Switched capacitor array based power supply without large electrolytic capacitor

Abstract

This invention discloses a capacitor-free voltage regulator based on a switched capacitor array, belonging to the fields of power electronics, power supply, and isolated power supply technology. The device includes an input conditioning unit, a switched capacitor array, a sampling unit, and a control unit, with no large-capacity electrolytic capacitors in the power path. It is compatible with both AC mains and external DC inputs, supporting DC voltage regulation, AC charge transfer, and filtering modes. This invention can be layered to include electrical isolation, active PFC, and system-wide timing linkage functions, corresponding to three product forms: a non-isolated basic version, an isolated general version, and a system-bound version. This invention eliminates the need for large-capacity electrolytic capacitors, offering advantages such as long lifespan, low ripple, fast dynamic response, and compact size. It can be widely applied in various scenarios including industrial equipment, consumer electronics, audio equipment, electric vehicle power systems, and industrial power controllers.

Description

Technical Field

[0001] This invention relates to the fields of power electronics, DC power supplies, AC signal filtering, isolated power supply, and power equipment power supply technology. Specifically, it relates to a capacitor-based voltage regulator without large-capacity electrolytic capacitors, particularly suitable for audio amplifiers, precision instruments, industrial control equipment, and new energy equipment with high requirements for power supply ripple, dynamic response, and lifespan. It can also be expanded into a version with electrical isolation to meet the safety requirements of consumer electronics. Furthermore, it can be integrated with audio processing, power amplification, electric vehicle power control, and industrial power controllers for collaborative operation. This invention is compatible with single-phase 220V residential mains power, three-phase 380V industrial power supply, and various external DC power inputs, adapting to the power supply needs of various scenarios such as consumer audio equipment, industrial control equipment, and new energy power systems. Background Technology

[0002] Traditional DC regulated power supplies typically employ an architecture of "power frequency transformer + rectifier bridge + large-capacity electrolytic capacitor filtering + linear / switching regulator". The large-capacity electrolytic capacitor (commonly known as a "large pond") performs energy storage and filtering functions, but it has the following inherent drawbacks: Electrolytic capacitors are filled with liquid electrolyte, which gradually dries up and evaporates as the operating time increases, resulting in capacitance decay and increased equivalent series resistance. They are the shortest-lived components in a power supply system. Electrolytic capacitors are large in size and weight, which limits the miniaturization of power supplies and the improvement of power density. Large-capacity electrolytic capacitors have limited charging and discharging speeds and poor dynamic response to load transients. Conventional solutions require the addition of a filter inductor, which further increases size and power loss.

[0003] Existing conventional switched-capacitor circuits mostly employ fixed timing control, enabling only simple charge transfer or basic filtering. They cannot dynamically regulate voltage based on input and load changes, thus limiting their application scenarios. Furthermore, civilian electronic devices are subject to mandatory national safety standards requiring electrical isolation between the power input and output sides. Industrial equipment and internal testing scenarios, however, do not have such mandatory isolation requirements. Integrated systems such as audio equipment, electric vehicle powertrains, and high-power industrial control equipment also require timing synchronization between the power supply and back-end functional circuits. Existing single-architecture power supplies struggle to adapt to multiple scenarios simultaneously.

[0004] Therefore, there is an urgent need for a power supply solution without large-capacity electrolytic capacitors that can be layered and expanded, accommodates both isolated and non-isolated configurations, is compatible with AC / DC input, and can be connected to various types of integrated systems. Summary of the Invention

[0005] Technical problems to be solved This invention provides a capacitor-free voltage regulator based on a switched capacitor array, aiming to solve the problems of short lifespan, large size, and poor dynamic response caused by the reliance on large-capacity electrolytic capacitors in existing power supplies. It also addresses the shortcomings of traditional switched capacitor circuits, such as limited control methods and inability to dynamically regulate voltage. Furthermore, it enables layered expansion to non-isolated basic, isolated general-purpose, and integrated versions, adapting to various application scenarios including industrial equipment, civilian safety equipment, audio equipment, electric vehicle power systems, and industrial power control equipment. Technical solution

[0006] A capacitor-free voltage regulator based on a switched capacitor array includes an input conditioning unit, a switched capacitor array, a sampling unit, and a control unit. The input conditioning unit conditions the external input power and outputs power adapted to the switching capacitor array's operating conditions. The external input power can be AC ​​mains or an external DC power supply. When applied to a three-phase four-wire 380V industrial power supply scenario, the input conditioning unit can be configured as a three-phase rectifier structure, or one phase can be used as a single-phase input to adapt to the power supply needs of different industrial equipment. The switched capacitor array is connected to the output of the input conditioning unit to store charge and generate output power. The sampling unit detects electrical parameters on the input and / or output sides. The control unit dynamically adjusts the equivalent voltage division ratio of the switched capacitor array based on the output of the sampling unit to stabilize the output voltage near a set value. No large-capacity electrolytic capacitors are used in the power path from the output of the input conditioning unit to the output of the device.

[0007] Patent Scope and Engineering Implementation Rules The claims and embodiments of this invention cover both non-isolated and electrically isolated topologies, falling within the scope of statutory patent protection. In engineering implementation and market application, the following rules apply: For consumer electronic devices, a topology with isolation units must be used to meet national mandatory electrical safety standards; For industrial control equipment, laboratory internal testing, and closed system scenarios, a non-isolated basic topology can be adopted; Switched capacitor arrays can directly perform charge transfer and waveform filtering operations on AC mains power. This mode is mainly used in industrial filtering and internal signal processing scenarios.

[0008] Definition of Commonly Known Components The EMI filter circuit, conventional rectifier circuit, high-frequency isolation transformer, secondary rectifier circuit, and active PFC unit are well-known supporting components in the field of power electronics. They are necessary peripheral circuits for realizing this invention, but not the core innovation of this invention. The core innovation of this invention lies in: using a switched capacitor array to achieve an integrated design of energy storage, filtering, and voltage regulation, eliminating the large-capacity electrolytic capacitor in the power path, and combining phase-locked loop super-linear decision rules to achieve dynamic timing and voltage divider control. At the same time, it can be layered to expand isolation, power factor correction, and whole-machine timing linkage functions.

[0009] Technical Defects of Adding / Replacing Large-Capacity Electrolytic Capacitors Adding a large-capacity electrolytic capacitor to the power path of this invention, or replacing the capacitor units inside the switched capacitor array with large-capacity electrolytic capacitors, would create several technical contradictions and prevent the realization of the core functions and technical effects of this invention. The equivalent series resistance (ESR) of large-capacity electrolytic capacitors is much higher than that of film capacitors and chip ceramic capacitors. The dynamic response speed drops from the microsecond level to the millisecond level, making it impossible to complete precise timing control and dynamic voltage division adjustment with the phase-locked super-linear decision rule. Conventional large-capacity aluminum electrolytic capacitors typically have a lifespan of only 2,000 to 8,000 hours under industry standard rated operating conditions, which will once again become a bottleneck in system lifespan and violate the long lifespan design goal of this invention. Large-capacity electrolytic capacitors are bulky, which would negate the advantages of miniaturization and high power density of this invention. If the switched capacitor array is completely replaced with a large-capacity electrolytic capacitor, the circuit will degenerate into a traditional electrolytic capacitor filtering and voltage regulation architecture, and will no longer possess the core characteristics of dynamic voltage regulation and high-speed response of this invention, thus losing the technical value of the invention itself.

[0010] Preferably, the input conditioning unit adopts a rectifier bridge structure, which can convert AC mains power into pulsating DC power. Further, the switched capacitor array consists of multiple capacitor units and a switching network. The control unit outputs a timing signal to control the switching network to change the series-parallel combination relationship of the multiple capacitor units, thereby achieving dynamic adjustment of the equivalent voltage division ratio. Further, the electrical parameters collected by the sampling unit can be normalized before being sent to the control unit to eliminate the influence of signal amplitude differences and noise interference on the decision accuracy; the timing signal output by the control unit can be synchronously calibrated to compensate for the transmission delay differences of different switches in the switching network, ensuring that each capacitor unit completes charge transfer at precise times. Further, the control unit can be configured to implement the phase-locked loop superlinear decision rule disclosed in the original application (application number: 2026105148169). This decision rule acquires the real-time phase signal of the target physical quantity and the reference phase, determines the effective phase window boundary based on the preset decision threshold, the peak value of the physical quantity and the phase delay coefficient, and outputs a precise control command when the real-time phase falls into the effective phase window, thereby realizing precise timing control of the switched capacitor array.

[0011] It should be noted that the auxiliary power supply for low-voltage logic circuits such as the control unit and sampling unit can be implemented using commercially available standardized isolated AC-DC modules. These modules are standard purchased components and are not included in the original topology of this invention, nor do they fall within the scope of power frequency transformers, large-capacity electrolytic capacitors, and high-frequency power inductors excluded in the claims. The specific implementation of the auxiliary power supply should not limit the scope of protection of the core architecture of this invention.

[0012] Furthermore, the basic configuration of this device does not include a power frequency transformer, large-capacity electrolytic capacitors, or high-frequency power inductors. The switched capacitor array combines energy storage, filtering, and voltage regulation functions, completely replacing the large-capacity electrolytic capacitor filtering and energy storage units in traditional power supplies.

[0013] As a preferred expansion option, this device can also be equipped with an isolation unit to achieve electrical isolation between the input and output sides. The isolation unit preferably uses a high-frequency isolation transformer to meet the enhanced insulation withstand voltage requirements of civilian equipment. As a further preferred option, an active PFC unit can be connected in series between the input conditioning unit and the isolation unit to correct the input power factor, meeting the energy efficiency standards for civilian equipment. For integrated system applications, the device is equipped with a timing synchronization interface, enabling timing linkage with the backend audio processing unit, power amplification unit, electric vehicle power control unit, and industrial power output controller, achieving coordinated operation of the entire unit. Beneficial effects

[0014] Long lifespan: The large-capacity electrolytic capacitors, which are a bottleneck for the lifespan of traditional power supplies, are eliminated. The core components are selected as long-life film capacitors and semiconductor devices. According to the MIL-HDBK-217F standard, the mean time between failures (MTBF) of the system under the preferred implementation method can reach more than 100,000 hours. The MTBF mentioned here is the system-level mean time between failures indicator and is not equivalent to the lifespan of a single component.

[0015] Full-scenario compatibility: Supports dual input of AC mains power and external DC power, and can work in DC voltage regulation and AC charge transfer / filtering modes; the basic form is a non-isolated architecture, and the extended form can add isolation and PFC circuits, adapting to various scenarios such as industrial equipment, consumer electronics, audio equipment, electric vehicle power systems, and industrial power control equipment.

[0016] Flexible layered protection: The basic version has a simple structure and low cost, making it suitable for closed industrial scenarios; the isolation version meets safety and energy efficiency requirements and can be used in the civilian market; the time-linked version is deeply compatible with various integrated systems.

[0017] Low ripple: Through precise timing control, the output voltage ripple can be as low as 5mVpp in the preferred implementation, resulting in excellent power supply quality.

[0018] High dynamic response: The switched capacitor array has a fast charge transfer speed, and the response time to load change can reach the microsecond level under typical operating conditions, making it suitable for dynamic load scenarios.

[0019] Compact size: The basic form factor eliminates the need for power frequency transformers, large-capacity electrolytic capacitors, and high-frequency power inductors, resulting in a significant reduction in overall size and weight, and higher power density. Attached Figure Description

[0020] Figure 1 is a block diagram of the overall basic architecture of the present invention; Figure 2 is a schematic diagram of dynamic adjustment of the equivalent voltage division ratio of the switched capacitor array; Figure 3 is a block diagram of the extended architecture with isolation and PFC of the present invention; Figure 4 is a block diagram of the whole machine adaptation architecture with isolation, PFC and timing linkage of the present invention. Detailed Implementation

[0021] Case Separation Statement This application is a divisional application of the original application (application number: 2026105148169, application date: April 17, 2026), the invention title of which is "Phase-locked superlinear control method and apparatus based on phase window decision".

[0022] Example 1: Non-isolated AC input DC output (basic power supply, for internal equipment / industrial power amplifier) This embodiment represents the basic device configuration without isolation units. Mains power is converted into pulsating DC power via EMI filtering and a rectifier bridge, and then fed into the switched capacitor array. A sampling unit collects input and output electrical parameters in real time and performs normalization preprocessing on the sampled data to eliminate interference. The control unit dynamically adjusts the series and parallel connections of the capacitor units according to the phase-locked loop super-linear decision rule, changing the equivalent voltage division ratio to stabilize the output voltage. This embodiment does not use large-capacity electrolytic capacitors in the power path; the switched capacitor array integrates energy storage, filtering, and voltage regulation functions. Under optimal operating conditions, the output ripple can be controlled within 5mVpp, and the dynamic response time does not exceed 10μs, making it suitable for non-civilian enclosed scenarios such as internal power supply for equipment and industrial power amplifiers.

[0023] Example 2: Non-isolated external DC input (precision instrument power supply) It can be directly connected to a standard DC power supply. The input conditioning unit only performs voltage adaptation and simple filtering, eliminating the need for a rectification stage. Dynamic voltage regulation via a switched capacitor array provides multiple stable DC output voltage levels. The design eliminates the need for large-capacity electrolytic capacitors, resulting in long lifespan and high reliability, making it suitable for precision instruments and industrial control equipment operating continuously for extended periods.

[0024] Example 3: Non-isolated AC direct-feed mode (mains filtering / charge transport) This embodiment does not include a rectifier bridge; the input conditioning unit only performs EMI and impedance matching, and the AC mains power is directly connected to the switched capacitor array. The switched capacitor array completes AC charge transfer and waveform filtering according to phase-locked loop superlinear timing, achieving mains power purification. This configuration is mainly used in industrial power grid filtering and internal AC signal processing scenarios.

[0025] Example 4: Non-isolated power supply for industrial control The device adopts a wide voltage AC input, has no isolation unit, can withstand harsh working conditions, and can operate stably for a long time in high temperature environments, meeting the DC power supply requirements of industrial control equipment.

[0026] Example 5: Isolation + Active PFC (General Purpose Isolated Switched Capacitor Power Supply) The basic architecture includes an active PFC unit, a high-frequency isolation transformer, and a matching secondary-side rectifier circuit. The high-frequency isolation transformer provides enhanced insulation isolation between input and output, meeting the safety requirements for civilian equipment. The active PFC unit improves the power factor to above 0.98, complying with energy efficiency standards for civilian equipment. This embodiment is fully compatible with independent audio devices such as civilian audio amplifiers, decoders, and preamplifiers, representing a standard form of civilian general-purpose isolated power supply.

[0027] Example 6: Power Supply with Isolation + PFC + Timing Linkage (Whole Machine Bonded Switched Capacitor Power Supply) Based on the architecture of Example 5, a timing synchronization interface is added. The device can achieve timing synchronization and collaborative operation with the back-end audio processing unit, power amplification unit, electric vehicle power control unit, and industrial power output controller. The circuit parameters can be deeply calibrated according to the requirements of the integrated system. This version is generally not sold separately, but is specifically adapted to various high-end integrated systems such as audio signal processing + power amplification integrated units, electric vehicle powertrains, and industrial power control equipment.

[0028] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For those skilled in the art, any improvements, modifications, and equivalent substitutions to the technical features of this invention without departing from the principles of this invention fall within the protection scope of this invention.

Claims

1. A large-capacitance electrolytic capacitor-free voltage regulator power supply device based on a switched capacitor array, characterized by, include: The input conditioning unit is used to condition the external input power and output working power adapted to the switched capacitor array. A switched capacitor array is connected to the output terminal of the input conditioning unit to store charge and generate output electrical energy; A sampling unit is used to detect the electrical parameters of the input-side electrical energy and / or the output-side electrical energy; a control unit dynamically adjusts the equivalent voltage division ratio of the switched capacitor array according to the output of the sampling unit to stabilize the output voltage near a set value; wherein, no large-capacity electrolytic capacitors are provided on the power path from the output terminal of the input conditioning unit to the output terminal of the device; each functional unit can be implemented using discrete devices, integrated and merged, replaced by equivalent circuits, or expanded by hierarchical nesting, all without departing from the protection scope of this invention.

2. The apparatus of claim 1, wherein, The external input power includes AC mains power or external DC power supply; the input conditioning unit includes a rectifier bridge for converting AC mains power into pulsating DC power; when the device operates in AC direct-draw mode, the switched capacitor array directly performs charge transfer and waveform filtering on the AC mains power.

3. The apparatus of claim 1, wherein, The switched capacitor array consists of multiple capacitor units and a switching network. The switching network is controlled by a timing signal output by the control unit to change the series-parallel combination relationship of the multiple capacitor units, thereby realizing the dynamic adjustment of the equivalent voltage division ratio. The switched capacitor array has three functions: energy storage, filtering, and voltage regulation, replacing the large-capacity electrolytic capacitor filtering and energy storage unit in traditional power supplies.

4. The apparatus of claim 1, wherein, The control unit is configured to implement the phase-locked superlinear decision rule disclosed in the original application (application number: 2026105148169).

5. The apparatus of claim 1, wherein, The device does not include a power frequency transformer, a large-capacity electrolytic capacitor, or a high-frequency power inductor.

6. The apparatus of claim 1, wherein, It also includes an isolation unit, which is located between the input conditioning unit and the switched capacitor array to achieve electrical isolation between the input side and the output side; the isolation unit is a high-frequency isolation transformer, and the primary and secondary sides meet the requirements for enhanced insulation withstand voltage.

7. The apparatus of claim 6, wherein, It also includes an active PFC unit, which is connected in series between the input conditioning unit and the isolation unit to correct the input power factor.

8. The apparatus of claim 6, wherein, The device also includes a timing synchronization interface for timing linkage with the back-end audio processing unit, power amplification unit, and power control unit to achieve coordinated operation of the whole machine.

9. The device of any one of claims 1 to 8, wherein, The device is applied to DC power supply, AC signal filtering and charge transport, and overall timing linkage scenarios in audio power amplifiers, precision instruments, industrial control, new energy equipment, electric vehicle power systems, and industrial power controllers; the device with isolation unit is further applicable to consumer electronic devices.

10. A method for regulating power supply without large-capacity electrolytic capacitors based on a switched capacitor array, characterized in that, The device according to any one of claims 1 to 9 comprises the following steps: 1) conditioning external input electrical energy through an input conditioning unit; 2) a sampling unit acquiring electrical parameters on the input side and / or output side in real time and transmitting them to a control unit; 3) the control unit dynamically adjusting the equivalent voltage division ratio of the switched capacitor array according to the sampling results and the phase-locked loop superlinear decision rule to stabilize the output voltage; 4) the switched capacitor array completing charge storage and transfer within the effective time interval to achieve electrical energy output.

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