Over power protection for power converter
10122259 ยท 2018-11-06
Assignee
Inventors
Cpc classification
H02M1/32
ELECTRICITY
H02M1/0058
ELECTRICITY
Y02B70/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
Abstract
A power conversion circuit is provided. A power level of the power conversion circuit is determined by taking a first sample of a voltage potential of a resonant capacitor at a first time. A second sample of the voltage potential of the resonant capacitor voltage is taken at a second time. An electric current is determined based on the first sample and second sample.
Claims
1. A power conversion circuit, comprising: an average current circuit including an input coupled for receiving a sampling signal representative of a current through a primary winding, wherein the average current circuit measures the sampling signal at a first time and a second time; a power level circuit including a first input coupled to an output of the average current circuit and a second input coupled for receiving an input voltage of the power conversion circuit to determine an input power of the power conversion circuit as a product of the input voltage and a difference between the measurements of the sampling signal at the first time and second time; a first amplifier including a first input coupled for receiving a power reference and a second input coupled to an output of the power level circuit; a variable feedback clamp including a control input coupled to an output of the first amplifier; and a second amplifier including a first input coupled for receiving the sampling signal and a second input coupled to the variable feedback clamp and further coupled for receiving a feedback signal of the power conversion circuit.
2. The power conversion circuit of claim 1, further including: a first power transistor including a first conduction terminal coupled for receiving the input voltage, a second conduction terminal coupled to the primary winding, and a control input coupled to an output of the second amplifier; and a second power transistor including a first conduction terminal coupled to the second conduction terminal of the first transistor, a second conduction terminal coupled to a ground terminal, and a control input coupled to the output of the second amplifier.
3. The power conversion circuit of claim 2, further including a driver logic circuit including an input coupled to the output of the second amplifier, a first output coupled to the control input of the first power transistor, and a second output coupled to the control input of the second power transistor.
4. The power conversion circuit of claim 1, further including a voltage offset circuit coupled between the sampling signal and the first input of the second amplifier.
5. The power conversion circuit of claim 1, further including: a first circuit node adapted for coupling to the primary winding of the power conversion circuit; a resonant capacitor coupled between the first circuit node and a ground terminal; a first capacitor coupled between the first circuit node and a second circuit node; and a second capacitor coupled between the second circuit node and ground terminal, wherein the second circuit node provides the sampling signal.
6. The power conversion circuit of claim 5, further including a resistor coupled between the second circuit node and the ground terminal.
7. A power conversion circuit, comprising: an average current circuit including an input coupled for receiving a sampling signal representative of a current through a primary winding, wherein the average current circuit measures the sampling signal at a first time and a second time; and a power level circuit including a first input coupled to an output of the average current circuit and a second input coupled for receiving an input voltage of the power conversion circuit to determine an input power of the power conversion circuit as a product of the input voltage and a difference between the measurements of the sampling signal at the first time and second time.
8. The power conversion circuit of claim 7, further including a first amplifier including a first input coupled for receiving a power reference and a second input coupled to an output of the power level circuit.
9. The power conversion circuit of claim 8, further including: a variable feedback clamp including a control input coupled to an output of the first amplifier; and a second amplifier including a first input coupled for receiving the sampling signal and a second input coupled to the variable feedback clamp and further coupled for receiving a feedback signal of the power conversion circuit.
10. The power conversion circuit of claim 9, further including: a first power transistor including a first conduction terminal coupled for receiving the input voltage, a second conduction terminal coupled to the primary winding, and a control input coupled to an output of the second amplifier; and a second power transistor including a first conduction terminal coupled to the second conduction terminal of the first transistor, a second conduction terminal coupled to a ground terminal, and a control input coupled to the output of the second amplifier.
11. The power conversion circuit of claim 10, further including a driver logic circuit including an input coupled to the output of the second amplifier, a first output coupled to the control input of the first power transistor, and a second output coupled to the control input of the second power transistor.
12. The power conversion circuit of claim 9, further including a voltage offset circuit coupled between the sampling signal and the first input of the second amplifier.
13. The power conversion circuit of claim 7, further including: a first circuit node adapted for coupling to the primary winding of the power conversion circuit; a resonant capacitor coupled between the first circuit node and a ground terminal; a first capacitor coupled between the first circuit node and a second circuit node; and a second capacitor coupled between the second circuit node and ground terminal, wherein the second circuit node provides the sampling signal.
14. A method of determining an input power for a power conversion circuit, comprising: measuring a sampling signal representative of a current through a primary winding at a first time and a second time; and determining the input power as a product of an input voltage of the power conversion circuit and a difference between the measurements of the sampling signal at the first time and second time.
15. The method of claim 14, further including comparing the determined input power and a power reference.
16. The method of claim 15, further including clamping a feedback signal of the power conversion circuit in response to comparing the determined input power and the power reference.
17. The power conversion circuit of claim 16, further including comparing the sampling signal to the clamped feedback signal.
18. The power conversion circuit of claim 17, further including controlling a power transistor in response to comparing the sampling signal to the clamped feedback signal.
19. The method of claim 14, further including sensing the current through the primary winding as a voltage across a resonant capacitor.
20. The method of claim 19, further including dividing down the voltage across the resonant capacitor as the sampling signal.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE DRAWINGS
(8) The following describes one or more embodiments with reference to the figures, in which like numerals represent the same or similar elements. While the figures are described in terms of the best mode for achieving certain objectives, the description is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the disclosure.
(9)
(10) The divided voltage across resonant capacitor 136 at circuit node 166, referred to as V.sub.CS, is supplied as an input to average current calculator 170. Average current calculator 170 samples the voltage potential at circuit node 166 to determine the average current through primary winding 132 while ignoring the current through magnetizing inductance 134, as explained in more detail with reference to subsequent figures. To ignore current through magnetizing inductance 134, average current calculator 170 takes a first sample of V.sub.CS at time 0 in
(11) Average current calculator 170 outputs a signal at circuit node 172 proportional to V.sub.CS divided by the on-time of MOSFET 112. Circuit node 172 contains an analog signal with a voltage potential representative of V.sub.CS over time in one embodiment. In other embodiments, circuit node 172 is a digital bus on an integrated circuit, or a hardware register value, that contains a digital value proportional to V.sub.CS over time. One formula for calculating electric power is given by the equation P=V*I, where P is electric power, V is voltage, and I is current. Input power calculator 174 calculates the input power of LLC resonant mode converter 100 by multiplying the average current value at circuit node 172 with the voltage potential received at circuit node 110.
(12) In some embodiments, an analog multiplier is used to output an analog signal at circuit node 176 proportional to the power input of LLC resonant mode converter 100. In one embodiment, input power calculator 174 receives or determines a digital value proportional to the voltage at circuit node 110, and uses a microprocessor to multiply the digital voltage value with a digital current value received at circuit node 172. In other embodiments, average current calculator 170 and input power calculator 174 represent subroutines executing on a microprocessor, and circuit nodes 172 and 176 represent hardware registers or other memory elements that store variables representative of input current and power.
(13) In some embodiments, input power calculator 174 introduces an offset to the power calculation output at circuit node 176. Adding an offset in input power calculator 174 allows the power level signal at circuit node 176 to compensate for inefficiencies in LLC resonant mode converter 100. The offset added by input power calculator 174 is a fixed value added to or subtracted from the input power calculation in some embodiments. In other embodiments, the offset is proportional to the input current, i.e., a larger offset is added by input power calculator 174 for larger input currents.
(14) Input power calculator 174 outputs an analog or digital signal at circuit node 176 that is proportional to the input power of LLC resonant mode converter 100. Power reference 180 provides a signal that represents a desired value of circuit node 176. Comparator 178 receives the power level signal at circuit node 176 and power reference 180. As illustrated, comparator 178 is an operational amplifier (op-amp), with capacitor 182 provided as a feedback path to turn comparator 178 into an integrator. In other embodiments, power reference 180 and input power calculator 174 output digital values, and comparator 178 is a digital comparator or integrator. In one embodiment, comparator 178 is a software subroutine running on a microprocessor, and circuit node 176, power reference 180, and circuit node 183 are variables stored in hardware registers or other memory.
(15) Comparator 178 compares the signal from power reference 180 to the power level signal at circuit node 176, and generates an output at circuit node 183 indicating how far off the input power signal at circuit node 176 is from power reference 180. Circuit node 183 is coupled as an input to variable feedback clamp 184. Variable feedback clamp 184 clamps a feedback voltage, V.sub.FB, at circuit node 185 to a maximum voltage potential dictated by a voltage potential at circuit node 183. In embodiments where circuit node 183 is a digital value, a digital-to-analog converter is coupled between comparator 178 and variable feedback clamp 184. In other embodiments, variable feedback clamp 184 is programmable with a digital value. Variable feedback clamp 184 is illustrated as a variable Zener diode used as a voltage clamp, but a variable current clamp is used in other embodiments. A feedback signal from secondary side 104 of LLC resonant mode converter 100 is generated as shown in
(16) An optional offset 188 is applied to the current sense voltage, V.sub.CS, at circuit node 166, and then V.sub.CS is compared to V.sub.FB by comparator 186. The output of comparator 186 is routed via circuit node 187 to driver logic 190. Driver logic 190 is a controller that turns MOSFETs 112 and 116 on or off by toggling a voltage at gate terminals 114 and 118. In one embodiment, driver logic 190 is a block formed on a common IC with average current calculator 170 and input power calculator 174. In some embodiments, an additional half-bridge driver is used between driver logic 190 and MOSFETs 112 and 116.
(17) Driver logic 190 turns off MOSFET 112 when V.sub.CS exceeds V.sub.FB, at time 2 in
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(19) Once the voltage potential at output circuit node 150 increases to reach or exceed a desired output voltage potential, voltage regulator 200 turns on optocoupler 202 to couple the input of buffer 210 to ground node 108 through the optocoupler. V.sub.FB at circuit node 185 is reduced, which reduces the on-time of MOSFET 112 and the amount of power transferred through transformer 130 to secondary side 104. Voltage regulator 200 increases or decreases power transfer through transformer 130 to keep output circuit node 150 at approximately a desired voltage potential.
(20) The control signal at circuit node 183, generated by OPP 160, limits the amount of power that is transferred when voltage regulator 200 turns off optocoupler 202. Limiting power output to a desired level protects MOSFET 112, MOSFET 116, transformer 130, diodes 142 and 144, and other parts of LLC resonant mode converter 100 from overheating and potentially from damage to the components. Without OPP 160, the maximum power output of LLC resonant mode converter 100 increases with input voltage. LLC resonant mode converter 100 might be calibrated to have a desired maximum power output, e.g., 100 Watts, at 120 Volt input, but might be capable of outputting 200 Watts of power at 230 Volt input which could overheat or damage the converter. OPP 160 limits output power of LLC resonant mode converter 100 to an approximately constant maximum value over a range of input voltages.
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(22) At step 230, average current calculator 170 waits for a rising edge of the control signal at gate terminal 114 of MOSFET 112, indicating that MOSFET 112 was turned on. Flow chart 220 advances to step 232 at the rising edge of gate terminal 114. In step 232, average current calculator 170 takes a sample of a voltage potential at V.sub.CS node 166 and starts a timing circuit to measure the length of time that gate terminal 114 remains high.
(23) After sampling V.sub.CS node 166 and starting the timer, OPP 160 advances to step 234, which is to wait for a falling edge of the voltage potential at gate terminal 114. Flow chart 220 remains in step 234 until the falling edge of gate terminal 114 is detected, at which time step 236 is reached. In step 236, OPP 160 takes a second sample of V.sub.CS and stops the timer. After step 236, OPP 160 has determined three variables: the voltage potential of V.sub.CS when MOSFET 112 was turned on, the voltage potential of V.sub.CS when MOSFET 112 was turned off, and the amount of time that MOSFET 112 was turned on. Those three variables are stored in three different hardware registers or other memory in one embodiment. In another embodiment, the three variables exist as three different analog voltage on three circuit nodes.
(24) At step 238, average current calculator 170 uses the three variables to calculate average input current. Average current is calculated based on V.sub.CS, i.e., the difference between the two samples of V.sub.CS node 166, divided by the time between the two samples. The average current calculated by average current calculator 170 in step 238 is stored in a variable for use by input power calculator 174 in steps 240-242.
(25) At step 240, input power calculator 174 takes a sample of the input voltage at circuit node 110. Input power calculator 174 samples circuit node 110 simultaneously with the first or second sample of V.sub.CS node 166 in some embodiments. In other embodiments, the sample of input voltage at circuit node 110 is taken between V.sub.CS samples, before the first V.sub.CS sample, or after the second sample of V.sub.CS. In some executions of flow chart 220, input power calculator 174 does not sample input voltage at circuit node 110 and instead uses a previously sampled value.
(26) At step 242, input power calculator 174 calculates the input power of LLC resonant mode converter 100 by multiplying the average current calculated at step 238 with the voltage detected at step 240. At step 244, the value at circuit node 183 is modified by comparator 178. Comparator 178 represents a calculation performed by a microprocessor, and circuit node 183 represents a digital value stored in a variable as a result of the calculation. A digital-to-analog converter outputs an analog value proportional to the stored digital value to variable feedback clamp 184. In other embodiments, an op-amp is used for comparator 178 and circuit node 183 contains an analog value output from the op-amp.
(27) The result of step 244 is a reduction in the voltage potential at V.sub.FB node 185 if input power to LLC resonant mode converter 100 exceeds a threshold. The reduction of V.sub.FB decreases on-time of MOSFET 112 in subsequent power transfer cycles, and thus reduces the power transferred through transformer 130 to secondary side 104. The controller of LLC resonant mode converter 100, e.g., driver logic 190, uses the same on-time for MOSFET 116 as MOSFET 112 in some embodiments. State 246 represents an optional delay between subsequent executions of flow chart 220. OPP 160 recalculates input power every 100 milliseconds, every second, every desired number of pulses of gate terminal 114, or any other appropriate amount of delay time in various embodiments. In some embodiments, OPP 160 recalculates input power every pulse of gate terminal 114. In other embodiments, OPP 160 calculates input power on pulses of gate terminal 118, or based on transitions of HB node 122.
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(29) Because negligible power is transferred from primary side 102 to secondary side 104 through transformer 130 during the on-time of MOSFET 112, magnetizing current 157 is the only significant component affecting V.sub.CS. As illustrated by magnetizing current 157 in
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(31) The heavy load on LLC resonant mode converter 100 in
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(33) An ADC triggering block 310 receives signals 312, 314, 114, and 118 as inputs, and triggers samples of V.sub.CS and V.sub.IN by ADC 302 using sample triggering signals 322, 324, and 326. An additional output 328 of ADC triggering block 310 causes counter 330 to count while MOSFET 112 is turned on. Input signal 312 is a signal that pulses on rising edges of the voltage at HB node 122. Input signal 314 is a signal that pulses on falling edges of voltage at HB node 122. Input signals 114 and 118 are control signals that control MOSFETs 112 and 116, respectively.
(34) ADC triggering block 310 triggers ADC 302 to take samples of V.sub.CS and V.sub.IN according to flow chart 220 of
(35) Sample triggering signal 322 causes ADC 302 to take a digital sample of V.sub.CS node 166 and store the sample in a register output as digital V.sub.CS sample 332 at time 0, i.e., the rising edge of gate terminal 114. Sample triggering signal 324 causes ADC 302 to take a digital sample of V.sub.CS node 166 and store the sample in a register output as digital V.sub.CS sample 334 at time 2, i.e., the falling edge of gate terminal 114. Sample triggering signal 326 causes ADC 302 to take a digital sample of V.sub.IN and store the sample in a register output as digital V.sub.IN sample 336 at any appropriate time. Sample triggering signals 322, 324, and 326 cause ADC 302 to take a sample at edges of the triggering signals, or based on a value of the triggering signals. ADC 302 can be triggered to take V.sub.CS sample 332 shortly before, during, or shortly after transitions of HB node 122 from low to high. ADC 302 can be triggered to take V.sub.CS sample 334 shortly before, during, or shortly after transitions of HB node 122 from high to low.
(36) Counter 330 is a digital counter that receives control signal 328 from ADC triggering block 310, and counts up for the on-time of MOSFET 112 using system clock input 340. After a falling edge of the control signal at gate terminal 114, the on-time of MOSFET 112 is output by counter 330 as T.sub.ON 342. In some embodiments, an analog timer is used instead of counter 330. A capacitor is charged or discharged at an approximately constant rate while MOSFET 112 is turned on. Measuring a voltage potential difference of the capacitor between when MOSFET 112 turns on and when MOSFET 112 turns off indicates the length of time that MOSFET 112 was on based on an approximately constant rate of voltage potential change. Other types of timing circuits besides digital counter 330 or an analog timer are used in other embodiments.
(37) Input power calculation block 344 receives first V.sub.CS sample 332, second V.sub.CS sample 334, V.sub.IN sample 336, and T.sub.ON 342. Input power calculation block 344 generates a value for the present power output of LLC resonant mode converter 100 based on equation 1 below.
(V.sub.CS Sample 334 V.sub.CS Sample 332)*V.sub.IN Sample 336/T.sub.ON342Equation(1):
(38) In equation 1, subtracting V.sub.CS sample 332 from V.sub.CS sample 334 yields a net amount of charge removed from or added to resonant capacitor 136. Dividing by T.sub.ON 342 converts the net charge to an average electric current. Multiplying by V.sub.IN sample 336 converts the current to a power value. Input power calculation block 344 outputs a digital value representative of the power input to LLC resonant mode converter 100 as input power data 350.
(39) Input power data 350 is routed to skip control block 352, which generates a skip control signal 354. Skip control block 352 uses skip control signal 354 to initiate skip mode. Skip mode is used to skip some power transfer cycles of LLC resonant mode converter 100 in low power situations to conserve energy. Skip control signal 354 is routed to the controller that generates signals to gate terminal 114 and gate terminal 118, e.g., driver logic 190, to tell the controller to initiate skip mode. Skip control block 352 is not used in all embodiments.
(40) Input power data 350 is routed to PFC control block 356. PFC control block 356 generates PFC control signal 358. PFC control signal 358 is routed to enable or disable a PFC front end. In some embodiments, PFC control block 356 disables the PFC front end when input power is below a threshold to conserve energy. PFC control block 356 is not used in all embodiments.
(41) Input power data 350 is routed to OPP control block 360. OPP control block 360 includes the functionality of comparator 178 in
(42) OPP 160 is implemented on an integrated circuit while only requiring inputs for V.sub.FB, V.sub.IN, and V.sub.CS. Control of OPP 160 is implemented by a microprocessor executing code, or by a state machine triggered by the control signals of MOSFETs 112 and 116. OPP 160 calculates average input current by taking two samples of a current sense voltage and dividing over time. Sampling V.sub.CS during turn-on and turn-off events, and calculating a slope defined by the two sampling points, cancels the magnetizing current component to ascertain average input current. Average input current information is multiplied with input voltage to get input power. Input power is limited to a reference level by reducing a feedback voltage via variable feedback clamp 184. Additional linear compensation is used in some embodiments to cancel differences between input power and output power caused by application inefficiency.
(43) While one or more embodiments have been illustrated and described in detail, the skilled artisan will appreciate that modifications and adaptations to those embodiments may be made without departing from the scope of the present disclosure.