the feedback signal, the reference signal, and the demagnetization signal, the demagnetization signal being related to multiple demagnetization periods of the power conversion system, the multiple demagnetization periods including a first demagnetization period and a second demagnetization period;

wherein the protection component is further configured to;

process the feedback signal and the reference signal during a first detection period, the first detection period including a first starting time and a first ending time, the first starting time being at or after a first demagnetization end of the first demagnetization period;

determine, during the first detection period, a first number of times that the feedback signal changes from being smaller than the reference signal to being larger than the reference signal in magnitude; and

determine whether the first number of times exceeds a predetermined threshold at the first ending time;

wherein the system controller is configured to, in response to the first number of times not exceeding the predetermined threshold at the first ending time, output a drive signal to cause a switch to open and remain open in order to protect the power conversion system, the switch being configured to affect a current flowing through a primary winding of the power conversion system.

2. The system controller of claim 1 wherein the system controller is further configured to, in response to the first number of times not exceeding the predetermined threshold at the first ending time, output the drive signal to cause the switch to open and remain open until the power conversion system is powered down and restarted.

3. The system controller of claim 1 wherein the system controller is further configured to, in response to the first number of times exceeding the predetermined threshold at the first ending time, output the drive signal to close and open the switch according to one or more modulation frequencies to operate the power conversion system.

4. The system controller of claim 1 wherein the protection component includes:

a comparator configured to receive the feedback signal and the reference signal and generate a comparison signal based at least in part on the feedback signal and the reference signal; and

a processing component configured to receive the comparison signal and output a first processed signal based at least in part on the comparison signal, the first processed signal being related to the first number of times that the feedback signal changes from being smaller than the reference signal to being larger than the reference signal in magnitude.

5. The system controller of claim 4 wherein the processing component is further configured to, in response to the first number of times not exceeding the predetermined threshold, keep the first processed signal at a first logic level.

6. The system controller of claim 5 wherein the processing component is further configured to, in response to the first number of times exceeding the predetermined threshold, change the first processed signal from the first logic level to a second logic level.

7. The system controller of claim 4 wherein the processing component includes:

an OR gate configured to receive the comparison signal and generate an input signal based at least in part on the comparison signal; and

a counter configured to receive the input signal and generate an output signal based at least in part on the input signal, the output signal being related to the first processed signal.

8. The system controller of claim 7 wherein the processing component further includes:

a first NOT gate configured to receive the demagnetization signal and output a second processed signal to the counter based at least in part on the demagnetization signal; and

a second NOT gate configured to receive the output signal and output the first processed signal based at least in part on the output signal.

9. The system controller of claim 8 wherein the counter includes one or more flip-flop components configured to receive the input signal and the second processed signal and generate the output signal based on at least information associated with the input signal and at least in part on the second processed signal.

10. The system controller of claim 7 wherein the OR gate is further configured to receive the first processed signal and generate the input signal based at least in part on the comparison signal and the first processed signal.

11. The system controller of claim 4, further comprising:

a timer configured to generate a timing signal associated with one or more pulses;

a first flip-flop component configured to receive the timing signal and the demagnetization signal and generate a trigger signal based at least in part on the timing signal and the demagnetization signal; and

a trigger configured to receive the trigger signal and generate an output signal based at least in part on the trigger signal.

12. The system controller of claim 11 wherein the timer is further configured to receive the trigger signal.

13. The system controller of claim 11 wherein the protection component is further configured to, if the timing signal is at a logic high level before the first demagnetization end and the timing signal changes from the logic high level to a logic low level in response to the first demagnetization end, determine, during the first detection period, the first number of times that the feedback signal changes from being smaller than the reference signal to being larger than the reference signal in magnitude.

14. The system controller of claim 11 wherein the processing component further includes:

a second flip-flop component configured to;

receive the first processed signal; and

in response to the first number of times not exceeding the predetermined threshold at the first ending time, output the protection signal at a logic level based at least in part on the first processed signal in order to cause the switch to open and remain open in order to protect the power conversion system.

15. The system controller of claim 11 wherein the first ending time is at or before an end of an off-time period including the first demagnetization period.

16. The system controller of claim 15 wherein the switch remains open during the off-time period.

17. The system controller of claim 11 wherein the protection component is further configured to, during a second detection period, process the feedback signal and the reference signal and determine a second number of times that the feedback signal changes from being smaller than the reference signal to being larger than the reference signal in magnitude, the second detection period being separated from the first detection period by one or more switching periods associated with the drive signal.

18. The system controller of claim 17 wherein the second detection period includes a second starting time and a second ending time, the second starting time being at or after a second demagnetization end of the second demagnetization period.

19. The system controller of claim 11, further comprising:

an AND gate configured to receive the protection signal and generate a third processed signal based at least in part on the protection signal; and

a third flip-flop component configured to receive the third processed signal and output a flip-flop signal to a driver based at least in part on the third processed signal.

20. The system controller of claim 1, further comprising a demagnetization detector configured to receive the feedback signal and generate the demagnetization signal based at least in part on the feedback signal.

21. The system controller of claim 1 wherein the second demagnetization period is separated from the first demagnetization period by one or more switching periods associated with the drive signal.

22. A system controller for protecting a power conversion system, the system controller comprising:

a protection component configured to receive a feedback signal, a reference signal, and a demagnetization signal generated based at least in part on the feedback signal and to generate a protection signal based at least in part on the feedback signal, the reference signal, and the demagnetization signal, the demagnetization signal being related to multiple demagnetization periods of the power conversion system, the multiple demagnetization periods including a first demagnetization period and a second demagnetization period;

wherein the protection component is further configured to;

process the feedback signal and the reference signal during a first detection period, the first detection period including a first starting time and a first ending time, the first starting time being at or after a first demagnetization end of the first demagnetization period;

determine, during the first detection period, a first number of times that the feedback signal changes from being larger than the reference signal to being smaller than the reference signal in magnitude; and

determine whether the first number of times exceeds a predetermined threshold at the first ending time;

wherein the system controller is configured to, in response to the first number of times not exceeding the predetermined threshold at the first ending time, output a drive signal to cause a switch to open and remain open in order to protect the power conversion system, the switch being configured to affect a current flowing through a primary winding of the power conversion system.

23. The system controller of claim 22 wherein the system controller is further configured to, in response to the first number of times not exceeding the predetermined threshold at the first ending time, output the drive signal to cause the switch to open and remain open until the power conversion system is powered down and restarted.

24. The system controller of claim 22 wherein the system controller is further configured to, in response to the first number of times exceeding the predetermined threshold at the first ending time, output the drive signal to close and open the switch according to one or more modulation frequencies to operate the power conversion system.

25. The system controller of claim 22 wherein the protection component includes:

a comparator configured to receive the feedback signal and the reference signal and generate a comparison signal based at least in part on the feedback signal and the reference signal; and

a processing component configured to receive the comparison signal and output a processed signal based at least in part on the comparison signal, the processed signal being related to the first number of times that the feedback signal changes from being larger than the reference signal to being smaller than the reference signal in magnitude.

26. The system controller of claim 25 wherein the processing component includes:

an OR gate configured to receive the comparison signal and generate an input signal based at least in part on the comparison signal; and

a counter configured to receive the input signal and generate an output signal based at least in part on the input signal, the output signal being related to the processed signal.

27. The system controller of claim 26 wherein the OR gate is further configured to receive the processed signal and generate the input signal based at least in part on the comparison signal and the processed signal.

28. The system controller of claim 25 wherein the processing component is further configured to, in response to the first number of times not exceeding the predetermined threshold, keep the processed signal at a first logic level.

29. The system controller of claim 28 wherein the processing component is further configured to, in response to the first number of times exceeding the predetermined threshold, change the processed signal from the first logic level to a second logic level.

30. The system controller of claim 25, further comprising:

a timer configured to generate a timing signal associated with one or more pulses;

a first flip-flop component configured to receive the timing signal and the demagnetization signal and generate a trigger signal based at least in part on the timing signal and the demagnetization signal; and

a trigger configured to receive the trigger signal and generate an output signal based at least in part on the trigger signal.

31. The system controller of claim 30 wherein the processing component further includes:

a second flip-flop component configured to;

receive the processed signal; and

in response to the first number of times not exceeding the predetermined threshold at the first ending time, output the protection signal at a logic level based at least in part on the processed signal in order to cause the switch to open and remain open in order to protect the power conversion system.

32. The system controller of claim 30 wherein the first ending time is at or before an end of an off-time period including the first demagnetization period.

33. The system controller of claim 32 wherein the switch remains open during the off-time period.

34. The system controller of claim 25 wherein the protection component is further configured to, if the timing signal is at a logic high level before the first demagnetization end and the timing signal changes from the logic high level to a logic low level in response to the first demagnetization end, determine, during the first detection period, the first number of times that the feedback signal changes from being larger than the reference signal to being smaller than the reference signal in magnitude.

35. The system controller of claim 25 wherein the protection component is further configured to, during a second detection period, process the feedback signal and the reference signal and determine a second number of times that the feedback signal changes from being larger than the reference signal to being smaller than the reference signal in magnitude, the second detection period being separated from the first detection period by one or more switching periods associated with the drive signal.

36. The system controller of claim 35 wherein the second detection period includes a second starting time and a second ending time, the second starting time being at or after a second demagnetization end of the second demagnetization period.

37. The system controller of claim 22 wherein the second demagnetization period is separated from the first demagnetization period by one or more switching periods associated with the drive signal.

38. A method for protecting a power conversion system, the method comprising:

receiving a feedback signal, a reference signal, and a demagnetization signal generated based at least in part on the feedback signal;

processing the feedback signal, the reference signal, and the demagnetization signal;

generating a protection signal based at least in part on the feedback signal, the reference signal, and the demagnetization signal, the demagnetization signal being related to multiple demagnetization periods of the power conversion system, the multiple demagnetization periods including a first demagnetization period and a second demagnetization period; and

outputting a drive signal;

wherein the processing the feedback signal, the reference signal, and the demagnetization signal includes;

processing the feedback signal and the reference signal during a detection period, the detection period including a starting time and an ending time, the starting time being at or after a demagnetization end of the first demagnetization period;

determining, during the detection period, a number of times that the feedback signal changes from being smaller than the reference signal to being larger than the reference signal in magnitude; and

determining whether the number of times exceeds a predetermined threshold at the ending time;

wherein the outputting a drive signal includes;

in response to the number of times not exceeding the predetermined threshold at the ending time, outputting the drive signal to cause a switch to open and remain open in order to protect the power conversion system.

39. The method of claim 38 wherein the outputting the drive signal to cause the switch to open and remain open in order to protect the power conversion system includes outputting the drive signal to cause the switch to open and remain open until the power conversion system is powered down and restarted.

40. The method of claim 38, wherein the ending time is at or before an end of an off-time period including the first demagnetization period.

41. The method of claim 40, wherein the switch remains open during the off-time period.

42. A method for protecting a power conversion system, the method comprising:

receiving a feedback signal, a reference signal, and a demagnetization signal generated based at least in part on the feedback signal;

processing the feedback signal, the reference signal, and the demagnetization signal;

generating a protection signal based at least in part on the feedback signal, the reference signal, and the demagnetization signal, the demagnetization signal being related to multiple demagnetization periods of the power conversion system, the multiple demagnetization periods including a first demagnetization period and a second demagnetization period; and

outputting a drive signal;

wherein the processing the feedback signal, the reference signal, and the demagnetization signal includes;

processing the feedback signal and the reference signal during a detection period, the detection period including a starting time and an ending time, the starting time being at or after a demagnetization end of the first demagnetization period;

determining, during the detection period, a number of times that the feedback signal changes from being larger than the reference signal to being smaller than the reference signal in magnitude; and

determining whether the number of times exceeds a predetermined threshold at the ending time;

wherein the outputting a drive signal includes;

in response to the number of times not exceeding the predetermined threshold at the ending time, outputting the drive signal to cause a switch to open and remain open in order to protect the power conversion system.

43. The method of claim 42 wherein the outputting the drive signal to cause the switch to open and remain open in order to protect the power conversion system includes outputting the drive signal to cause the switch to open and remain open until the power conversion system is powered down and restarted.

44. The method of claim 42, wherein the ending time is at or before an end of an off-time period including the first demagnetization period.

45. The method of claim 44, wherein the switch remains open during the off-time period.