US 10,348,185 B1Grant

Output current sensing for DC/DC converter with external power stage

Issue Date:2019-07-09

•18 Claims

•5 Drawing Sheets

Abstract

A method for sensing an output current of a Direct Current-to-Direct Current (DC/DC) converter having an external power stage configured to supply a converted current to an external inductor. During a calibration phase at a first start-up of the DC/DC converter: the method includes injecting a calibration current through a switching node of the power stage and through the inductor; and determining a calibration gain of the DC/DC converter to compensate for DC Resistance (DCR) variation by comparing a gain-adjusted voltage across the inductor with a reference voltage. During a measurement phase, the method includes reducing ripple voltage of a switching voltage at the switching node to generate a ripple-reduced switching voltage; and sensing the output current based on a DCR-compensated voltage across the inductor, which is a difference between the ripple-reduced switching voltage and an output voltage of the DC/DC converter with compensation for the DCR variation based on the calibration gain.

Metadata

Assignee

Infineon Technologies AG

Inventor

Vratislav Michal

Application Information

Application Number:US 16/043,834

Filing Date:2018-07-24

Priority Date:2018-07-24

Art Unit:2838

Classifications

IPC:

H02M1/15H02M3/158H02M3/335H02M1/00

Field of Search:

H02M 1/14H02M 1/15H02M 3/158H02M 3/1584H02M 3/33507H02M 2003/158H02M 2001/0009

Patent Drawings (5 sheets)

Description

Background

[0001] A Direct Current-to-Direct Current (DC/DC) converter converts a DC voltage from one voltage level to another.

[0002] Current sensing in a DC/DC converter with external power switches is used for optimizing power flow in high computation power microcontrollers and current sharing applications. While most power efficiency optimization focuses on circuit optimization, power savings may be realized by a microcontroller implementing more power-efficient software algorithms. Also, the sensed output current may be used by a feedback controller, an Current-Limitation circuit, feed into an Analog-to-Digital converter (A/D), helps to build a power-save mode, and/or in current sharing in interleaving converters.

Brief Description of the Drawings

[0003] FIG. 1 illustrates a schematic diagram of a DC/DC converter with a current sensing circuit in accordance with aspects of the disclosure.

[0004] FIG. 2A illustrates a schematic diagram of a calibration circuit, which is the current sensing circuit of FIG. 1 during a calibration phase, in accordance with aspects of the disclosure.

[0005] FIG. 2B illustrates a schematic diagram of a measurement circuit, which is the current sensing circuit of FIG. 1 during a measurement phase, in accordance with aspects of the disclosure.

[0006] FIG. 3 illustrates a flowchart of a method of operating the current sending circuit of FIGS. 1, 2A, and 2B in accordance with aspects of the disclosure.

Detailed Description

[0007] The present disclosure is directed a Direct Current-to-Direct Current (DC/DC) converter with a current sensing circuit configured to measure the DC/DC converter's output current. The current sensing circuit performs a calibration to reduce variations in inductor DC Resistance (DCR) and in package and Printed Circuit Board (PCB) resistances. The calibration is based on a reference voltage and a reference resistance. Eventually, it can be based also on a reference current which is often unavailable or inaccurate. The current sensing circuit may additionally perform active ripple cancellation to enable faster sensing, and/or thermal monitoring to compensate for thermal variations of the inductor resistance.

[0008] FIG. 1 illustrates a schematic diagram of a DC/DC converter with a current sensing circuit 100 in accordance with aspects of the disclosure.

[0009] The DC/DC converter comprises an external power stage 10 and an output filter 20. The external power stage 10 comprises a dead-time non-overlapping generator 12, driver circuit 14, and external switches 16. The dead-time non-overlapping generator 12 is configured to receive a Pulse Width Modulation (PWM) signal and generate gate driving signals CMD_P, CMD_N with dead time. The amplifying driver circuit 14 is configured to provide strong gate driving signals CMD_P, CMD_N before input to the gates of the external switches PMOS, NMOS. The dead time avoids short-circuit conditions occurring when both of the external switches PMOS, NMOS are on at the same time.

[0010] The output filter 20 comprises an external inductor L, a coil parasitic resistor R_coil, and an output capacitor C_out. The output filter 20 is configured to provide an average value of the switching voltage V_LXat the switching node N_LXbetween the external switches PMOS, NMOS of the power stage 10.

[0011] The current-sensing circuit 100 is configured around the inductor L of the DC/DC converter's output filter 20. The current sensing circuit 100 comprises a temperature sensor 110, a current injection circuit 120, a calibration gain determination circuit 130, and a ripple cancellation circuit 140. The calibration gain determination circuit 130 comprises a differential amplifier 132 and a calibration controller 134. The calibration controller 134 is configured to receive a reference voltage V_REF, a clock signal CLK, and an enable signal EN.

[0012] The DC/DC converter has an initial calibration phase, followed by measurement phases. The calibration phase occurs, for example, only during a first turn-on of the DC/DC converter. During the calibration phase, the external switches 16 (PMOS and NMOS) are off, and the current injection circuit 120 (120-1 and 120-2) is configured to inject a calibration current I_CALthrough the switching node N_LXof the power stage 10 and through the inductor L of the output filter 20. The calibration phase begins when the calibration switch 120 clamps the DC/DC converter output voltage V_outto ground, and by triggering the switching node N_LXto high impedance. During the subsequent measurement phases, the calibration switch 110 is opened, thereby enabling the output of the filter 20.

[0013] FIGS. 2A and 2B illustrate the DC/DC converter with details of the current sensing circuit 100 during the calibration and measurement phases. More specifically, FIG. 2A illustrates the current sensing circuit 100 during the calibration phase, and FIG. 2B illustrates the current sensing circuit 100 during the subsequent measurement phases.

[0014] FIG. 2A illustrates a schematic diagram of a calibration circuit 200A, which is the current sensing circuit 100 of FIG. 1 during the calibration phase, in accordance with aspects of the disclosure.

[0015] The calibration circuit 200A comprises a temperature sensor 210, a current injection circuit 220, and a calibration gain determination circuit 230.

[0016] The temperature sensor 210 is configured to measure, during the calibration phase, a calibration temperature T of the inductor L. The temperature sensor 210 may comprise an on-chip temperature sensor of, for example, the microprocessor, or alternatively, an external temperature sensor placed near the inductor L.

[0017] The current injection circuit 220 comprises a calibration switch (SW_cal) 220-1 and a current mirror 220-2. The current injection circuit 220 is configured to inject a calibration current I_CALthrough the switching node N_LXof the power stage 10 and through the inductor L of the output filter 20 to the output node N_out. The current mirror 220-2 is configured to mirror a reference current I_REFto generate the calibration current I_CAL. The reference current I_REFis based on the reference voltage V_REFand a reference resistance R_REF. The reference resistance R_REFis formed by a resistive divider comprising resistors R_Aand R_B, and is equal to R_B/R_A+R_B. Eventually, reference current can be supplied from external source, if available.

[0018] The calibration gain determination circuit 230 comprises an operational amplifier 232, a differential amplifier 234, a comparator 236, a calibration controller 238, and various resistors. The calibration gain determination circuit 230 is configured to determine a calibration gain G of the current sensing circuit to compensate for DC Resistance (DCR) variation by comparing a gain-adjusted voltage V_SNSacross the inductor L with a reference voltage β·V_REF. The calibration determination circuit 230 adjusts a gain of the differential amplifier 234 until a calibration condition is reached, and then the calibration gain G is stored, as discussed in more detail below.

[0019] The calibration controller 238 is configured to adjust the gain of the differential amplifier 234 by increasing a value of a feedback resistance R_SNSand comparing the gain-adjusted voltage V_SNSacross the inductor L with the reference voltage β·V_REF. More specifically, the calibration controller 238 is configured to increment a first resistance value of a first calibration resistor R_CAL1coupled between the switching node N_LXand a first input (+) of the differential amplifier 234 to generate a gain-adjusted switching voltage V_CAL1, and to increment a second resistance value of a second calibration resistor R_CAL2coupled between the output node N_outand a second input (−) of the differential amplifier 234 to generate a gain-adjusted output voltage V_CAL2. The differential amplifier 234 is configured to determine a difference between the gain-adjusted switching voltage V_CAL1and the gain-adjusted output voltage V_CAL2, and output the gain-adjusted voltage V_SNSacross the inductor L.

[0020] The comparator 236 is configured to compare the gain-adjusted voltage V_SNSacross the inductor L with the reference voltage β·V_REF, and to signal the calibration controller 238 to stop incrementing the resistance values of the first and second calibration resistors R_CAL1, R_CAL2when the gain-adjusted voltage V_SNSacross the inductor L equals the reference voltage β·V_REF, that is, V_SNS=β·V_REF. At this time, the calibration gain G is reached, and the current mirror 220-2 is disconnected and the calibration switch 220-1 opened so that the DC/DC converter may operate normally. The feedback resistance R_SNSis then a scaled image of the coil resistance R_DCR.

[0021] The calibration controller 238 is further configured to store in a memory 260 (shown in FIG. 2B) the calibration gain G, which is based on the first resistance value of the first calibration resistor R_CAL1and/or the second resistance value of the second calibration resistor R_CAL2when the gain-adjusted voltage V_SNSacross the inductor L equals the reference voltage β·V_REF. This memory 260 may be, for example, a One-Time-Programmable (OTP) memory or EEPROM memory.

[0022] Further, the temperature sensor 210 is configured to measure, during the calibration phase, a calibration temperature T of the inductor L. The memory 260 (shown in FIG. 2B) is further configured to store the measured calibration temperature T. Alternatively, the calibration may be performed at known temperature, for example, during a first startup of the DC/DC converter.

[0023] The calibration gain G and a calibration temperature T are stored in a memory 260 during the calibration phase at a first startup of the DC/DC converter. This calibration gain G and temperature T are recalled from the memory 260 during subsequent measurement phases. The calibration relies on the value of the reference resistor R_REF. A reference current, which is often unavailable or inaccurate, is not required for the calibration. In some cases, when a supply voltage V_DDis accurate enough, the reference voltage V_REFis not required because the reference voltage V_REFcan be derived from the supply voltage V_DD.

[0024] To assist in a more detailed understanding of the operation of the calibration phase, the following few paragraphs include equations representing how the calibration gain G is determined.

[0025] The parasitic inductor resistance R_DCRis derived from the reference voltage V_REFand the resistors R_Aand R_Bas follows:

[0026]

\begin{matrix} V_{DCR} = α \frac{V_{REF}}{R_{A} + R_{B}} \cdot R_{DCR} & (Equation 1) \end{matrix}

whereas the calibration current I_CALis an α-scaled image of the reference current I_REF. The reference voltage V_REFis provided by the differential amplifier 232. The differential amplifier gain R_SNS/(R_LP+R_CAL) provides the output voltage V_SNSon the output of the differential amplifier 234 as follows:

[0027]

\begin{matrix} V_{SNS} = \frac{R_{SNS}}{R_{CAL} + R_{LP}} \cdot V_{DCR} & (Equation 2) \end{matrix}

[0028] The value of the calibration resistance R_CALis incremented in order to adjust the gain of the differential amplifier 234. The calibration condition is defined as:
V_SNS=β·V_REF, (Equation 3)
where β=R_B/(R_A+R_B) is attenuation of resistive divider considered constant. As the outcome of the calibration, the feedback resistance R_λ=R_CAL+R_LPis the scaled image of R_DCR:

[0029]

\begin{matrix} R_{λ} = α \cdot \frac{R_{SNS}}{R_{B}} \cdot R_{DCR} . & (Equation 4) \end{matrix}

[0030] In other words, the calibration current I_CALis derived based on trimmed on-chip resistances R_Aand R_B, whereas R_SNSand R_λ are process dependent on-chip resistances. The process dependency is then removed during current measurement, as the gain of the differential amplifier 234 depends on an accurate ratio R_SNS/R_λ.

[0031] Since the calibration is performed only once during the lifetime of the DC/DC converter, the power components, such as the calibration switch 220-1 and the current mirror 220-2, can be sized reasonably small and do not need to sustain reliability. The requirement on the calibration switch resistance is also relaxed, as it is preferred to provide clamping around several hundred mV referred to ground.

[0032] During the calibration phase, the low offset of the differential amplifier 234 (<1 mV) is required. Additionally, a temperature T of the DC/DC converter is stored for subsequent temperature correction, as described further below. In order to reduce the voltage drop on the on-chip parasitic layout resistance, double bonding may be used, with separated current and voltage paths for the switching node N_LX.

[0033] FIG. 2B illustrates a schematic diagram of a measurement circuit 200B, which is the current sensing circuit 100 of FIG. 1 during a measurement phase, in accordance with aspects of the disclosure.

[0034] The measurement circuit 200B comprises a ripple cancellation circuit 240, a passive first-order low-pass filter 250, a memory 260, an active second-order low-pass filter 270, an output current sensing amplifier 280, and temperature compensation controller. The temperature compensation controller may be part of a same controller as the calibration controller 238 or a separate controller.

[0035] During the measurement phase, the calibration switch 110 is open, thereby enabling the output filter 20.

[0036] The ripple cancellation circuit 240 is configured to reduce ripple voltage of the switching voltage V_LXat the switching node N_LXto generate a ripple-reduced switching voltage V_LX-R. During the measurement phase, the switching node voltage V_LXfeeds high ripple voltage to the sensitive input of the differential amplifier, which is an output current sensing circuit 280. While the output of the DC/DC converter is supposed to provide an output voltage V_OUThaving low ripple, the switching node N_LXoperates in the ground-to-VDD range. Accordingly the ripple current I_ACinside a passive filter in the differential amplifier 280 is mainly due to the current in the filtering capacitor and R_LP(R_LP>>R_CAL) and is approximately:

[0037]

\begin{matrix} I_{A C} \approx \frac{V_{DD}}{Z (C (ω) + 2 \cdot R_{LP})} & (Equation 5) \end{matrix}

In other words, the differential amplifier 280 receives in one terminal a stable “DC” voltage V_OUT, while in the other terminal a square voltage V_LXwith high amplitude. Filtering this high voltage provides a long time constant of, for example, several tens of switching cycles.

[0038] The ripple cancellation circuit 240 comprises an inverter Inv, a resistor R and a capacitor C. The ripple cancellation circuit 240 is configured to provide an opposing-phase switching voltage having a 180° phase difference from that of the switching voltage V_LX. This is realized by the inverter Inv and matched resistor-capacitor (R-C) coupled in series creating a ripple current having a 180° phase difference from that of the switching voltage V_LX. The opposing-phase switching voltage is combined at node N with the switching voltage V_LX, thereby eliminating the AC components of the switching voltage V_LXto result in a rippled-reduced switching voltage V_LX-R. Also as a result, the number of switching cycles during which the sensed current is determined is reduced.

[0039] The passive first-order low-pass filter 250 comprises low pass filter resistors R_LP1and R_LP2. Resistor R_LP1is coupled between the switching node N_LXand the first calibration resistor R_CAL1. Resistor R_LP2is coupled between the output node N_outand the second calibration resistor R_CAL2. The passive first-order low-pass filter 250 is configured to first-order low-pass filter the switching voltage V_LXand the output voltage V_OUTof the DC/DC converter.

[0040] The active low-pass filter 270 comprises an RC circuit comprising resistor R_SNS3and capacitor C_SNS3coupled in parallel between a positive input and an output of the differential amplifier 280. The filter 270 also comprises an RC circuit having resistor R_SNS4and capacitor C_SNS4coupled in parallel and between the negative input of the differential amplifier 280 and ground. The active second-order low-pass filter 270 and 250 is configured to second-order low-pass filter the DCR-compensated voltage V_SNSacross the inductor L.

[0041] The calibration gain G stored in the memory 260, during the calibration phase as discussed above, is used to adjust the calibration resistors R_CAL1and R_CAL2to calibrate the DC/DC converter during the subsequent measurement phases.

[0042] The output current sensing circuit 280, that is, the differential amplifier, is configured to receive at the positive input the output voltage V_OUTof the DC/DC converter with compensation for DCR variation based on the calibration gain G, to receive at the negative input the ripple-reduced switching voltage V_LX-Rwith compensation for DCR variation based on the calibration gain G, and to output the DCR-compensated voltage V_SNSacross the inductor L. The output current sensing circuit 280 senses the output current I_outbased on a DCR-compensated voltage V_SNSacross the inductor L, which is a difference between the ripple-reduced switching voltage V_LX-Rand an output voltage V_outof the DC/DC converter with compensation for the DCR variation based on the calibration gain G.

[0043] The sensed output current I_outmay then be transmitted to a microprocessor, a feedback controller, an Over-Current Protection (OCP) or current limitation circuit, an Analog-to-Digital converter (A/D), or other device.

[0044] During the measurement phase, the current through the inductor L is much higher than during the calibration phase. This results in relaxed requirements on the offset of the differential amplifier 280.

[0045] The parasitic drop on R_DCRtogether with the amplification chain provides the output voltage of:

[0046]

\begin{matrix} V_{SNS} = I_{COIL} R_{DCR} \cdot \frac{R_{SNS}}{R_{λ}} . & (Equation 6) \end{matrix}

However, as R_λ has the same process variation as R_SNS, the process dependences of the resistor absolute value are eliminated.

[0047] The temperature compensation controller, which may be part of a same controller as the calibration controller 238 or a separate controller, is configured to correct the DCR-compensated voltage V_SNSacross the inductor L based on a measurement-phase temperature Ts (sensing temperature) and the calibration-phase temperature Tc of the inductor L.

[0048] The thermal coefficient R_ϑº of copper is about 0.3%/° C., and should be taken into account in a final current sensing or measurement result. Additionally, the copper thermal coefficient R_ϑº has decent linearity. The sensing of the temperature can be performed during a condition of good thermal equilibrium, for example, less than 15° of difference between thermal sensor and actual inductor temperature, by an on-chip temperature sensor 210, where the temperature of the inductor L is substituted with the temperature of the chip. Alternatively, the sensing of the temperature can be performed by an external temperature sensor placed near the inductor L; this alternative option is more accurate, but requires an additional component and extra pin.

[0049] The final image of the sensed current V_SNS^′ is then obtained by a linear correction of the sensed voltage V_SNSat the sensed temperature T_s, accounting for the temperature of the calibration T_CALas follows:
V_SNS^′=V_SNS(1+α(T_s−T_CAL)) (Equation 7)

[0050] To assist in a more detailed understanding of the operation of the measurement phase, the following few paragraphs include equations representing how the measurements are determined.

[0051] While analyzing the current-to-voltage transfer function, the focus is on

[0052]

L \frac{di}{dt}

compound of the output filter impedance. As result, the V/I transfer function of the inductor L can be written as impedance as follows:

[0053]

\begin{matrix} \frac{V_{coil} (s)}{I_{coil} (s)} = R_{L} + sL . & (Equation 8) \end{matrix}

[0054] This signifies that the voltage across the inductor L during a transient event is highly influenced by the sL component. The desired output voltage of the current sensor may be written as follows:
V_SNS=k·I_coil=F_SNS(s)·(R_L+sL)·I_coil (Equation 9)
where k is the constant related to the sensing gain. Then desired transfer function F_SNS(s) should then compensate the term sL:

[0055]

\begin{matrix} F_{SNS} (s) = \frac{k}{R_{L} + sL} = \frac{k / R_{L}}{1 + sL / R_{L}} & (Equation 10) \end{matrix}

[0056] The small-signal transfer function of the sensing circuit can be assumed as 3^rd-order transfer function of the form:

[0057]

\begin{matrix} F_{SNS} = \frac{G_{0}}{(s + ω_{p 1}) (s + ω_{p 2}) (s + \frac{1}{R_{SNS} C})} & (Equation 11) \end{matrix}

[0058] It can be shown, that the dominant transfer pole

[0059]

\frac{1}{R_{SNS} C}

can sufficiently compensate the zero coming from the inductor impedance term sL. This term can be therefore used to compensate the term sL mentioned previously. In order to obtain this compensation, the following equation is to be fulfilled:

[0060]

\begin{matrix} \frac{R_{L}}{L} = \frac{1}{R_{SNS} C}, & (Equation 12) \end{matrix}

leading to a condition:

[0061]

\begin{matrix} C = \frac{L}{R_{coil}, \cdot R_{SNS}} . & (Equation 13) \end{matrix}

[0062] FIG. 3 illustrates a flowchart of a method 300 of operating the current sensing circuit 100 (200A, 200B) of FIGS. 1, 2A, and 2B, in accordance with aspects of the disclosure.

[0063] During a calibration phase 310 at a first start-up of the DC/DC converter, a calibration current I_CALis injected through a switching node N_LXof the power stage 10 and through the inductor L (Step 312). A calibration gain G of the DC/DC converter is then determined to compensate for DC Resistance (DCR) variation by comparing a gain-adjusted voltage V_SNSacross the inductor L with a reference voltage β·V_REF(Step 314).

[0064] During a measurement phase, a ripple voltage of a switching voltage V_LXis reduced at the switching node N_LXto generate a ripple-reduced switching voltage V_LX-R(Step 322). The output current I_OUTis then sensed based on a DCR-compensated voltage V_SNSacross the inductor L, which is a difference between the ripple-reduced switching voltage V_LX-Rand an output voltage V_OUTof the DC/DC converter with compensation for the DCR variation based on the calibration gain G (Step 324).

[0065] The DC/DC converter as described herein has many advantages over prior devices. The aspects of this disclosure are based on a calibration by a current generated by trimmed integrated resistance. The reference current has then an accurate value. There is no need for an accurate external current source for the calibration process. The current sensing required is fast in that it requires few switching cycles.

[0066] The value of the output current of the DC/DC converter is important for power efficiency optimization, the feedback controller, over-current protection, built-in power-save mode, improved current sharing of an interleaved DC/DC converter, etc.

[0067] Current sharing/balancing in multiphase DC/DC converters is one application of the disclosed current sensor. Temperature sensing of the coil to remove copper temperature dependence is not needed, nor are trimmed reference resistors. Of course the disclosure is not limited to copper, but is applicable to other materials used to form circuit components.

[0068] While the foregoing has been described in conjunction with exemplary embodiment, it is understood that the term “exemplary” is merely meant as an example, rather than the best or optimal. Accordingly, the disclosure is intended to cover alternatives, modifications and equivalents, which may be included within the scope of the disclosure.

[0069] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This disclosure is intended to cover any adaptations or variations of the specific embodiments discussed herein.

Claims

What is claimed is:

1. A method for sensing an output current of a Direct Current-to-Direct Current (DC/DC) converter having an external power stage configured to supply a converted current to an external inductor, the method comprising:

during a calibration phase at a first start-up of the DC/DC converter:

injecting a calibration current through a switching node of the power stage and through the inductor; and

determining a calibration gain of the DC/DC converter to compensate for DC Resistance (DCR) variation by comparing a gain-adjusted voltage across the inductor with a reference voltage;

during a measurement phase:

reducing ripple voltage of a switching voltage at the switching node to generate a ripple-reduced switching voltage; and

sensing the output current based on a DCR-compensated voltage across the inductor, which is a difference between the ripple-reduced switching voltage and an output voltage of the DC/DC converter with compensation for the DCR variation based on the calibration gain.

2. The method of claim 1, further comprising:

measuring a calibration-phase temperature of the inductor during the calibration phase; and

storing the measured calibration-phase temperature in the memory.

3. The method of claim 2, further comprising:

correcting the DCR-compensated voltage across the inductor based on a measurement-phase temperature and the calibration-phase temperature.

4. The method of claim 1, wherein the reducing the ripple voltage from the switching voltage at the switching node comprises:

providing an opposing-phase switching voltage having a 180° phase difference from that of the switching voltage; and

combining the opposing-phase switching voltage with the switching voltage to generate a ripple-reduced switching voltage.

5. The method of claim 1, further comprising:

first-order low-pass filtering the switching voltage and the output voltage of the DC/DC converter.

6. The method of claim 1, further comprising:

second-order low-pass filtering the DCR-compensated voltage across the inductor.

7. The method of claim 1, further comprising:

outputting the sensed output current to a microprocessor.

8. A method for sensing an output current of a Direct Current-to-Direct Current (DC/DC) converter having an external power stage configured to supply a converted current to an external inductor, the method comprising:

reducing ripple voltage of a switching voltage at a switching node of the power stage to generate a ripple-reduced switching voltage; and

sensing the output current based on a difference between the ripple-reduced switching voltage and an output voltage of the DC/DC converter across the inductor compensated for DC Resistance (DCR) based on a calibration gain.

9. The method of claim 8, further comprising:

correcting the DCR-compensated voltage across the inductor based on a temperature of the inductor and a calibration temperature measured during a determination of the calibration gain.

10. A Direct Current to Direct Current (DC/DC) converter having an external power stage configured to supply a converted current to an external inductor, comprising:

a calibration circuit comprising:

a current injection circuit configured to inject a calibration current through a switching node of the power stage and through the inductor; and

a calibration gain determination circuit configured to determine a calibration gain of the DC/DC converter to compensate for DC Resistance (DCR) variation by comparing a gain-adjusted voltage across the inductor with a reference voltage;

a measurement circuit comprising:

a ripple cancellation circuit configured to reduce ripple voltage of a switching voltage at the switching node to generate a ripple-reduced switching voltage; and

an output current sensing circuit configured to sense the output current based on a DCR-compensated voltage across the inductor, which is a difference between the ripple-reduced switching voltage and an output voltage of the DC/DC converter with compensation for the DCR variation based on the calibration gain.

11. The DC/DC converter of claim 10, wherein the current injection circuit comprises:

a calibration switch configured to clamp the output voltage to ground during calibration gain determination; and

a current mirror configured to mirror a reference current, which is based on the reference voltage and a reference resistor.

12. The DC/DC converter of claim 10, wherein the calibration gain determination circuit comprises:

a differential amplifier;

a calibration controller configured to increment a first resistance value of first calibration resistor coupled between the switching node and a first input of the differential amplifier to generate a gain-adjusted switching voltage, and to increment a second resistance value of a second calibration resistor coupled between the output node and a second input of the differential amplifier to generate a gain-adjusted output voltage,

wherein the differential amplifier is configured to determine a difference between the gain-adjusted switching voltage and the gain-adjusted output voltage, and output the gain-adjusted voltage across the inductor; and

a comparator configured to compare the gain-adjusted voltage across the inductor with the reference voltage, and to signal the calibration controller to stop the incrementing the first and second resistance values when the gain-adjusted voltage across the inductor equals the reference voltage,

wherein the calibration controller is further configured to store in a memory the calibration gain, which is based on the first or second resistance value when the gain-adjusted voltage across the inductor equals the reference voltage.

13. The DC/DC converter of claim 10, wherein the output current sensing circuit comprises:

a differential amplifier configured to receive at a first input the output voltage of the DC/DC converter with compensation for DCR variation based on the calibration gain, to receive at a second input the ripple-reduced switching voltage with compensation for DCR variation based on the calibration gain, and to output the DCR-compensated voltage across the inductor.

14. The DC/DC converter of claim 10, further comprising:

a temperature sensor configured to measure a calibration temperature of the inductor during calibration gain determination,

wherein the memory is further configured to store the measured calibration temperature in the memory.

15. The DC/DC converter of claim 14, further comprising:

a temperature compensation controller configured to correct the DCR-compensated voltage across the inductor based on a sensing temperature of the inductor during output current sensing and the calibration temperature.

16. The DC/DC converter of claim 10, wherein the ripple cancellation circuit comprises:

an inverter circuit configured to invert the switching voltage to provide an opposing-phase switching voltage having a phase opposite that of the switching voltage; and

a node configured to combine the opposing-phase switching voltage with the switching voltage to generate a ripple-reduced switching voltage.

17. The DC/DC converter of claim 10, further comprising:

a passive first-order low-pass filter configured to first-order low-pass filter the switching voltage and the output voltage of the DC/DC converter.

18. The DC/DC converter of claim 10, further comprising:

an active second-order low-pass filter configured to second-order low-pass filter the DCR-compensated voltage across the inductor.

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