Factorized power architecture with point of load sine amplitude converters

A method of increasing power density in point-of-load converters for supplying a regulated DC voltage, Vload, to a load, where the load may vary over a normal operating range, from an input source, the method comprising:

• factorizing away from the point-of-load a power-conversion function of voltage regulation, wherein the factorizing comprises installing a first regulator module (RM) having an RM input and an RM output and being a self-contained assembly adapted to be installed as a unit, and using the first regulator module to convert power from the input source to a controlled voltage, Vf, delivered to a factorized bus;
• localizing at the point-of-load a function of DC voltage transformation wherein the localizing comprises installing a voltage transformation module (“VTM”) at the point-of-load, the VTM having a VTM input and a VTM output and being a self-contained assembly adapted to be installed as a unit, and using the VTM to convert the factorized bus voltage at the point-of-load, Vin, to an output voltage, Vout, essentially equal to Vload;
• and
• adapting the VTM to convert power via a transformer, and to provide an essentially constant DC voltage gain, K, and an output resistance, Rout, to deliver a VTM output voltage, Vout, at an output current, Iout, the VTM having a transfer function essentially equal to Vout=K (Vin)−Rout(Iout);
• and
• regulating Vload, by controlling the voltage of the factorized bus, Vf.

A method of distributing electrical power in a vehicle comprising;

• using a first regulator located at a first location near a source of power in the vehicle to convert power from the source at a source voltage, Vsource, and deliver, at an output of the first regulator, a controlled DC voltage, Vf, to a factorized bus;
• using the factorized bus to distributes the controlled DC voltage, Vf, to a plurality of locations throughout the vehicle;
• using a plurality of voltage transformation modules (“VTMs”) distributed throughout the vehicle to provide power to loads distributed throughout the vehicle;
• each VTM having a VTM input and a VTM output, each VTM being a self-contained assembly adapted to be installed as a unit at a remote location to convert power, via a transformer, from the factorized bus at a VTM input voltage Vin, to deliver a VTM output voltage, Vout, at an output current, Iout, and each VTM having an essentially constant voltage gain, K, an output resistance, Rout, and a transfer function essentially equal to Vout=K (Vin)−Rout(Iout);
• wherein each load is supplied with a respective voltage, Vload, essentially equal to the respective VTM output voltage, Vout.

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

• a first regulator module having a first input and a first output and being a self-contained assembly adapted to be installed as a unit at a first location and having circuitry adapted to convert power received from the input source via the first input at a source voltage, Vsource, and deliver a controlled DC voltage, Vf, to the first output;
• a factorized bus connected to the first output of the first regulator and extending to a remote location;
• and
• a voltage transformation module (“VTM”) having a VTM input and a VTM output and being a self-contained assembly adapted to be installed as a unit at the remote location and having circuitry, including a transformer, adapted to convert power from the factorized bus at a VTM input voltage, Vin, to deliver a VTM output voltage, Vout, at an output current, Iout, the VTM having an essentially constant voltage gain, K, an output resistance, Rout, and a transfer function essentially equal to Vout=K (Vin)−Rout(Iout);
• wherein the load is supplied with a voltage, Vload, essentially equal to the VTM output voltage, Vout, and the VTM output voltage, Vout, is regulated by controlling the factorized bus voltage, Vf.

Apparatus for converting power at a point-of-load from a factorized bus driven by a source of controlled DC voltage, Vf, for delivering a regulated DC voltage, Vload, to a load where the load may vary over a normal operating range, the apparatus comprising:

• a voltage transformation module (“VTM”) having power conversion circuitry, an input terminal, and an output terminal and being a self-contained assembly adapted to be installed as a unit at the point-of-load;
• the power conversion circuitry comprising:
• an input connected to the input terminal and adapted to receive a DC input voltage, Vin, from the factorized bus;
• an output connected to the output terminal and adapted to deliver a DC output voltage, Vout, essentially equal to Vload, at an output current, Iout;
• a transformer;
• two or more primary switches arranged in a bipolar drive circuit connected to drive the transformer with power received from the input;
• and
• a controller adapted 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 and power is transferred from the input to the output via the transformer, and
• (b) two energy-recycling intervals during which the primary switches are OFF;
• wherein the VTM has an essentially constant DC voltage gain, K, an output resistance, Rout, and a transfer function essentially equal to Vout=K (Vin)−Rout(Iout).

Apparatus for providing scalable electric power conversion capability in which power is converted from a factorized bus driven by a voltage source of controlled DC voltage, Vf, and delivered to a load at a regulated DC output voltage, Vload, where the load may vary over a normal operating range, the apparatus comprising:

• two or more voltage transformation modules (“VTMs”) each having
• (a) an input adapted to receive a DC input voltage, Vin, from the factorized bus;
• (b) an output adapted to deliver an output voltage, Vout, essentially equal to Vload;
• (c) a transformer;
• (d) two or more primary switches arranged in a bipolar drive circuit connected to drive the transformer with power received from the input;
• and
• (e) a controller operating the primary switches in a series of converter operating cycles;
• (f) an essentially constant voltage gain K;
• and
• (g) an output resistance, Rout;
• wherein each VTM is a self-contained assembly adapted to be installed as a unit;
• wherein the outputs of the two or more VTMs are connected in parallel;
• and
• wherein the power delivered to the load is shared by each VTM connected in parallel in inverse proportion to the output resistance of each VTM.

A method of increasing circuit density in an electronic system comprising:

• distributing power to a load assembly at a DC voltage, Vf, that is N times a voltage, Vload, required by load circuitry on the load assembly;
• providing a voltage transformation module (“VTM”) having an input for receiving the DC voltage, Vf and an output for delivering the voltage, Vload, the VTM being a self contained assembly adapted to be installed as a unit on the load assembly and providing voltage transformation from the input to the output at an essentially constant voltage gain, K=1/N, using a power transformer excited by a bipolar drive circuit;
• mounting the VTM on the load assembly and using the VTM to supply power to the load circuitry;
• and
• providing voltage control of the DC voltage, Vf external to the VTM to regulate Vload.

A method of distributing power to a plurality of loads each having a respective DC voltage level and tolerance requirements, comprising:

• providing a plurality of voltage transformation modules (“VTMs”) at points of load, each VTM being a self-contained assembly adapted to be installed as an individual unit, to receive power via a respective VTM input at a VTM input voltage, Vin, to deliver power via a respective VTM output at a VTM output voltage, Vout, at an output current, Iout, to a respective load, and to provide galvanic isolation and DC voltage transformation between the respective VTM input and the respective VTM output, each VTM having a transfer function essentially equal to Vout=K (Vin)−Rout(Iout) wherein K is an essentially constant voltage gain and Rout is an output resistance;
• unifying power distribution requirements using the respective voltage gain of each a VTM to transform the respective DC voltage level requirements of the respective load into a common voltage level;
• distributing power at essentially the common voltage level to the VTM inputs for delivery to the respective loads;
• and
• controlling the common voltage to satisfy the DC voltage tolerance requirements of the plurality of loads.

A method of distributing power in a system comprising:

• providing a first point-of-load (“POL”) converter, the first POL converter being a self-contained assembly adapted to be installed as an individual unit, to receive power via a first POL input at a DC input voltage, Vin, to deliver power via a first POL output at a DC output voltage, Vout1, to convert power received from a bus over a normal operating input voltage range for delivery to a first load at a first load voltage;
• providing the first POL converter with a transfer function essentially equal to Vout1=K1 (Vin)−Rout1(Iout1) wherein K1 is a fixed voltage gain, Rout1 is an output resistance of the first POL converter, and Iout1 is the output current of the first POL converter, and using a bipolar drive circuit with balanced switch cycles to drive a power transformer using a power conversion duty cycle greater than 80%;
• selecting the voltage gain K1 for the first POL converter to deliver the first load voltage from a first bus voltage;
• and
• controlling the first bus voltage to satisfy a voltage tolerance set by the first load.

A method of distributing power in electronic equipment comprising

• receiving power from an input source over a normal input operating range of voltages including a minimum input voltage and a maximum input voltage;
• converting power received from the input source for delivery to load circuitry, wherein the converting power comprises a first power processing stage and a second power processing stage, the second power processing stage receiving power processed by the first power processing stage;
• the first power processing stage being provided at a first location in a first self-contained module assembly adapted to be installed as an individual unit and adapted to receive power from the source via a first-module input and deliver power via a first-module output at a controlled DC voltage, Vf, regulated to stay within a predetermined control range, the first power processing stage providing voltage regulation;
• the second power processing stage being provided at a remote location in a second self-contained module assembly adapted to be installed as an individual unit and adapted to receive power via a second-module input at a DC input voltage, Vin, and deliver power to the load circuitry at a DC output voltage, Vout, at an output current, Iout, via a second-module output using a transfer function essentially equal to Vout=K (Vin)−Rout(Iout) wherein K is an essentially constant voltage gain and Rout is an output resistance, the second power processing stage providing galvanic isolation and providing DC voltage transformation;
• and
• bussing the controlled DC voltage from the first module output of the first stage to the second module input of the second stage.