APPARATUS AND METHODS INVOLVING CONTROL OF PIEZOELECTRIC RESONANCE CIRCUITS
20230130908 · 2023-04-27
Inventors
- Eric Stolt (Stanford, CA, US)
- Juan M. Rivas-Davila (Palo Alto, CA, US)
- Weston D. Braun (Stanford, CA, US)
Cpc classification
H02M3/33507
ELECTRICITY
H10N30/802
ELECTRICITY
International classification
Abstract
In certain examples, methods and semiconductor structures are directed to operation of a piezoelectric-based device (e.g., a DC-DC converter) and such operation may involve selectively switching inputs of the piezoelectric-based device at a modulation frequency and, in response, decoupling of the modulation frequency from output power delivered by the piezoelectric-based device. In some examples, the inputs of the piezoelectric-based device are selectively switched to cause decoupling the modulation frequency from output power delivered by the piezoelectric-based device and/or cause operation of the piezoelectric-based device without spurious mode operation.
Claims
1. A method comprising selectively switching inputs of a piezoelectric-based device at a modulation frequency and, in response, decoupling the modulation frequency from output power delivered by the piezoelectric-based device.
2. The method of claim 1, further including causing circulation of current in the piezoelectric-based device by the step of selectively switching inputs.
3. The method of claim 1, wherein the modulation frequency is a fixed frequency, and the selectively switching inputs provide control that does not rely on acoustic optimization.
4. The method of claim 1, wherein the piezoelectric-based device operates without manifesting a spurious mode.
5. The method of claim 1, wherein the piezoelectric-based device refers to or is integrated as part of a DC-DC converter.
6. The method of claim 1, wherein the piezoelectric-based device operates without detrimentally effecting operation efficiency over a maximum load range specified for the piezoelectric-based device while the modulation frequency overlaps with one or more spurious mode frequency regions.
7. The method of claim 1, wherein the inputs of the piezoelectric-based device are selectively switched to provide closed-loop, hysteretic control, and said selectively switching inputs of the piezoelectric-based device causes decoupling the modulation frequency from output power delivered by the piezoelectric-based device and causes operation of the piezoelectric-based device without spurious mode operation.
8. An apparatus comprising: a piezoelectric-based device; and a logic circuit to selectively switch inputs of the piezoelectric-based device at a modulation frequency and, in response, decouple the modulation frequency from output power delivered by the piezoelectric-based device.
9. The apparatus of claim 8, wherein the logic circuit is to cause circulation of current in the piezoelectric-based device.
10. The apparatus of claim 8, wherein the piezoelectric-based device is to operate without manifesting a spurious mode while the modulation frequency is at a fixed frequency.
11. The apparatus of claim 8, wherein the inputs are selectively controlled but using a mixed switching sequence having an integer number of forward cycles and an integer number of zero cycles, wherein the integer number of forward cycles is at least one and the integer number of zero cycles is at least one.
12. A method comprising: selectively switching inputs of a piezoelectric-based device at a frequency in a frequency range that intersects with a spurious mode region of the piezoelectric-based device (to cause current circulation in the piezoelectric-based device) while avoiding spurious mode operation of the piezoelectric-based device.
13. The method of claim 12, further including causing circulation of current in the piezoelectric-based device by the step of selectively switching inputs, and the piezoelectric-based device operates without manifesting a spurious mode.
14. The method of claim 12, wherein the piezoelectric-based device operates without detrimentally effecting operation efficiency over a maximum load range specified for the piezoelectric-based device while the frequency is a modulation frequency which overlaps with one or more spurious mode frequency regions.
15. The method of claim 12, wherein the inputs of the piezoelectric-based device are to be selectively switched to provide closed-loop, hysteretic control.
16. The method of claim 12, wherein the inputs are selectively controlled but using a mixed switching sequence having an integer number of forward cycles and an integer number of zero cycles, wherein the integer number of forward cycles is at least one and the integer number of zero cycles is at least one.
17. An apparatus comprising: a piezoelectric-based device; and a logic circuit to selectively switch inputs of the piezoelectric-based device at a frequency in a frequency range that intersects with a spurious mode region of the piezoelectric-based device while avoiding spurious mode operation of the piezoelectric-based device.
18. The apparatus of claim 17, wherein the logic circuit is to cause circulation of current in the piezoelectric-based device, and the piezoelectric-based device operates without manifesting a spurious mode, and wherein the piezoelectric-based device refers to or is integrated as part of a DC-DC converter.
19. The apparatus of claim 17, wherein the piezoelectric-based device operates without detrimentally effecting operation efficiency over a maximum load range specified for the piezoelectric-based device while the frequency is a modulation frequency which overlaps with one or more spurious mode frequency regions.
20. The apparatus of claim 17, wherein the inputs are selectively controlled but using a mixed switching sequence having an integer number of forward cycles and an integer number of zero cycles, wherein the integer number of forward cycles is at least one and the integer number of zero cycles is at least one.
21. The apparatus of claim 17, wherein the control does not rely on unidirectional powerflow with each resident cycle and on soft charging of output capacitance of the piezoelectric-based device, and the inputs of the piezoelectric-based device are to be selectively switched to provide closed-loop, hysteretic control with fast transients.
Description
BRIEF DESCRIPTION OF FIGURES
[0015] Various example embodiments, including experimental examples, may be more completely understood in consideration of the following detailed description in connection with the accompanying drawings, each in accordance with the present disclosure, in which:
[0016]
[0017]
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027] While various embodiments discussed herein are amenable to modifications and alternative forms, aspects thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure including aspects defined in the claims. In addition, the term “example” as used throughout this application is only by way of illustration, and not limitation.
DETAILED DESCRIPTION
[0028] Aspects of the present disclosure are believed to be applicable to a variety of different types of apparatuses, systems and methods including but not necessarily limited to devices characterized at least in part by controlling a piezoelectric-based resonance device (e.g., a piezoelectric resonator and/or a piezoelectric transformer) as may be used as part of a DC-DC converter, with a frequency-applied control at the inputs for avoiding spurious modes in operation of the device. While the present disclosure is not necessarily limited to such aspects, an understanding of specific examples in the following description may be understood from discussion in such specific contexts.
[0029] Accordingly, in the following description various specific details are set forth to describe specific examples presented herein. It should be apparent to one skilled in the art, however, that one or more other examples and/or variations of these examples may be practiced without all the specific details given below. In other instances, well known features have not been described in detail so as not to obscure the description of the examples herein. For ease of illustration, the same connotation and/or reference numerals may be used in different diagrams to refer to the same elements or additional instances of the same element. Also, although aspects and features may in some cases be described in individual figures, it will be appreciated that features from one figure or embodiment can be combined with features of another figure or embodiment even though the combination is not explicitly shown or explicitly described as a combination.
[0030] Exemplary aspects of the present disclosure are related to directed to methods and apparatuses involving use, operation and/or design of a piezoelectric-based resonance device (e.g., a DC-DC converter), wherein the device is operated by way of selectively switching inputs of the piezoelectric-based device to cause a decoupling of the modulation frequency from output power delivered by the piezoelectric-based device and/or to control the device to cause the device to operate in the regions corresponding to spurious mode operation. In some examples, the switching inputs are selectively switched to realize this decoupling and such avoidance of the device operating in a spurious mode region.
[0031] Consistent with the above aspects, such a manufactured device or method of such manufacture may involve aspects presented and claimed in U.S. Provisional Application Ser. No. 63/253,418 filed on Oct. 7, 2021 (STFD.435P1 S21-346) with an Appendix, to which priority is claimed. Such subject matter is incorporated by reference in its entirety generally and to the extent that further aspects and examples (such as experimental and/more-detailed embodiments) may be useful to supplement and/or clarify.
[0032] According to certain more specific examples, the present disclosure is directed to a circuit-based apparatus (e.g., system, arrangement of components and/or device including circuitry) and alternatively, a method of using such an apparatus including a piezoelectric-based resonance device by selectively switching inputs of the piezoelectric-based device to cause a decoupling of the modulation frequency from output power delivered by the piezoelectric-based device and/or to control the device so as to cause the device to avoid operating in the regions corresponding to spurious mode operation. The switching inputs may be selectively switched at a modulation frequency (e.g., a fixed modulation frequency) to realize circulation of current within the device and to bring about this decoupling and/or avoidance of the device operating in a spurious mode region.
[0033] While certain previous DC-DC conversion applications employing piezoelectric resonators or piezoelectric transformers have used closed-loop regulation with frequency-modulation for voltage regulation, they rely on sensing multiple voltages throughout a resonant period and they use variable frequency-modulation control that results in spurious resonances, which can lower efficiency and restrict operation to narrow load ranges. Spurious resonant modes are secondary resonances in a piezoelectric resonator that disturb the ideal inductive operating region with pockets of high resistance, lower than 90° phase, and non-uniform impedance. These disruptive resonances are difficult to predict with a zero cycle, which is a cycle that shorts the resonator (across terminals of the resonator such as by turning on switches S.sub.2 and S.sub.3 in the stacked topology of
[0034] According to certain specific example embodiments, the present disclosure is directed to a circuit-based apparatus and/or a method of using such an apparatus including a piezoelectric-based (resonance) device by selectively switching inputs of the piezoelectric-based device, via a mixed sequence (or combination) of forward and zero cycles, to cause a decoupling of the modulation frequency from output power delivered by the piezoelectric-based device and/or to control the device so as to cause the device to avoid operating in the regions corresponding to spurious mode operation. The mixed sequence of switching inputs realize circulation of current within the device and to bring about this decoupling and/or avoidance of the device operating in a spurious mode region. By using a combination of forward and zero cycles results in a mixed switching sequence, the switching sequence is controlled to provide sufficient freedom to allows modulation of output power at a fixed switching frequency (e.g., as may be used in more-specific example embodiments) and conversion ratio.
[0035] Before turning to the drawing to be discussed in detail below, it is noted that certain of the example embodiments presented herein involve prototype piezoelectric-based (resonance) devices in the form of DC-DC converters to illustrate exemplary aspects and certain example embodiments of the present disclosure, wherein piezoelectric-based (resonance) devices refer to or include devices that use a piezoelectric device in a circuit that is to resonate. However, as is apparent to the skilled artisan, such example embodiments, aspects, and applications of the present disclosure are not so limited. In this context, in addition to or instead of DC-DC converters, further specific examples of the present disclosure may be directed to embodiments, aspects, and applications involving other circuits (e.g., amplifiers, regulators, buffers, etc.) which may use one or more piezoelectric-based devices with switchable inputs which can be controlled so that the one or more piezoelectric-based devices may resonate according to one or more aspects consistent with the claimed invention.
[0036]
[0037] While each of
[0038] Also, as shown by “(I-circulating)” in
[0039] As yet a further possible variation also according to an example aspect of the present disclosure, but not shown in either of
[0040] Consistent with this closed-loop hysteretic control aspect according to the present disclosure,
[0041]
[0042] Lithium niobate is a beneficial piezoelectric material due to its high-coupling coefficient and lower loss than in PZT. The resonator's thickness extensional mode achieves higher power density and lower impedance than other resonant modes, such as radial and lateral, but at the cost of more spurious modes. The ideal operating range of this type of resonator is bounded by the series resonant frequency at 6.83 MHz and the parallel resonant frequency at 7.64 MHz. The first spurious mode appears at 6.87 MHz where the impedance is disturbed and the resistance rises far above the modeled resistance. Beyond 6.87 MHz, more spurious modes cause the resonator's resistance to continue diverging from the single motional branch model. These spurious modes are often difficult to predict and control when designing a resonator because they require a full 3-D resonator model and are sensitive to fabrication variations. Even though spurious modes are difficult to predict, batch fabrication of resonators from lithium niobate wafers yielded resonators with identical spurious modes. Thus, any implementation at scale could reliably pre-program the spurious mode locations without having to measure every resonator. Although techniques exist for reducing spurious modes, these techniques often reduce device performance such as the resonator's coupling coefficient, quality factor, and capacitance density. Moreover, most techniques for eliminating spurious modes in certain types of resonators (e.g., MEMs) do not translate to resonators for power conversion due to different design goals and orders of magnitude difference in size.
[0043] When a converter's switching frequency intersects with a spurious mode, losses often become too high to operate due to high resistance and a less inductive phase causing the loss of zero-voltage switching (ZVS). While standard control maximizes efficiency, the dependence of output power on frequency limits converters to only the load conditions corresponding to spurious-free frequency regions. For example, spurious modes restrict the type of prototype resonator used in experiments in the present disclosure to only operate between 6.835 MHz and 6.861 MHz despite a design aimed at maximizing the spurious-free frequency region.
[0044] In certain specific example embodiments, the present disclosure is directed to aspects concerning use of a fixed-frequency modulation control for avoiding spurious modes in operation of the piezoelectric-based device. This type of control may be used to enable the realization of piezoelectric resonator DC-DC converters, via relatively simple front-end modulation circuitry, that can operate across a full load range (e.g., as a significant improvement over the load range delivered by certain previously-known devices). In a related and more-specific example according to the present disclosure, an experimental example embodiment employs fixed-frequency control mode for decoupling power and frequency in piezoelectric resonator DC-DC converters. The fixed-frequency control enables the converters to operate efficiently across a full load range while avoiding spurious modes. Further, models for power, efficiency, and ripple scaling of a mixed sequence for the inputs are implemented along with a simplified method for calculating mixed sequence switch timings. These experimental examples verify that fixed-frequency control can avoid spurious modes and extend operating range with a prototype piezoelectric resonator DC-DC converter and lithium niobate resonator. For example, at a conversion ratio of 60 V to 30 V, fixed-frequency control extends the prototype's output power range by a factor of 2.7. The development of fixed-frequency control represents how using certain energy storage elements such as high quality factor piezoelectric resonators can enable improved ways of controlling converters and while yielding better performance.
[0045] In connection with an experimental test as background leading up to discoveries in connection with the present disclosure, the measured impedance of a lithium niobate resonator and the modeled impedance of a BVD equivalent circuit were plotted to fit to the resonator's main resonant mode. Lithium niobate is chosen as the piezoelectric material for its known high coupling coefficient and lower loss than PZT. The resonator's thickness extensional mode achieves higher power density and lower impedance than other resonant modes, such as radial and lateral, but at the cost of more spurious modes. An ideal operating range of this particular resonator (as used in such exemplary experimental implementation) is bounded by the series resonant frequency at 6.83 MegaHertz (“MHz”) and the parallel resonant frequency at 7.64 MHz. The first spurious mode appears at 6.87 MHz where the impedance is disturbed and the resistance rises far above the modeled resistance. Beyond 6.87 MHz, more spurious modes cause the resonator's resistance to continue diverging from the single motional branch model. These spurious modes are often difficult to predict and control when designing a resonator because they involve a full 3-D resonator model and are sensitive to fabrication variations. Even though spurious modes are difficult to predict, batch fabrication of exemplary resonators from lithium niobate wafers yielded resonators with identical spurious modes. Thus, any implementation at scale could reliably pre-program the spurious mode locations without having to measure every resonator. Although techniques exist for reducing spurious modes, these techniques often reduce device performance such as the resonator's coupling coefficient, quality factor, and capacitance density. Moreover, most techniques for eliminating spurious modes in MEMS resonators do not translate to resonators for power conversion due different design goals and orders of magnitude difference in size.
[0046] When a converter's switching frequency intersects with a spurious mode, losses often become too high to operate due to high resistance and a less inductive phase causing the loss of ZVS. While standard control maximizes efficiency, the dependence of output power on frequency limits converters to only the load conditions corresponding to spurious-free frequency regions. For example, spurious modes restrict certain experimental prototype resonators including resonators used in certain experimental efforts disclosed herein, to only operate between 6.835 MHz and 6.861 MHz despite a design aimed at maximizing the spurious-free frequency region. Other research into piezoelectric resonator DC-DC converters also reports spurious modes reducing efficiency and operating range.
[0047] Control of piezoelectric resonator DC-DC converters can be analyzed as a pattern of switching states, called a switching sequence, over one or more resonant cycles to establish a periodic steady state operating point. Maximum efficiency switching sequences constraints for unidirectional power flow each resonant cycle have been studied and reported. To achieve high-efficiency, soft-switching operation, the resonator is switched between alternating open and connected states. Connected states involve one switch of each switching node to conduct, which transfers power between the resonator, the input, and the output. Open states commutate switching modes for soft switching by turning off both switches connected to the commutating node and turning on one switch at the opposing node. The composition of alternating connected and open states throughout one resonant period constitutes a switching cycle. A switching cycle with unidirectional power flow from the input to the output is referred to here as a forward cycle, and standard control employs operation with continuously repeated forward cycles. Piezoelectric resonator DC-DC converters have largely, if not exclusively, been demonstrated using standard control because this maximizes efficiency and minimizes circulating current.
[0048]
[0049] Producing exact expressions for a switching sequence's periodic steady state behavior involves solving and concatenating multiple equations for each switching state. This yields complex, non-intuitive results; however, making a few approximations can accurately model the system with tangible equations. Due to the high quality factor of piezoelectric resonators (as may be characterized by an ability to oscillate for many cycles (e.g., more than several)), the motional current can be approximated as sinusoidal with:
I.sub.m(t)=I.sub.m0 sin(wt) (1)
[0050] The amplitude of the motional current for a standard sequence, I.sub.m.sub.
I.sub.mo=V.sub.mo/Z.sub.m (2)
[0051] V.sub.m0 is the fundamental component of the voltage across the resonator, and Z.sub.m is the series impedance of R.sub.m, L.sub.m, and C.sub.m at the switching frequency. The “naught” subscript denotes the standard switching sequence throughout the present disclosure. At different switching frequencies, variations in switch timings and open state durations will change V.sub.m.sub.
P.sub.out.sub.
[0052] Neglecting switch parasitics, the output DC current relates to the amplitude of the AC motional current through:
[0053] Variable A depends on conversion ratio and topology, and A=1 for the stacked topology with a 2:1 conversion ratio tested in Section V. At larger values of I.sub.m, the constant term in (4) can be approximated as negligible producing the relationship:
I.sub.out.sub.
[0054] For standard sequence control, equations (2-5) show how changing the switching frequency changes Z.sub.m, which in turn sets I.sub.m.sub.
[0055] In connection with certain exemplary embodiments according to the present disclosure, the piezoelectric-based devices are controlled such that their operational efficiency may be optimized (e.g., without detrimentally effecting operation) over a maximum load range specified for the piezoelectric-based device, and this control may occur while the modulation frequency overlaps with one or more spurious mode frequency region. Surprisingly, this converter operation may be realized without dependency of output power on the switching frequency which has been known (e.g., with use of the standard switching sequence in efforts to maximize efficiency) to prevent operation at loads corresponding to spurious mode frequencies. Accordingly, certain exemplary aspects of the present disclosure overcome the dependency of output power on switching frequency and, hence, overcome preventing operation at loads corresponding to spurious mode frequencies. This may be realized, consistent with aspects of the present disclosure, by using a called mixed switching sequence.
[0056] Exemplary uses of a mixed switching sequence have been implemented in experimental embodiments to resolve the above issue and in certain more-specific examples, such mixed switching sequences may be used to enable fixed-frequency control of the modulation frequency driving the inputs of the converter. In exemplary contexts, a mixed switching sequence consists of or includes an integer number of forward cycles, n.sub.f, mixed with an integer number of zero cycles, n.sub.z. A zero cycle has a single switching state, which turns on the switches that short circuit the resonator for the entire resonant period. For the stacked topology, the zero cycle turns on switches S.sub.2 and S.sub.3 as shown in Table 1. Unlike forward cycles, zero cycles transfer zero energy since the input and output are never connected to the resonator.
TABLE-US-00001 TABLE 1 Stacked Converter Switching States State V.sub.A V.sub.B V.sub.P Switches On A V.sub.out Open Open S.sub.2 B V.sub.out 0 V.sub.out S.sub.2, S.sub.4 C Open 0 Open S.sub.4 D V.sub.in 0 V.sub.in S.sub.1, S.sub.4 E V.sub.in Open Open S.sub.1 F V.sub.in V.sub.out V.sub.in − V.sub.out S.sub.1, S.sub.3 G Open V.sub.out Open S.sub.3 Zero V.sub.out V.sub.out 0 S.sub.2, S.sub.3
[0057] Circulating current, as a zero cycle does, is usually avoided in power converters as it causes extra loss and reduces efficiency. However, piezoelectric resonators are high quality factor devices which allow current to circulate with almost no loss. During a zero cycle, short circuiting the RLC motional branch causes a damped oscillation of the motional current at the series resonant frequency. The oscillation is damped with a time constant of =Q/πf.sub.s, where Q is the motional branch's quality factor and f.sub.s is the resonator's series resonant frequency. Since the zero cycle frequency clamps to the series resonant frequency F.sub.s, the forward cycle frequency shifts to keep the average cycle frequency equal to f.sub.sw.sub.
[0058] Although forward cycle frequency f.sub.f will shift higher potentially into spurious mode frequencies, FFT analysis in simulation can confirm that the dominant frequency component occurs at f.sub.sw.sub.
[0059] These waveforms are simulated with a resonator of Q=4200, causing the motional branch current amplitude I.sub.m to remain nearly constant during the zero cycles. The motional current resonates at the same switching frequency in both examples, yet the steady-state amplitude I.sub.m differs because of the different n.sub.f:n.sub.z ratios.
[0060] A family of mixed sequences is defined as all ratios of n.sub.f:n.sub.z that operate at a single cycle frequency, f.sub.sw0. Although the family's motional current oscillates at f.sub.sw.sub.
[0061] Zero cycles short circuit the resonator's terminals, so V.sub.mz is zero. Neglecting the switch timing variations, V.sub.mf can be approximated as equal to the standard sequence fundamental voltage component, V.sub.m0, even though V.sub.mf will change slightly throughout a family's different mixed sequence ratios. Similar to how V.sub.m0 changes less significantly than Z.sub.m in equation (2), V.sub.mf will change less significantly than n.sub.f(n.sub.f+n.sub.z) allowing for this approximation. Therefore, I.sub.m can be represented as a scaling of I.sub.m.sub.
I.sub.m=(n.sub.f/(n.sub.f+n.sub.z))I.sub.m.sub.
[0062] This approximation is not exact since varying I.sub.m will change switch timings and V.sub.m.sub.
(n.sub.f/(n.sub.f+n.sub.z))I.sub.m (9)
[0063] Assuming the same proportionality factor, substituting equation (8) gives the scaling of I.sub.out as being equal to:
(n.sub.f/(n.sub.f+n.sub.z)).sup.2I.sub.out0 (10)
[0064] Again referring to certain example aspects of the present disclosure, experiments consistent therewith have shown that converter performance via mixed sequence control is effective in scaling for power and efficiency. Mathematically, this may be appreciated as follows. Based on equation (3) and (10), a mixed sequence family's output power relates to its standard sequence power P.sub.out.sub.
(n.sub.f/(n.sub.f+n.sub.z)).sup.2I.sub.out0 (11)
[0065] Equation (11) represents how the mixed sequence decouples power and frequency since P.sub.out can scale down from P.sub.out0 at the mixed sequence family's fixed switching frequency, f.sub.sw0. For spurious mode avoidance, f.sub.sw0 can be chosen just below the spurious mode frequency range, where standard sequence efficiency is highest. Although equation (11) suggests power can only be scaled with integer ratios, switching frequency is still an optional control variable. Satisfying equation (11) for certain loads may require large values of n.sub.f and n.sub.z, yet modulating f.sub.sw0 within the spurious-free frequency region in conjunction with modulating the mixed sequence ratio can achieve arbitrary output power with only small values of n.sub.f and n.sub.z.
[0066] To maintain efficient operation, the power loss must also scale down with the output power. The three primary sources of power loss in the converter are the I.sup.2R loss in the motional branch P.sub.m, the I.sup.2R loss from the on-resistance of the switches P.sub.sw, and the dielectric loss in the resonator's parallel input capacitance P.sub.d. For the standard sequence, these losses are given by:
[0067] R.sub.sw is the switch on-resistance, and Q.sub.E is the quality factor of the dielectric of the resonator. Since both switches do not conduct during open states, equation (13) overestimates switch conduction loss especially for conditions where open state durations lengthen. The definition of
and thee peak voltage swing across the resonator in equation (14) are used to derive the dielectric loss P.sub.d0 with the full derivation presented as described in the above-referenced U.S. Provisional Application. These loss sources result in a standard sequence efficiency of:
[0068] Comparing how the mixed sequence losses scale with output power, the motional and switch conduction losses depend on I.sub.m.sup.2 and will scale with
The dielectric loss depends on the frequency of forward cycles and will scale with
Substituting, the efficiency of the mixed sequence follows:
[0069] At higher power when n.sub.f>n.sub.z, the I R losses for P.sub.m.sub.
[0070] In certain experimental implementations, use of a mixed switching sequence may introduce more input current ripple and output voltage ripple. Even in the standard control mode, charge only flows to the output during certain connected switching states. Thus, the output voltage ripple can be approximated by how much the voltage decreases when the output is disconnected and only the converter's output capacitance C.sub.out can supply current to the load. For the standard sequence, the longest period the output is disconnected varies with load but can be roughly approximated as T.sub.sw/4, a quarter of the switching cycle. This yields a standard sequence output voltage ripple of:
[0071] A mixed sequence will cause the output load to be disconnected for the forward cycle's T.sub.sw/4 in addition to k.sub.zT.sub.sw, where variable k.sub.z is the largest number of consecutive zero cycles throughout the mixed sequence. To minimize output voltage ripple, mixed sequences should alternate forward and zero cycles as much as possible to minimize h.sub.z. Any sequence with n.sub.f≥n.sub.z can mix the forward and zero cycles to make k.sub.z=1. For example, arranging a 3:2 sequence as [2n.sub.f, n.sub.z, n.sub.f, n.sub.z] yields k.sub.z=1 rather than arranging as [3n.sub.f, 2n.sub.z] with k.sub.z=2. Substituting for current scaling, the mixed sequence output voltage ripple becomes:
A worst case Δν.sub.out,pp may occur in the limit as “n.sub.f/(n.sub.f+n.sub.z)” approaches one with an output voltage ripple five times greater than Δν.sub.out,pp.sub.
[0072]
[0073] To better understand response in connection with such experimental embodiments, it is appreciated that the mixing of forward and zero cycles in fixed-frequency control can be implemented to resemble on/off modulation used for controlling resonant DC-DC converters (such as described above and in the above-referenced U.S. Provisional Application). Both schemes pulse power to the output, which enables low complexity hysteretic control and fast transitions to lower power levels. However, converters using on/off modulation dissipate their resonant branch energy immediately at turn-off through a low quality factor output branch. Alternatively, the proposed mixed sequence control circulates energy within its resonant branch, which enables fast transitions to higher power states, as well. An instructive way to view the circulating energy is by examining the ratio of energy stored in the resonator to the average energy delivered to the output each cycle:
E.sub.stored/E.sub.out=f.sub.sw0L.sub.mI.sup.2m/2P.sub.out (19)
[0074] The two variables I.sup.2m and P.sub.out scale with (n.sub.f/(n.sub.f+n.sub.z)).sup.2, so this ratio will stay constant for all n.sub.f and n.sub.z. Essentially, the excess energy being circulated serves as a reservoir for fast transitions to higher power, while the discrete on/off nature of the mixed-sequence allows fast transitions to lower power. Closed-loop hysteretic voltage regulation with fixed-frequency control can also alleviate the slow transients incurred from the piezoelectric resonator's high quality factor by operating at a lower switching frequency and resonator impedance than standard control, so this ratio will stay constant for all n.sub.f and n.sub.z. Essentially, the excess energy being circulated serves as a reservoir for fast transitions to higher power, while the discrete on/off nature of the mixed-sequence allows fast transitions to lower power. Closed-loop hysteretic voltage regulation with fixed-frequency control can also alleviate the slow transients incurred from the piezoelectric resonator's high quality factor by operating at a lower switching frequency and resonator impedance than standard control. To help appreciate what is meant by fast transitions to lower power, as examples, the term fast refers to or includes signal transition speeds at which the voltage or current settling time of the input or output occurs faster than what is capable without the proposed fixed-frequency control with circulating current, and the term lower power refers to or includes any step in output power in which the final output power is less than the starting output power.
[0075] Discussion now turns to exemplary switch timings in certain experimental embodiments according to the present disclosure. Common methods of calculating switch timings oftentimes require solving systems of many equations using conservation of charge and energy constraints. The number of equations to solve is proportional to the number of switching states in a sequence, and the mixed switching sequence produces over n.sub.f times more states than the standard sequence. In lieu of solving systems of hundreds of equations, a simplified approach starts with the assumption that the motional current is a constant amplitude sine wave. Making this assumption over the whole mixed sequence (no damping or frequency variations), leads to the expression for motional current: i.sub.m(t)=I.sub.m sin (2πf.sub.sw.sub.
Integrating for state C gives:
[0076] The beginning and end of open state C occur at times t.sub.B and t.sub.C, respectively. The change in voltage ΔV.sub.p,open follows from the chosen switching sequence. For example, looking at the connected state switching node voltages bordering the open states in Table 1 for the stacked topology's [V.sub.out, V.sub.in−V.sub.out] sequence gives expressions for ΔV.sub.p,open.
[0077] Additionally, energy must be conserved for the input and output during connected states. For [V.sub.out, V.sub.in−V.sub.out] sequence, the conservation of energy constraint is given by:
−q.sub.BV.sub.out+q.sub.DV.sub.m+q.sub.F(V.sub.in−V.sub.out)=0 (22)
The q.sub.n represents the charge transferred during a connected state, which is equal to the integral of the motional current throughout the state. For example, state B has a charge transfer of:
[0078] Solving the system of equations produced by applying equations (8), (21), (22), and (23) to a switching sequence results in switch timings in terms of I.sub.m0, n.sub.f, n.sub.z, and known parameters. Table 2 shows the switch timings calculated for the sequence [V.sub.out, V.sub.in−V.sub.out] and conversion ratios of V.sub.out<V.sub.in<2V.sub.out where t.sub.A corresponds with the time state A ends.
[0079] For more accurate switch timings, this method could be modified to include the cycle to cycle variations of I.sub.m as the current ramps up or dampens depending on the type of cycle. Another improvement could compensate for the frequency differences of forward and zero cycles using (6).
TABLE-US-00002 TABLE 2 Scaled Switch Timings for Sequence [V.sub.out, V.sub.in, V.sub.in − V.sub.out] Time Value t.sub.A
[0080] To verify the fixed-frequency control, an exemplary type of prototype piezoelectric resonator DC-DC converter was tested via an experimental prototype with the lithium niobate resonator from above equation [6]. A modified mounting scheme enabled a reduction in Rm to 100 mQ from 190 mQ in the previous demonstration with this resonator. This mounting scheme attaches bond wires to both edges of the resonator instead of one, reducing the series resistance through the 400 nm resonator electrodes and bond wires. Table 3 lists the resonator's BVD circuit parameters, and
TABLE-US-00003 TABLE 3 Prototype Converter and Resonator Component Values Component Value S1-4 EPC2012C Gate Driver LMG1210 5V Isolators ADuM5028-5BRIZ L.sub.m 15.1 μH C.sub.m 36.0 pF R.sub.m 100.0 mΩ C.sub.o 145.0 pF
[0081] One such experimental prototype converter includes a power board and a resonator carrier board. The carrier board only houses the mounted resonator and connects to the power board using board-to-board connectors with a 1.5 mm mated height. The use of a carrier board for the resonator allows a single converter to test multiple resonators and keeps the series inductance to the resonator low by placing it right beneath the switching nodes. The switch signals, which are calculated with the methods described herein for calculating switching timings, are produced externally by an XC7S25 FPGA and sent to the power board through a ribbon cable for open loop control. A 24-length bit array loaded to the FPGA defines the sequence of forward and zero cycles. A power supply and an electronic DC load were connected to the input and output, respectively, to step up voltage to the desired operating point at a fixed ratio.
[0082] First, the prototype converter tested the standard sequence control across its spurious-free operating range. All of the following testing used a conversion ratio of 60 V to 30 V. A 2:1 conversion ratio was chosen since it maximizes efficiency, yet piezoelectric resonator DC-DC converters can operate across a wide range of conversion ratios as shown with the same resonator in equation [6]. Just past series resonance at 6.84 MHz, the converter achieves a maximum output power of 51.3 W with efficiency of 94.5%. Here, the 32×13×0.5 mm resonator achieves a component power density of 246.6 W/cm.sup.3. Shown in
[0083] Next, the converter tested the 6.861 MHz family of mixed sequences to verify the fixed-frequency control mode.
from (11) matches we measured data across all the mixed sequence ratios as seen in
[0084] Fixed-frequency control was also applied to the mixed sequence family with at 6.952 MHz. At low output power, the 6.952 MHz family has higher efficiency than the 6.861 MHz family clue to its lower mixed sequence ratios. This exemplifies how the fixed-frequency control can enable spurious mode hopping where the converter operates at multiple spurious-free fixed frequencies that have spurious modes between them. At the load conditions corresponding to the spurious-free frequencies, maximum efficiency standard sequence control can be used. But to bridge between the spurious-free regions, fixed-frequency control can be used. Enabling the ability for spurious mode hopping can further simplify resonator design. Designing a resonator free of spurious modes across its entire operating range is exceedingly difficult and likely comes at the cost of higher resistance from damping out minor spurious modes. However, designing a resonator with localized, high quality factor spurious modes and well-defined spurious-free regions can be readily achieved.
[0085] It is recognized and appreciated that as specific examples, the above-characterized figures and discussion are provided to help illustrate certain aspects (and advantages in some instances) which may be used in the manufacture of such structures and devices. These structures and devices include the exemplary structures and devices described in connection with each of the figures as well as other devices, as each such described embodiment has one or more related aspects which may be modified and/or combined with the other such devices and examples as described hereinabove may also be found in the Appendix of the above-referenced Provisional Application.
[0086] The skilled artisan would also recognize various terminology as used in the present disclosure by way of their plain meaning. As examples, the Specification may describe and/or illustrates aspects useful for implementing the examples by way of various semiconductor materials/circuits which may be illustrated as or using terms such as layers, blocks, modules, device, system, unit, controller, and/or other circuit-type depictions (e.g., control logic 120, 120′ and switching circuitry 115, 115′ of
[0087] Based upon the above discussion and illustrations, those skilled in the art will readily recognize that various modifications and changes may be made to the various embodiments without strictly following the exemplary embodiments and applications illustrated and described herein. For example, methods as exemplified in the Figures may involve steps carried out in various orders, with one or more aspects of the embodiments herein retained, or may involve fewer or more steps. Such modifications do not depart from the true spirit and scope of various aspects of the disclosure, including aspects set forth in the claims.