METHOD AND APPARATUS FOR GENERATING HIGH CURRENT, FAST RISE TIME STEP-FUNCTIONS

Abstract

Method and apparatus to produce a step function with a designed transition (rise and/or fall) time on the order of <10 ns that reaches steady state by implementing a system that sums a number of currents at different rise times (frequencies) to generate the step function. The system also includes a passive output filter, composed of low resistance, inductance and very low capacitance to mitigate overshoot and high frequency noise.

Claims

1. A method of producing a high current signal with a designed rise or fall time wherein: actuating a switch to charge or discharge a capacitance, the method comprising: structuring the capacitance to provide a different types of capacitors, and summing current outputs provided by the different types of capacitors to achieve a designed rise or fall time.

2. The method of claim 1 wherein at least some of the different types of capacitors have different values.

3. The method of claim 1, wherein the different types of capacitors include some capacitors that are the same type and have the same value.

4. The method of claim 1, wherein the different types of capacitors and their values are selected to provide a desired amount of current output.

5. The method of claim 1, wherein the different types of capacitors provide a plurality of sinusoids that when summed results in a step function, where rise time of the step function depends on the frequency bandwidth and more particularly the number of frequencies of the sum of the sinusoids, and the number of frequencies is greater than two and preferably greater than four.

6. The method of claim 1, wherein filtering the output with a passive output filter composed of low resistance, inductance and very low capacitance to mitigate overshoot and high frequency noise.

7. The method of claim 1, wherein configuring connections of the different capacitors to provide different inductances and associated charge or discharge delays.

8. A system for producing a high current signal with fast rise time comprising: a capacitance; and a switch connected to selectively charge and discharge the capacitance, the capacitance being structured to provide a variety of different types of capacitors, and a summing node that sums current outputs provided by the variety of different types of capacitors.

9. The system of claim 8 wherein at least some of the variety of different types of capacitors have different values.

10. The system of claim 8, wherein the variety of different types of capacitors include some capacitors that are the same type and have the same value.

11. The system of claim 8, wherein the variety of different types of capacitors and their values are selected to provide a desired amount of current output.

12. The system of claim 8, wherein the variety of different types of capacitors provide a plurality of sinusoids that when summed results in a step function, where the rise time depends on the frequency bandwidth and more particularly the number of frequencies of the sum of the sinusoids, and the number of frequencies is greater than two and preferably greater than four

13. The system of claim 8, wherein a passive output filter composed of low resistance, inductance and very low capacitance to mitigate overshoot and high frequency noise.

14. The system of claim 8, wherein the system is provided as a flexible stand-alone system controlled by a signal generator such as microprocessor to test the frequency response of non-contact magnetic field, current sensors, current transducers and similar devices.

15. The system of claim 8, wherein the system is packaged into a high-power signal generator which has other types of signal built in, such as sinusoids and triangle waves.

16. The system of claim 8, wherein the capacitors are disposed on the same or different substrates, are disposed on the same or different sides of a substrate, are connected into one or more than one bank, and have the same or different length leads.

17. The system of claim 8, wherein at least some of the capacitors are connected via meandering traces that introduce adjustable amounts of inductance and associated charge/discharge delay.

18. A system for producing a high current signal with designed transition time comprising: a capacitor bank; and a switch connected to selectively charge and discharge the capacitor bank, the capacitor bank comprising a first capacitor connected to a summing node by a first connection and a second capacitor connected to a summing node by a second connection, the first and second connections having different inductances, and the summing node that sums current outputs provided by first and second capacitors to provide a designed current signal transition time.

19. The system of claim 18 wherein the first and second capacitors each comprise capacitor banks.

20. The system of claim 18 wherein the first and second capacitors comprise different capacitor values or different capacitor types

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 shows a block diagram of an example non-limiting embodiment of a high current low rise time step function generating circuit.

[0013] FIG. 1A shows an example non-limiting schematic circuit diagram of a step function generating circuit providing a step-current pulse with <=2.5 ns rise time. A copper trace may be connected between the connections labeled out1 and in1 to take the step function near or to the device to be tested.

[0014] FIGS. 2A, 2B illustrate an example non-limiting step-current generated by the FIG. 1A circuit. On the left (FIG. 2A), the step current rises fast and settles with minimal noise and fast settling time. The image on the right (FIG. 2B) zooms in to the rise time portion to show the time interval during which the current rises.

[0015] FIGS. 3A, 3B present magnitude (top) and phase (bottom), respectively of the frequency response of the derivative of the step function. Ideally, the magnitude should be constant across all frequencies. The phase repeats depending on the sampling frequency (1/2.5 ns).

[0016] FIG. 4 shows an example non-limiting screenshot from an oscilloscope trace of the step-function (probe 3). The other curves comprise the sensor response triggered by the step-function.

[0017] FIG. 5 shows a variety of capacitors that can be used to realize the FIG. 1A capacitor bank.

[0018] FIG. 6 shows an example non-limiting capacitor bank connection.

[0019] FIG. 7 shows an additional example non-limiting capacitor bank connection.

[0020] FIG. 8 shows an example non-limiting capacitor bank layout.

[0021] FIG. 9 shows an additional example non-limiting capacitor bank layout.

[0022] FIG. 10 shows an example non-limiting meandering capacitor connection.

[0023] FIG. 11 shows an example further non-limiting circuit providing charging and discharging.

[0024] FIG. 12 shows an example non-limiting flowchart of program control steps for controlling the FIG. 11 circuit.

DETAILED DESCRIPTION OF EXAMPLE NON-LIMITING EMBODIMENTS

[0025] The example non-limiting embodiments herein provide method and apparatus to produce a step function with a rise time on the order of 2.5 ns or less that reaches steady state, by implementing a system that sums a number of currents at the different rise times (frequencies) to generate the step function. However, if for a given application a longer rise time is desirable, the method and apparatus provided here may also be used to design a step-function of arbitrary or predetermined (e.g., desired) rise time and current level. The system also includes a passive output filter, composed of low resistance, inductance and very low capacitance to mitigate overshoot and high frequency noise.

[0026] To practically realize the sum of frequencies, a capacitor bank with different types of capacitors composed of different materials with different time constants and values is placed at the input to store the current/power. At the output, very small filter capacitors are used to filter the high-frequency noise. Between the input and output, the resistance and inductance of the path is carefully considered. To protect the primary power supply (for example, a battery or a benchtop power supply), Schottky diodes which can source sufficient current are employed. With this design we can also vary the current level between 0 and the desired maximum current, while maintaining the desired waveform.

[0027] An illustrative non-limiting example circuit is shown in FIG. 1. In this example, input power (+12 VDC) is applied to a DC-to-DC converter that produces double rail (+12 VDC, 12 VDC) supply voltages. The +12 VDC supply voltage is supplied via a bank of high current Schottky diodes D1-D5 to a capacitor bank C3-CN. Capacitor bank C3-CN comprises a variety of different capacitors with different characteristics and time constants. The resulting conditioned power is applied via an OUT1 connection to one part or end of a current sensor trace T or other component under test. Another part or end of the current sensor trace T or other component under test is connected via an IN1 connection to a high power MOSFET switching transistor Q1. The switching transistor Q1 switches in response to a gate drive signal supplied by a MOSFET driver U1, which in turn is triggered by a gating pulse produced by a control source.

[0028] When MOSFET switch Q1 is in a high impedance state, the capacitor bank C3-CN charges with current the Schottky diodes D1-D5 supply. When switch Q1 switches to a low impedance (current sink) state, the capacitor bank C3-CN discharges at high current through the trace and the switch to ground. The capacitor bank C3-CN is structured and configured so that some capacitive elements discharge more rapidly than others such that the resulting summed signal waveform approaches a step function.

[0029] High-power switch Q1 is controlled by MOSFET driver U1 to discharge the power in the capacitor bank C3-CN through copper trace T, which in one embodiment is externally connected at connections labeled IN1 and OUT1 in the schematic. The high-power switch Q1 may be controlled for example via GATE_PULSE by a microcontroller executing software instructions stored in a non-transitory storage device, by a normal low-power signal generator pulse, or by other means. The low-power signal generator or microcontroller or similar device produces a square pulse GATE_PULSE signal, which turns on the MOSFET driver for a desired (e.g., controlled) duration.

[0030] FIG. 1A shows an example non-limiting schematic circuit diagram of the FIG. 1 generator. In this example, the DC to DC converter may comprise a monolithic PDM2-S Series 2 W, 1:1 Input Range, Single/Dual Unregulated Output, 6 Pin SIP, 1500 VDC Isolation, High Temp Range, DC-DC Converter manufactured by CUI Inc. The POS_12V power is supplied via 1V 10 Amp Schottky diodes D1-D5 to capacitor bank C3-C15. Schottky diodes D1-D5 have low forward voltage and higher switching speeds.

[0031] The capacitor bank C3-C15 in this particular non-limiting example comprises 12 discrete capacitors with the following non-limiting characteristics:

TABLE-US-00001 C3 0.1 F Mica C4 0.1 F Mica C5 Extra or not used C6 0.1 F Mica C7 47 F Electrolytic C8 100 F Electrolytic C9 100 F Electrolytic C10 200 F Electrolytic C11 1 F film C12 2.24 F film C13 2.24 F film C14 Extra C15 Extra

[0032] As can be seen, this particular non-limiting configuration comprises three different capacitor types (mica, electrolytic, film). Other capacitor types such as ceramic, polyethylene, air core, oil, Tantalum or other (see FIG. 5) are possible. Film capacitors generally are able to supply high surge currents, electrolytics are slow but stable and able to supply large quantities of current, and mica capacitors discharge small amounts of current rapidly.

[0033] The non-limiting capacitor bank also comprises several different capacitor values (0.1, 1, 2.24, 47, 100 and 200 aF). In the example shown, the capacitors are all being used at relatively low voltage (e.g., 12 VDC) that are well below their maximum ratings (which could be 1000 or 1500 VDC for film or mica capacitors). By initiating the discharge all at the same time of different capacitor types with different values that supply current at slightly different times and in different amounts and for different durations, a sequence of discharging current pulses result. This sequence of discharging current pulses are summed together to design a step-function or square wave function in the time domain in this non-limiting illustrative embodiment. If a heterogeneous collection of a plethora of different types and values of discharging capacitors are properly selected, the overall summed discharge resembles a sinc function pulse in the frequency domain, i.e., the Fourier transform of the rectangular function in the time domain. The effect is similar to superposition of cosines to create a square wave.

[0034] Although the capacitor bank discharge is initiated at the same time, all of the capacitors do not discharge exactly at the same time. Since these capacitors are positioned in parallel to each other and cannot be plugged directly into the same holes, there is a trace connecting one end of each capacitor, for example, the positive end, if the purpose of the capacitor bank is to generate a rising edge. Any trace connecting two components has inductance and causes a delay depending on the geometry of the trace. If a high-speed pulse capacitor is placed further away from the output, the trace connecting it to the output will provide a delay, via its inductance, that will also help dampen the overshoot and help balance its speed with the other slower capacitors. In addition, if three of the same type and value capacitor are placed in parallel, they will not necessarily discharge exactly at the same time unless the lead length added to the trace length and electrical properties between the body of the capacitor and the output are identical. By purposely creating a short distance between similar and different types of capacitors via the connecting traces and designing the geometry of the connecting traces with specific geometries, it is possible to delay the discharge timing of some capacitors relative to others and thus gain more precise control over the timing the sequential discharge of each capacitor in the bank. As an alternative to traces, small inductive elements in series or other switches that are sequentially turned on may be used as well.

[0035] While empirical experimentation can be used to determine an appropriate mixture of capacitor types and values, a more rigorous mathematical approach is possible that models the capacitor bank with equations that describe the peak discharge current of each capacitor. To achieve a sufficiently high peak discharge value at a particular time after overall discharge has been initiated, it is possible to have redundant capacitors of the same type and value (e.g., 3 identical mica capacitors of all the same value, 2 identical 100 F electrolytics, 2 identical 2.24 F thin film capacitors, etc.). Generally speaking, the individual discharge current pulses get broader as they occur later and later in the discharge sequence.

[0036] A rough visualization might be to imagine a line of people some of whom are taller and some of whom are shorter. First in line might be a short person who stands up first. The next person in line to stand up might be a person of medium height but who is relatively wide. Next might be a very tall but skinny person. Next could be another medium height person. In this analogy, each person who stands up in line represents a current discharge from a different type and/or value of capacitor. The resulting summed envelope of superimposed multiple capacitive discharges provides a sustained current discharge for a desired duration.

[0037] FIG. 1A shows additional resistors R2, R3, R4 connected as an output filter. The purpose of this resistive network is three-fold: (1) it is desirable to have resistors in parallel so that the capacitors can discharge safely in the event that the circuit is turned off before the capacitor bank is discharged, (2) to provide an alternative way to monitor the charge and discharge rate of the capacitor bank without taking away power from the output, and (3) when combined with very small capacitance, the resistive network forms a filter which can reduce high frequency noise. Given the high current application of the non-limiting embodiment, the series-connected resistor R2 has a small resistance value to reduce heat dissipation but also provides an output current limiting function that protects the capacitor bank. It also permits the measurement of exactly how much current over time is discharged from the capacitor bank by measuring the voltage across this resistor.

[0038] FIG. 1A shows a single bank of capacitors C3-C4, C6-C15 where all of the capacitors are connected in parallel. However, the effects described above may also be achieved by using a plurality of capacitor banks which are connected in parallel, as shown in FIGS. 6 & 7. Each capacitor bank may consist of a single type of capacitor with similar or different values. Alternatively, the capacitor bank may comprise a variety of different types of capacitors. Or, a combination of both types of capacitor banks may be used. In these figures, the letters A, B and C represent different capacitor types. In FIG. 6, the top bank comprises four capacitors of type A, A, B C, whereas the middle bank comprises four capacitors of types A, B, A, C and the bottom bank comprises four capacitors of types B, B, B, A, with the three banks connected in parallel. FIG. 7 shows how different banks can have different numbers of capacitors, some banks can comprise homogeneous capacitor types (e.g, the FIG. 7 top bank is made up of all A type capacitors), and other banks can comprise heterogeneous types (e.g., see FIG. 6). Different banks can have different quantities of capacitors or the same quantities of capacitors. Banks can be switched in and out as desired for programming different output durations and other characteristics. All may connected in parallel by one or more switches. For some applications, where space is constrained, it may be advantageous to connect the capacitor banks in parallel vertically, horizontally, or a combination of both, as FIG. 8 shows. An individual capacitor bank may have components on the top and bottom of a single printed circuit board (PCB) in order to put them closer together, as FIG. 9 illustrates, or they may be disposed on different PCBs (as FIG. 8 shows) with spacers or other structures connecting the boards. The boards can be stacked, disposed side by side, or provided in other orientations relative to one another. In the FIG. 9 embodiment, some of the capacitors have longer leads than others, which can introduce an adjustable amount of inductance (depending on lead length) and thus further delay (as well as to allow more capacitors to fit into a given real estate, with some being high rise units that tower over and horizontally overlap low rise units. In FIG. 9, the capacitors on opposing sides of the board could be the same or different types. FIG. 10 shows the use of a meandering or other configured PCB trace to provide adjustable (add or subtract) inductance/delay for connection of particular capacitors.

[0039] The capacitor banks may also be integrated into one component or a new device. This device or multiplicity of them could then be connected to the power source and switch so that it would discharge to generate the desired waveform. In some implementations, it may be possible to use capacitances provided by capacitive-providing circuits such as certain types of transistors instead of lumped capacitors for some or all of the capacitors in the bank(s).

[0040] Example non-limiting output waveforms are shown in FIG. 2A, 2B. The left image of FIG. 2A shows a typical high current step-function. The right image of FIG. 2B zooms in to show the rise time, which in this particular data capture is extremely fast, 7.5 ns. Higher speeds are possible using the same circuit.

[0041] FIGS. 3A, 3B show the corresponding magnitude and phase of the frequency response of the derivative of the step function. In the time domain, the derivative of a step function is a delta function. The magnitude of the Fourier transform of the delta function is constant over all frequencies. For the given frequency range the magnitude of the derivative of our step function is also constant. FIG. 4 shows original data collected from an oscilloscope. The probe 3 trace recorded a voltage of 10V across the low inductance 1 resistor, which implies that the current was 10 A. This kind of circuit could be applied as a flexible stand-alone system if it is controlled by a signal generator such as microprocessor to test the frequency response of non-contact magnetic field-, current sensors, current transducers, Rogowski coils, inductors and similar devices. It could also be packaged into a high-power signal generator which has other types of signals built in, such as sinusoids or triangle waves, etc. A system that generates an adjustable high-current fast rise time step response is helpful to quickly test current sensors and similar components that will be integrated in the smart energy grid. First of all it can be used to test the ability of such a component to detect the current. However, it can also be used to test the immunity of such a component to high currents which change quickly, generating a band of high frequencies (EMI). For example, it could also be used to test EMI shields, absorbers, and concentrators or for rapid repetitive current testing of many components. Typically, semiconductor wafers and devices are subject to fast high current pulse discharge as part of their quality control testing.

[0042] Applications other than testing are possible. The embodiment is useful for any application that benefits from a high current discharge step function with a short rise time. For example, it could be used to extend the range of a low power, high current radar pulse generator for the same power. It could also be used for pulsed LED or other lighting. It could also be used to supplement or redirect power towards certain devices or power lines quickly.

[0043] In another non-limiting illustrative embodiment, if the order of the capacitor bank and the switch were reversed, such that the purpose were to charge the capacitor bank quickly, this capacitor bank could also be used to sink power quickly from another charged capacitor bank and then output could be returned to a zero level just as quickly to produce a short fall time. Additionally, if a capacitor bank with a fast rise time and a series of switches were combined with an empty capacitor bank with similar properties connected via another switch, it is also possible to create a more precise square wave by alternating the discharge of the current through the trace and then charging the capacitor bank at the desired duty cycle by careful control of the switches. FIG. 11 shows such a configuration and FIG. 12 shows a flowchart of steps performed by computer instructions executed on a processor or other controller to control the FIG. 11 circuit. In this example embodiment, capacitor bank 100 comprises an initially full bank, and capacitor bank 102 comprises an initially empty bank used as a current sink. Power (PWP) is applied to bank 100 to initially charge it. Switches 104, 106 are then closed at the same time to send current to the output trace T, creating a fast rise time (FIG. 12 block 202). To create a fast fall time, switch 104 is opened, switch 108 is closed, and switch 106 remains closed, to sink current into the discharged capacitor bank 102 (FIG. 12 block 204). The compositions and characteristics of banks 100, 102 can be the same or different, e.g., in order to adjust or tailor the rise time characteristics relative to the fall time characteristics. A further one-way current path from bank 102 to bank 100 via switch 110 can be used to discharge the sink capacitor bank 102 into the source capacitor bank 100, thereby conserving energy (FIG. 12 block 206). After discharge, switch 110 is then opened so the discharge bank 100 can recharge (FIG. 12, blocks 208, 210). In summary, any capacitor bank or circuit that can be used to source current/energy, can also be used to sink current/energy. Such a capacitor bank could also be used as a very wideband filter.

[0044] The example non-limiting technology herein has been described in the above detailed description, in which some, but not all embodiments are described. Indeed, this example non-limiting technology may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

[0045] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms a, an, and the are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

[0046] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0047] It will be understood that a number of techniques and steps have been disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description has refrained from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the example non-limiting technology herein.