Control of secondary switches based on secondary winding voltage in a power converter

[0001] The present invention relates generally to power converters, and more specifically to controlling secondary switches.

[0002] Switch mode power supplies are used in a variety of household or industrial appliances that require a regulated direct current (dc) voltage for their operation. A controller for switch mode power supplies for controlling the power switch for the transfer of energy can use PWM (pulse width modulation) or PFM (pulse frequency modulation) to regulate the output voltage.

[0003] One type of power supply topology is a resonant switch mode power supply. Resonant switched mode power supplies with PFM control have some advantages, which include having sinusoidal waveforms and intrinsic soft switching compared to non-resonant converters. Resonant switch mode power supplies can also operate at higher frequencies with low switching loss, utilize smaller magnetic elements, which therefore require smaller packaging, and still operate with high efficiency. Since resonant switch mode power supplies generally do not have waveforms with sharp edges (e.g. waveforms having high di/dt or dv/dt). EMI performance is improved, which therefore enables the use of smaller EMI filters. The output of a resonant switch mode power supply is often achieved by sensing the output and controlling the power supply in a closed loop by varying the switching frequency.

[0004] LLC converters are a type of resonant switched mode power supply, which utilizes the resonance between two inductors and a capacitor. LLC converters are popular due to the savings on cost and size which can be realized by utilizing the magnetizing and leakage inductance of the transformer as at least a part of the resonance component of the LLC converter. In addition, LLC converters can achieve stability when they are operated at above resonance with zero voltage switching, which results in less switching loss and increased efficiency. Furthermore, LLC converters can achieve output regulation in a narrow band of frequency control because of their negative and high slope gain characteristic when operating above resonance.

[0013] Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding, of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present disclosure.

[0014] Examples of a control circuit to determine when to turn on a secondary switch in a power converter are described herein. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one having ordinary skill in the art that the specific detail need not be employed to practice the present invention. In other instances, well-known materials or methods have not been described in detail in order to avoid obscuring the present invention.

[0015] Reference throughout this specification to “one embodiment”, “an embodiment”, “one example” or “an example” means that a particular feature, structure or characteristic described in connection with the embodiment or example is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment”, “in an embodiment”, “one example” or “an example” in various places throughout this specification are not necessarily all referring to the same embodiment or example. Furthermore, the particular features, structures or characteristics may be combined in any suitable combinations and/or subcombinations in one or more embodiments or examples. Particular features, structures or characteristics may be included in an integrated circuit, an electronic circuit, a combinational logic circuit, or other suitable components that provide the described functionality. In addition, it is appreciated that the figures provided herewith are for explanation purposes to persons ordinarily skilled in the art and that the drawings are not necessarily drawn to scale.

[0016] Resonant power converters can provide higher efficiency due to soft-switching relative to hard switching power converters. When power is supplied to the output, the secondary side of a resonant converter includes diodes used for rectification. A constant voltage drop across the diode can be a source of power loss and reduced efficiency. To reduce the constant voltage drop and improve efficiency, the diode can be replaced by an active controlled switch such as a metal-oxide semiconductor field-effect transistor (MOSFET) or bipolar junction transistor (BJT). An actively controlled switch on the secondary side can be referred to as a secondary switch.

[0017] However, the challenge of controlling secondary switches is to determine the right time to turn it on. The time to turn on the actively controlled switch where it is most efficient when the secondary switch signal is at or close to zero. In one example, the secondary switch signal can be a drain voltage of the secondary switch. At higher loads, it is easier to distinguish when the secondary switch signal is at or close to zero. However, as the load becomes lighter, the secondary switch signal can include ringing due to parasitics. If the secondary switch signal crosses the turn on threshold of on the secondary switch, the secondary switch can turn on at the wrong time due to ringing caused by parasitics. In one embodiment, a control circuit can determine when to turn on the secondary switch based on the previous behavior of the secondary switch signal. For example, the control circuit can count the number of times a secondary switch signal crosses below a threshold, and saves the count to be used for the next half cycle.

[0018] To illustrate, FIG. 1 shows a functional block diagram of an example resonant power converter 100 illustrated as an LLC half bridge converter including a primary controller 124 and a secondary controller 125 in accordance with the teachings of the present disclosure. FIG. 1 includes a high side switch 105, a low side switch 106, an inductance L1 108, a magnetizing inductance 110, a resonant capacitor 112, an energy transfer element T1 114 secondary side switches 118, 119, an output capacitor 120, a load, 122, a sense circuit 128, resistances 136, 138, input return 150 and a secondary controller 125. In one example, the high side switch 105 and low side switch 106 can be referred to as power switches 104.

[0019] Energy transfer element T1 114 further includes a magnetizing inductance L_M 110, a primary winding 115, a first output winding 116, and a second output winding 117. The primary winding 115 may be referred to as an input winding, and the output windings 115,116 may be referred to as a secondary winding In some examples, the inductance of L1 108 may be an embedded property of the energy transfer element T1 114 such that the inductance L1 106 is not discrete physical component. The secondary controller 125 includes a switch request circuit 132, and a control circuit 134.

[0020] In operation, the resonant power converter 100 provides output power to the load 122 from an input voltage V_IN 102. In one example, the input voltage V_IN 102 is a rectified input voltage from an ac voltage source. The high side switch 105 is coupled to receive the input voltage V_IN 102 from a first end of the high side switch 105. The second end of high side switch 105 is coupled to a first end of the low side switch 106 by half bridge node 103. The second end of low side switch 106 is further coupled to the input return 113. The inductance L1 108 is coupled to one end of primary winding 115, and the resonant capacitor C_RES 112 is coupled to the other end of the primary winding and may function together as a tank circuit coupled to the high side switch 105 and low side switch 106 at the half bridge node 103. Energy transfer element T1 114 is coupled to the tank circuit such that energy is transferred from the primary winding 115 to the output windings 116 and 117 in response to the switching of the high side switch 105 and low side switch 106. First output winding 116 is coupled to a first secondary switch 118. The first secondary switch 118 includes a transistor used as a synchronous rectifier and is controlled by a secondary drive signal 140. Energy is transferred and rectified by secondary switch 118 when is closed and the high side switch 105 is turned ON and the low side switch 106 is OFF.

[0021] The second output winding 117 is coupled to a second secondary switch 119. The secondary switch 119 includes a transistor and a rectifier used as a synchronous rectifier which is controlled by a secondary drive signal 142. Energy is transferred and rectified by secondary switch 119 is closed and when the high side switch 105 is turned OF and the low side switch 106 is ON.

[0022] The output capacitor C_O 120 and load 122 are coupled to the first secondary switch 118 and the second secondary 119. An output is provided to the load 126 and may be provided as either an output voltage V_O 127, and output current I_O 129, or a combination of the two. For a resonant power converter, the output voltage is controlled by adjusting the switching frequency and not the duty cycle. The duty cycle of a LLC half bridge is ideally fifty percent for the second power switch and first power switch.

[0023] The resonant power converter 100 further includes circuitry to regulate the output, which is exemplified as output quantity U_O 130. in general, the output quantity U_O 130 is either an output voltage V_O127, an output current I_O 129, or a combination of the two. A sense circuit 128 is coupled to sense the output quantity U_O130 and to provide a feedback signal U_FB 131, which is representative of the output quantity U_O130. The feedback signal U_FB 131 may be a voltage signal or a current signal.

[0024] The switch request circuit 132 can receive the feedback signal U_FB 131 to determine when to request a transfer of energy from the primary side of the resonant power converter. In response to a feedback signal U_FB 131 that is below a threshold, the switch request circuit 132 generates a request signal U_REQ 149 that is communicated to a primary controller 124. In one example, there may be a galvanic isolation (not shown) between the secondary controller 125 and the primary controller 124. In one example, the request signal U_REQ 149 can be communicated through a communication link. In one example, the communication is a magnetically coupled communication link. In another example, the request signal U_REQ 149 can be communicated through an optically coupled communication link.

[0025] As mentioned previously, monitoring the voltage at the drain of secondary switch 118 can indicate when to turn ON and OFF the secondary switch 118. To measure the voltage at the drain of secondary switch 118, optionally a resistance 138 is coupled to one end of output winding 117. To measure the drain at the voltage of secondary switch 119, optionally a resistance 136 is coupled to one end of output winding 116. As will be explained in FIG. 2, the control circuit is coupled to receive a secondary switch voltage signal of the secondary switch. The secondary drive signal is generated in response to how many times the secondary switch voltage signal crosses below a turn on threshold to a limit set in a last half period. The control circuit turns ON the secondary switch by a secondary drive signal.

[0026] FIG. 2A illustrates one example of a control circuit of the secondary controller of FIG. 1. Thus, it is noted that control circuit 234 of FIG. 2 may be one example of control circuit 134 of FIG. 1, and that similarly named and numbered elements referenced below are coupled and function similar to as described above.

[0027] The control circuit 234 is coupled to receive the first secondary switch signal 236 and the second secondary switch signal 238, and generates the secondary drive signals 240 and 241. The control circuit 234 includes a winding polarity circuit 252, a first turn on detection circuit 254, a second turn on detection circuit 256, a drive circuit 258, high voltage transistors 260, 262 and comparators 264,265,266,267.

[0028] As will be discussed, the operation to turn on the first secondary switch and the second secondary switches are identical. In one example, the control circuit 234 receives the first secondary switch signal 236. The high voltage transistor 260 is coupled to receive the first secondary switch signal 236 at a drain terminal of the high voltage transistor 260. The gate terminal of the high voltage transistor 260 is coupled to a voltage reference V_DD 263. The high voltage transistor 260 is needed because the first secondary switch signal 236 could be at a voltage greater than supported by the secondary controller, and the secondary controller may not be compatible to sense it directly. In one example, the first secondary switch signal 236 could be at a voltage up to 150 volts. The high voltage transistor 260 provides a proportional voltage that is compatible for use within the secondary controller in the order of −1 volt to 5 volts. Comparator 264 is coupled to receive the secondary switch signal 236 at the inverting input, and an ON threshold TH_ON 270. Comparator 264 is coupled to generate the first turn on detection signal U_D1 272 when the first secondary switch voltage signal 236 crosses below the ON threshold TH_ON 270. A first turn on detection circuit 254 generates a first turn on signal U_ON1 274 when a count reaches the limit set in the last half period. Comparator 265 is coupled to receive the first secondary switch signal 236 at the non-inverting input, and an OFF threshold TH_OFF 271 at the inverting input. Comparator 265 generates a first turn off signal U_OFF1 275 when the first secondary switch voltage signal 236 is above the turn OFF threshold TH_OFF 271. The drive circuit 258 is coupled to receive the first turn on signal U_ON1 274, the first turn off signal U_OFF1 275 to control the first secondary switch 118 with a secondary drive signal 240.

[0029] To control the second secondary switch, the control circuit 234 receives the second secondary switch signal 238. The high voltage transistor 262 is coupled to receive second secondary switch signal 238 at a drain terminal of the high voltage transistor 262. The gate terminal of the high voltage transistor 262 is coupled to a voltage reference V_DD 263. The high voltage transistor 262 is needed because the second secondary switch signal 238 could be at a voltage greater than supported by the secondary controller and the secondary controller may not be compatible to sense it directly. In one example, the second secondary switch signal 238 could be at a voltage up to 150 volts, The high voltage transistor 262 provides a proportional voltage that is compatible for use within the secondary controller in the order of −1 volt to 5 volts. Comparator 266 is coupled to receive the second secondary switch signal 238 at the inverting input, and an ON threshold TH_ON 270 at the non-inverting input. Comparator 266 is coupled to generate the second turn on detection signal U_D2 273 when the second secondary switch voltage signal 238 crosses below the ON threshold TH_ON 270. A second turn on detection circuit 256 generates a second turn on signal U_ON2 276 when a count reaches the limit set in the last half period. Comparator 267 is coupled to receive the second secondary switch signal 238 at the non-inverting input, and an OFF threshold TH_OFF 271 at the inverting input. Comparator 265 generates a second turn off signal U_OFF2 276 when the second secondary switch voltage signal 238 is above the turn OFF threshold TH_OFF 271.

[0030] The winding polarity circuit 252 receives the secondary switch signals 236, 238 and generates a first clock winding signal U_W1 268 and a second clock winding signal U_W2 269. The first winding clock signal U_W1 268 represents when the secondary switch voltage signal 236 changes polarity. In one example, when the secondary switch 118 is closed, the secondary switch voltage signal 238 should be close to or at zero volts. The first winding clock signal U_W1 can be a logic low. Meanwhile, when the secondary switch 119 is open, the secondary switch voltage signal 238 should be at a value greater than zero. The second clock winding signal U_W2 269 should be logic high. Either the first winding signal U_W1 268 or second winding signal UW2 269 can be logic high at a time. Further details of the winding polarity circuit will be provided in FIG. 3.

[0031] FIG. 2B illustrates another example of a control circuit of the secondary controller of FIG. 1, in accordance with an embodiment of the present disclosure. In FIG.2A, separate comparators 264 and 265 determine when to turn on and off the first secondary switch, and separate comparators 266 and 267 determine when to turn off the second secondary switch. In FIG. 2B, to determine when to turn on and off the first secondary switch, a comparator 264 with hysteresis can be used to fulfill the same function. The comparator 264 with hysteresis is coupled to receive the first secondary switch signal 236 at the non-inverting input and at the inverting input is coupled to receive the turn on threshold TH_ON 270, with a hysteresis threshold of the turn off the threshold TH_OFF 271. To determine when to turn on and off the second secondary switch, a comparator 266 with hysteresis is used. The threshold for comparator 266 is the turn ON threshold TH_ON 270, and hysteresis threshold can be the OFF threshold TH_OFF 27.

[0032] In addition, FIG. 3 includes inverters 294 and 295. When the first turn on signal U_ON1 is a logic high, therefore the first turn off signal U_OFF1 is a logic low. In addition, if the first turn on signal U_ON1 is a logic low, therefore the first turn off signal U_OFF1 is a logic high. When the second turn on signal U_ON2 276 is a logic high, therefore the first turn off signal U_OFF2 277 is a logic low. When the second turn on signal U_ON2 276 is a logic low, therefore the second turn off signal U_OFF2 277 is a logic high.

[0033] FIG. 3 illustrates a winding polarity circuit as shown in FIG. 2, Thus, it is noted that winding polarity circuit 352 of FIG. 1 may be one example of winding polarity circuit 252 of FIG. 2, and that similarly named and numbered elements referenced below are coupled and function similar to as described above.

[0034] The winding polarity circuit 352 is coupled to receive the first secondary switch 236 voltage signal and generates a first winding clock signal U_W1 368 when the first secondary switch voltage signal 336 changes polarity. Furthermore, the winding polarity circuit 352 is coupled to receive the second secondary switch 238 and generates a second winding clock signal U_W2 369 when the second secondary switch voltage 338 changes polarity. The winding polarity circuit 352 includes inverters 345, 351 comparators 353, 355, latches 357, 359, 361, and delay circuits 391, 392. The comparator 353 is coupled to receive the first secondary switch signal 336 at the non-inverting input, and is coupled to a reference threshold at the inverting input. The comparator 355 is coupled to receive the second secondary switch signal 338 at the non-inverting input, and is coupled to a reference threshold at the inverting input.

[0035] In operation, the comparator 353 determines if the first secondary switch signal 236 and the reference threshold is greater than a threshold reference TH_REF 587, The output of comparator 353 is coupled to latches 357, 359 and captures the output of the comparator 353. In one example latches 357, 359, 356 are SR NOR latches. The output of latch 357 is coupled to an inverter 345. The output of the inverter 345 is coupled to latch 361, which generates the first winding clock signal U_W1 368. To generate the second winding lock signal U_W2 369, the comparator 355 determines if the second secondary switch signal 338 is greater than threshold reference TH_REF 587. The output of comparator 355 is coupled to latches 357, 359 and captures the output of the comparator 353. The output of latch 359 is coupled to an inverter 345. The output of the inverter 345 is coupled to latch 361, which generates the second winding clock signal U_W2 359.

[0036] FIG. 4 illustrates a turn on detection circuit and is representative of both the first turn on detection circuit and second turn on detection circuit as shown in FIG. 2 Thus, it is noted that the first turn on detection circuit 254 and second turn on detection circuit 256 of FIG. 2 may be one example of first turn on detection circuit of FIG. 4, and that similarly named and numbered elements referenced below are coupled and function similar to as described above. What will be described is with respect to the first turn on detection circuit, however the operation for the second turn on detection is substantially same.

[0037] The first turn on detection circuit 454 is coupled to receive the first turn on detection signal U_D1 472, a first winding clock signal U_W1 468 and generates a first turn on signal U_ON1 474. The first turn on detection circuit includes a shift register 478, counter circuit 479, flop flip 480, a persistence checker 481, a multiplexer 482, a first logic gate 483, and a second logic gate 484.

[0038] In operation, the shift register 478 is coupled to receive the first turn on detection signal U_D1 472 at the clock terminal, a supply voltage V_DD 463 is coupled to an input terminal, and a first winding clock signal U_W1 468 at the reset terminal, and generates a shift register output. The shift register can include N-bits, where N is representative of the number of output bits of the shift register. A counter circuit 479 is coupled to receive the first detection signal U_D1 472 at the clock terminal, the first winding clock signal U_W1 468 at the reset terminal and generates an output count signal U_COUNT 490. The count signal U_COUNT 490 can be an N-bit signal where N is representative of the number of bits. The counter circuit increments the count signal U_COUNT 490 in response to the first detection signal U_D1 472. The N flip flop 480 is coupled to store the count signal when the first winding signal U_W1 468 is a logic high. In one example, the number N represents the same number of bits for flip flop 480 and the counter circuit 479. The stored count signal is the limit that is used in the next half period in order to determine when to generate the first turn on signal U_ON1 474. In next half period, the shift register 478 and counter circuit 479 are reset by the first winding clock signal U_W1 468. As the first turn on detection signal U_D1472 toggles, the shift register 478 generates outputs denoted by Q_O, Q₁and Q_N, where N is representative of the number of outputs of the shift register. A first input of multiplexer is coupled to receive the first turn on detection signal U_D1 472. Furthermore, multiplexer 482 is coupled to receive a plurality of outputs of the shift register. The stored count signal Q_N 491 selects the output of the multiplexer 482. The first logic gate 483 is coupled to receive the shift register output and the first turn on detection signal U_D1 472. The output of logic gate 483 is asserted when the first detection signal U_D 472 is logic high, and the output of the multiplexer 482 is logic high. The OR logic gate 484 is coupled to receive the output of the logic gate 483, which generates a first turn on signal U_ON1 474.

[0039] In another example, the count signal U_COUNT 490 may change from one half cycle to the next due to changing load conditions. As such, the output of logic gate 484 would not be logic high because there may not be an instance in which both the first turn on detection signal U_D1 472 and the output of the multiplexer 482 is logic high. To circumvent this potential issue, the first turn on detection circuit 454 further includes a persistence checker 381 that is coupled to receive the first turn on detection signal U_D1 472, and generates a persistence signal U_PER 493 after an expiration of an adaptive maximum deadtime or an adaptive blanking time. The adaptive maximum deadtime can be measured from the period of ringing of one turn on threshold to the next turn off threshold. In one example, the adaptive maximum deadtime can be 1 microsecond. In another example, the adaptive maximum deadtime can adapt to the ringing frequency during turn-on of the secondary switch. In other words, if the ringing period is shorter than 1 microsecond, the adaptive deadtime can reduce the deadtime to the ringing frequency.

[0040] FIG. 5 illustrates a timing diagram illustrating the operation of the secondary controller to determine when to turn on the secondary switch. FIG. 5 includes a first secondary drive signal G1 540, a second secondary drive signal G2 542, a secondary switch signal 536 representative of the drain voltage of the first secondary switch, a secondary switch signal 538 representative of the drain voltage of the second secondary switch.

[0041] As mentioned previously, as the load of the resonant power converter becomes lighter, the ringing of the secondary switch signal 536 is more pronounced as illustrated inside boxes 588 and 589. As shown in the third timing diagram, the first turn on detection circuit determines how many times the secondary switch signal 536 crosses below the turn on threshold even in the presence of ringing. In this example, the count signal U_COUNT is 6, which is representative of the number of times the secondary switch signal 536 must cross below the turn ON threshold before a first secondary drive signal G1 540 is asserted. A close-up of the waveform in box 588 is shown in the fourth timing diagram.

[0042] As shown in the fourth timing diagram, the second turn on detection circuit determines how many times the second secondary switch signal 538 crosses below the turn on threshold in the presence of ringing. In this example, the count signal U_COUNT is 6, which is representative of the number of times the second secondary switch signal 536 must cross below the turn ON threshold TH_ON before a second secondary drive signal G2 542 is asserted. A close-up of the waveform in box 589 is shown in the fourth timing diagram.

[0043] FIG. 6 illustrates a timing diagram illustrating the operation of the secondary controller to determine when to turn on the secondary switch when the count changes from one half cycle to the next. FIG. 6 includes a first secondary drive signal G1 540, a second secondary drive signal G2 542, a secondary switch signal 536 representative of the drain voltage of the first secondary switch, a secondary switch signal 538 representative of the drain voltage of the second secondary switch.

[0044] As mentioned previously, as the load of the resonant power converter becomes changes, the ringing in the first secondary switch signal 536 and the second secondary switch signal 538 caused by parasitics can vary. In one example, at full load, parasitics are negligible as such the ringing is minimal in comparison to a light load condition. In FIG. 6, as shown in the fourth timing diagram of the second secondary switch signal 538, the second turn on detection circuit determines how many times the secondary switch signal crosses below the turn ON threshold TH_ON. In this example for a first half period, the count signal U_COUNT is 6, while in the second half period, the count signal U_COUNT is 4. A close-up of the waveforms in boxes 588 and 589 are shown in the bottom timing diagram. When the second secondary switch signal crosses 538 below a turn ON threshold TH_ON after a count set in the last half period, the second secondary drive signal 540 transitions to logic high to turn on the secondary switch. The count signal U_COUNT of 6 is stored for the next half cycle of the second secondary switch signal 538. At next half cycle, the second turn on detection circuit expects to see a count signal U_COUNT value of 6 before a second secondary drive signal 540 is generated A close-up of the waveform in box 489 is shown in the bottom timing diagram. However, the secondary switch signal 538 only crosses below the turn on threshold TH_ON four times. The persistence checker of the secondary turn on detection circuit would generate a persistence signal U_PER 539, and the second secondary drive signal 540 can be generated. Although only the half cycles of the second secondary switch signal 538 are shown, the same operation can apply to the first secondary switch signal 536.

[0045] The above description of illustrated examples of the present invention, including what is described in the Abstract, are not intended to be exhaustive or to be limitation to the precise forms disclosed. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible without departing from the broader spirit and scope of the present invention. Indeed, it is appreciated that the specific example voltages, currents, frequencies, power range values, times, etc., are provided for explanation purposes and that other values may also be employed in other embodiments and examples in accordance with the teachings of the present invention.