US 6,930,893 B2 · Factorized power architecture with point of load sine amplitude converters

Abstract

A Factorized Power Architecture (“FPA”) includes a power regulator providing controlled DC bus voltages distributed and converted to load voltages, at the load, using DC voltage transformation modules (“VTMs”) having fixed transformation ratios. Optional feedback from the load improves regulation. A Sine Amplitude Converter (“SAC”) VTM locks the conversion frequency to resonance of a resonant circuit including a transformer, uses complementary primary switches, balanced switching, and a high conversion duty cycle, and may use primary ZVS and secondary ZVS and ZCS, low Q, and a low profile core structure, and may exhibit greater than 400 Watts/cubic-inch power density and 95% efficiency. Common-source gate-control topologies efficiently drive switches higher than 1 MHz. Symmetrical power trains reduce common-mode noise. Modulated converter output resistance controls Vout, limits Iout, or improves current sharing. Gate drive circuitry recycles energy from the transformer magnetizing inductance. A DC—DC converter includes a non-isolated converter followed by a SAC.

Claims122

Dependent claims

A method of converting power from an input source for delivery to a load, where the load may vary over a normal operating range, comprising:

providing a transformer;
forming a resonant circuit including the transformer having a Q less than 13 and having a characteristic resonant frequency and period;
providing output circuitry connected to the transformer for delivering a rectified output voltage to the load;
providing two or more primary switches to drive the resonant circuit;
providing a switch controller to operate the primary switches in a series of converter operating cycles, each converter operating cycle characterized by two power transfer intervals of essentially equal duration each interval having a duration less than the characteristic resonant period, during which one or more of the primary switches are ON and power is transferred from the input to the output via the transformer;
and
providing a conversion efficiency from the source to the load having a peak greater than 90% within the normal operating range.

4 more elements

A method of converting power from an input source for delivery to a load, where the load may vary over a normal operating range, comprising:

providing a transformer;
forming a resonant circuit including the transformer and having a characteristic resonant frequency and period;
providing output circuitry connected to the transformer for delivering a rectified output voltage to the load;
providing two or more primary switches to drive the resonant circuit;
and
providing a switch controller to sense current in the transformer and to operate the primary switches in a series of converter operating cycles, each converter operating cycle characterized by
(a) two power transfer intervals of essentially equal duration, during which one or more of the primary switches are ON, a resonant current at the charateristic resonant frequency and a magnetizing current flow through a winding of the transformer, and power is transferred between the input and the output via the transformer, each power transfer interval having a duration that results in essentially canceling reactive impedances in the resonant circuit;
and
(b) two energy-recycling intervals each having an essentially constant duration over the normal operating range during which the primary switches are OFF;
and
using the switch controller to turn the primary switches OFF essentially a times when the resonant current returns to zero;
using the magnetizing current to charge and discharge capacitances during the energy-recycling intervals;
and
providing an essentially resistive output impedance over a bandwidth approaching the resonant frequency.

11 more elements

A method of converting power from an input source for delivery to a load, where the load may vary over a normal operating range, in a converter having two or more primary switches connected to drive a resonant circuit including a transformer and having a charateristic resonant frequency and period, output circuitry connected to the transformer for delivering a rectified output voltage to the load, and a switch controller to operate the switches, the method comprising:

sensing current in the transformer;
operating the switches in a series of converter operating cycles, each converter operating cycle charaterized by:
(a) first and second power transfer intervals during which one or more of the primary switches are ON, a resonant current at the characteristic resonant frequency flows a through a winding of the transformer, and power is transferred between the input source and the load via the transformer, the first and second power transfer intervals having a duration that results in essentially canceling reactive impedances in the resonant circuit;
and
(b) two energy-recycling intervals during which the primary switches are OFF;
wherein the switch controller turns the primary switches OFF at times essentially when the resonant current returns to zero;
and
wherein currents in the converter are used to charge and discharge capacitances in the converter during the energy-recycling intervals;
providing an essentially constant voltage gain K=Vout/Vin at a load current for the power conversion, where Vin is the input source voltage and Vout is the rectified output voltage accross the load;
and
providing an essentially resistive output impedance over a bandwidth approaching the resonant frequency.

8 more elements

A method of converting power from an input source for delivery to a load, where the load may vary over a normal operating range, in a converter having two or more primary switches connected to drive a resonant circuit including a transformer and having a characteristic resonant frequency and period, output circuitry connected to the transformer for delivering a rectified output voltage, and a switch controller to operate the switches the method comprising:

operating the primary switches in a series of converter operating cycles, each converter operating cycle being characterized by:
(a) first and second power transfer intervals during which one or more of the primary switches are ON, a resonant current at the characteristic resonant frequency and a magnetizing current flow through a winding of the transformer, and power is transferred between the source and the load via the transformer;
the first and second power transfer intervals having a duration that results in essentially canceling reactiveimpedances in the resonant circuit over the normal operating range;
and
(b) two energy-recycling intervals during which the primary switches are OFF;
and
(c) a period having an essentially constant duration over the normal operating range;
sensing current in the transformer;
controlling the primary switches as a function of the sensing;
using the magnetizing current to charge and discharge capacitances during the energy recycling intervals;
and
providing an essentially resistive output impedance over a bandwidth approaching the resonant frequency.

9 more elements

Apparatus for converting power from an input source for delivery to a load, where the load may vary over a normal operating range, comprising:

a transformer;
a resonant circuit including the transformer and having a characteristic resonant frequency and period;
output circuitry connected to the transformer for delivering a rectified output voltage to the load;
two or more primary switches connected to drive the resonant circuit;
and a switch controller adapted to sense current in the transformer and operate the primary switches in a series of converter operating cycles, each converter operating cycle characterized by
(a) two power transfer intervals of essentially equal duration, during which one or more of the switches are ON, a resonant current at the characteristic resonant frequency and a magnetizing current flow through a winding of the transformer, and power is transferred between the input and the output via the transformer, the power transfer intervals having a duration that results in essentially canceling reactive impedances in the resonant circuit;
and
(b) two energy-recycling intervals each having an essentially constant duration over the normal operating range during which the primary switches are OFF;
wherein the switch controller is adapted to turn the primary switches OFF essentially at times when the resonant current returns to zero;
wherein the magnetizing current is used to charge and discharge capacitances during the energy-recycling intervals;
and
wherein the apparatus comprises an essentially resistive output impedance over a bandwidth approaching the resonant frequency.

9 more elements

Apparatus for converting power from an input source for delivery to a load, where the load may vary over a normal operating range, comprising;

a transfomer;
a resonant circuit including the transfermor and having a characteristic resonant frequency and period;
output circuitry connected to the transformer for delivering a rectified output voltage to the load;
two or more primary switches connected to drive a resonant circuit;
and
a switch controller adapted to sense current in the transformer and operate the primary switches in a series of converter operating cycles as a function of the sensing, each converter operating cycle characterized by
(a) first and second power transfer intervals during which one or more of the primary switches are ON, a resonant current at the characteristic resonant frequency and a magnetizing current flow through a winding of the transformer, and power is transferred between the source and the load via the transformer, the first and second power transfer intervals having a duration that results in essentially canceling reactive impedances in the resonant circuit over the normal operating range;
and
(b) two energy-recycling intervals during which the primary switches are OFF;
and
(c) a period having an essentially constant duration over the normal operating range;
and an essentially constant voltage gain K=Vout/Vin at a load current for the power conversion, where Vin is the input source voltage and Vout is the rectified output voltage;
wherein the magnetizing current is used to charge and discharge capacitance during the energy-recycling intervals;
and
wherein the apparatus comprises an essentially resistive output impedance over a bandwidth approaching the resonant frequency.

12 more elements

Dependencies are inferred from the claim text.

Factorized power architecture with point of load sine amplitude converters

Life of this patent

Factorized power architecture with point of load sine amplitude converters

Life of this patent

Abstract

Claims122