Wide voltage seamless handoff switching regulator circuit

Abstract

The utility model discloses a wide voltage seamless connection switching voltage stabilizing circuit relates to integrated circuit technical field, including voltage input comparison module, is used for dividing input voltage range into multiple intervals and carries out voltage comparison, voltage selection module is used for selecting corresponding voltage interval pass according to the result of voltage comparison, boost and buck module is used for carrying out boost or buck processing to input voltage based on selected voltage interval pass, to output stable voltage, ideal diode module is used for guaranteeing seamless switching between different voltage interval pass, and only one output pass is ensured at the same time. The utility model can divide 2.5V~60V wide voltage range into multiple intervals through voltage input comparison module, and combines the synergetic work of voltage selection module, boost and buck module and ideal diode module, realizes seamless switching and voltage stabilizing output in the industrial control system of aluminum electrolysis etc. greater work voltage fluctuation.

Description

Technical Field

[0001] This utility model relates to the field of integrated circuit technology, and more specifically, to a wide voltage seamless switching voltage regulator circuit. Background Technology

[0002] In modern large-scale industrial control systems, accurate measurement of various parameters of industrial equipment is required to achieve precise control strategies and schemes. These measurement processes mainly rely on the application of various sensors. However, because sensors on the market come from different manufacturers, their design standards and power supply requirements vary. Furthermore, the operating voltage ranges of different industrial process control systems differ significantly; for example, zinc electrolysis operates at 2.8V–3.6V, while aluminum electrolysis operates at 3.6V–60V or even higher. This makes voltage compatibility a key challenge for sensor applications in industrial settings.

[0003] Currently, most sensors on the market operate within specific voltage ranges, such as 2.0V to 15V, 3V to 20V, 5V to 30V, or 15V to 60V. These sensors typically use linear regulators or simple buck circuits for power supply. While these voltage regulation solutions work well within their specific voltage ranges, they often require multiple independent circuit modules connected in series or external power adapters when faced with wide voltage input requirements. This not only increases system complexity and size but also makes the voltage conversion process prone to fluctuations and delays.

[0004] However, existing voltage regulation solutions are ill-suited for the continuous measurement requirements of industrial control systems operating at voltages ranging from 3.6V to 60V, such as those used in aluminum electrolysis, and other systems with wide voltage variations. Especially in environments with drastic voltage fluctuations, traditional voltage regulator circuits are prone to overheating, inefficiency, and unstable switching, failing to achieve seamless connection and smooth transition across a wide voltage input range. This severely impacts sensor stability and measurement accuracy, hindering the reliable operation of industrial automation systems. Therefore, developing a voltage regulator circuit capable of seamless switching across a wide voltage range is crucial for improving the adaptability and reliability of industrial control systems.

[0005] No effective solutions have yet been proposed to address the problems in the relevant technologies. Utility Model Content

[0006] In view of the problems in the related technologies, this utility model proposes a wide voltage seamless switching voltage regulator circuit to overcome the above-mentioned technical problems existing in the existing related technologies.

[0007] Therefore, the specific technical solution adopted by this utility model is as follows:

[0008] Wide voltage seamless switching regulator circuit, including:

[0009] The voltage input comparison module is used to divide the input voltage range into multiple intervals and perform voltage comparisons.

[0010] The voltage selection module is used to select the appropriate voltage range path based on the voltage comparison result.

[0011] A buck-boost module is used to boost or buck the input voltage based on a selected voltage range path to output a stable voltage.

[0012] An ideal diode module is used to ensure seamless switching between different voltage range paths and to ensure that there is only one output path at any given time.

[0013] The voltage input comparison module is connected to the buck-boost module via the voltage selection module, and the buck-boost module is connected to the ideal diode module.

[0014] Furthermore, the voltage input comparison module includes chip U2. The fourth pin of chip U2 is grounded, the third pin of chip U2 is grounded through resistor R8, and the third pin of chip U2 is connected in series with the total input voltage through resistors R52, R7, and R6 in sequence. The second pin of chip U2 is connected to the total input voltage through resistor R6, and the first pin of chip U2 is connected to the total input voltage. The fifth pin of chip U2 is connected to the first shutdown path, the sixth pin of chip U2 is connected to the first fault path, the seventh pin of chip U2 is grounded through capacitor C5, and the seventh pin of chip U2 is connected to the first output terminal. The eighth pin of chip U2 is connected to the gate of the first switching transistor U1.

[0015] Furthermore, the voltage input comparison module also includes chip U6. The fourth pin of chip U6 is grounded, the third pin of chip U6 is connected to ground in series with resistors R17 and R54, and the third pin of chip U6 is connected in series with the total input voltage through resistors R16 and R15. The second pin of chip U6 is connected to the total input voltage through resistor R15, and the first pin of chip U6 is directly connected to the total input voltage. The fifth pin of chip U6 is connected to the second shutdown path, the sixth pin of chip U6 is connected to the second fault path, the seventh pin of chip U6 is grounded through capacitor C13, and the seventh pin of chip U6 is connected to the second output terminal. The eighth pin of chip U6 is connected to the gate of the second switching transistor U5.

[0016] Furthermore, the voltage input comparison module also includes chip U10. The fourth pin of chip U10 is grounded, the third pin of chip U10 is grounded through resistor R28, and the third pin of chip U10 is connected in series with the total input voltage through resistors R56, R27, and R25 in sequence. The second pin of chip U10 is connected to the total input voltage through resistor R25, and the first pin of chip U10 is directly connected to the total input voltage. The fifth pin of chip U10 is connected to the third shutdown path, the sixth pin of chip U10 is connected to the third fault path, the seventh pin of chip U10 is grounded through capacitor C23, and the seventh pin of chip U10 is connected to the third output terminal. The eighth pin of chip U10 is connected to the gate of the third switching transistor U9. The voltage of the first output terminal is less than the voltage of the second output terminal, and the voltage of the second output terminal is less than the voltage of the third output terminal.

[0017] Furthermore, the buck-boost module includes chip U4. The fifth and fourth pins of chip U4 are both grounded. The third pin of chip U4 is grounded through resistor R10 and connected to the first regulated output terminal through resistor R9. The second pin of chip U4 is grounded through capacitor C7. The first pin of chip U4 is connected to the first output terminal through parallel capacitors C1 and C2. The seventh pin of chip U4 is connected to the first regulated voltage output terminal. The eighth pin of chip U4 is connected to the tenth pin through capacitor C4 and inductor L1. The ninth pin of chip U4 is used for mode selection. The tenth pin of chip U4 is connected to the preamp input through parallel capacitors C1 and C2.

[0018] Furthermore, the buck-boost module also includes chip U7. The fourth pin of chip U7 is connected to the fifth pin through capacitor C16. The third pin of chip U7 is connected to the input of the preamplifier through capacitors C14 and C15 in parallel. The fifth pin of chip U7 is connected to the third regulated output terminal through inductor L2. The sixth and seventh pins of chip U7 are connected. The eighth pin of chip U7 is grounded.

[0019] Furthermore, the buck-boost module also includes chip U12. Pin 16 of chip U12 is connected to the second regulated output terminal via resistor R50; pin 13 of chip U12 is grounded via capacitor C51; pin 12 of chip U12 is connected to the preamp input via resistors R57 and R40; pin 9 of chip U12 is grounded via resistor R59; pin 8 of chip U12 is grounded via capacitor C44; pin 4 of chip U12 is grounded via capacitor C46; pin 17 of chip U12 is connected to the preamp input via resistor R51; and pin 19 of chip U12 is connected to the upper bridge switch Q1 and the lower bridge switch Q2. Pin 21 of chip U12 and capacitor C49 are connected in series to the upper bridge switch Q1 and the lower bridge switch Q2. Pin 22 of chip U12 is connected to the lower bridge switch Q2. Pin 24 of chip U12 and capacitor C48 are connected in series to the ground along with pin 23. Pin 25 of chip U12 is connected to the fifth switch U14. Pin 26 of chip U12 and capacitor C45 are connected in series to the fourth switch U13. Pin 27 of chip U12 is connected to the fourth switch U13. Pin 29 of chip U12 is connected to the fourth switch U13. Pin 33 of chip U12 is grounded.

[0020] Furthermore, the ideal diode module includes chip U3. The eighth pin of chip U3 is connected to the tenth pin through resistor R12. The seventh pin of chip U3 is connected to the first fault path. The sixth pin of chip U3 is connected to the eleventh pin through resistors R53 and R13. The fifth pin of chip U3 is connected to the pre-amplifier input through resistor R4. The first, second, and third pins of chip U3 are all connected to the pre-amplifier input. The ninth pin of chip U3 is grounded. The twelfth pin of chip U3 is connected to the pre-amplifier input in sequence through capacitor C12, resistor R11, and resistor R4. The fifteenth and sixteenth pins of chip U3 are both connected to the output terminal.

[0021] Furthermore, the ideal diode module also includes chip U11. The eighth pin of chip U11 is connected to the tenth pin through resistor R41. The seventh pin of chip U11 is connected to the second fault path. The sixth pin of chip U11 is connected to the eleventh pin through resistors R58 and R42. The fifth pin of chip U11 is connected to the pre-amplifier input through resistor R34. The first, second, and third pins of chip U11 are all connected to the pre-amplifier input. The ninth pin of chip U11 is grounded. The twelfth pin of chip U11 is connected to the pre-amplifier input in sequence through capacitor C47, resistor R38, and resistor R34. The fifteenth and sixteenth pins of chip U11 are both connected to the output terminal.

[0022] Furthermore, the ideal diode module also includes chip U8. The eighth pin of chip U8 is connected to the tenth pin through resistor R23. The seventh pin of chip U8 is connected to the third fault path. The sixth pin of chip U8 is connected to the eleventh pin through resistors R55 and R24. The fifth pin of chip U8 is connected to the pre-amplifier input through resistor R21. The first, second, and third pins of chip U8 are all connected to the pre-amplifier input. The ninth pin of chip U8 is grounded. The twelfth pin of chip U8 is connected to the pre-amplifier input in sequence through capacitor C22, resistor R22, and resistor R21. The fifteenth and sixteenth pins of chip U8 are both connected to the output terminal.

[0023] The beneficial effects of this utility model are as follows:

[0024] 1. This utility model can divide a wide voltage range of 2.5V to 60V into multiple intervals through a voltage input comparison module. Combined with the collaborative work of a voltage selection module, a step-up / step-down module, and an ideal diode module, it achieves seamless switching and regulated output in industrial control systems with large operating voltage fluctuations, such as aluminum electrolysis. The output voltage setting range reaches 3.3V to 25V, covering the power supply requirements of most sensors on the market. It also features small size, strong anti-interference ability, good compatibility, fast response, and low hysteresis, thus effectively solving the technical problem that traditional voltage regulator circuits cannot work continuously and stably under wide voltage input environments.

[0025] 2. By setting a voltage switching mechanism implemented entirely in hardware, this utility model does not rely on MCU control. The voltage input range and fixed voltage regulated output can be determined simply by setting the resistance value of the hardware resistor. At the same time, three ideal diodes are used to ensure that there is only one output path at any given time. While improving the resource utilization efficiency of the microcontroller in the industrial control system, it also supports continuous measurement of the control system by the sensor without an external power supply. When used with a heat sink, the size can be further reduced, realizing miniaturized design, maximizing space utilization and reducing costs, meeting the safety requirements of industrial sites, and has extremely high practicality and market application prospects. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a circuit diagram of a wide voltage seamless switching voltage regulator circuit according to an embodiment of the present invention;

[0028] Figure 2 This is a detailed implementation diagram of the wide voltage seamless switching voltage regulator circuit according to an embodiment of the present invention;

[0029] Figure 3 This is a circuit diagram of chip U2 in the voltage input comparison module of the wide voltage seamless switching voltage regulator circuit according to an embodiment of the present invention;

[0030] Figure 4 This is a circuit diagram of chip U6 in the voltage input comparison module of the wide voltage seamless switching voltage regulator circuit according to an embodiment of the present invention;

[0031] Figure 5 This is a circuit diagram of chip U10 in the voltage input comparison module of the wide voltage seamless switching voltage regulator circuit according to an embodiment of the present invention;

[0032] Figure 6 This is a circuit diagram of chip U4 in the buck-boost module of the wide voltage seamless switching voltage regulator circuit according to an embodiment of the present invention;

[0033] Figure 7 This is a circuit diagram of chip U7 in the buck-boost module of the wide voltage seamless switching voltage regulator circuit according to an embodiment of the present invention;

[0034] Figure 8 This is one of the circuit schematic diagrams of chip U12 in the buck-boost module of the wide voltage seamless switching voltage regulator circuit according to an embodiment of the present utility model;

[0035] Figure 9 This is the second circuit schematic diagram of chip U12 in the buck-boost module of the wide voltage seamless switching voltage regulator circuit according to an embodiment of this utility model;

[0036] Figure 10 This is a circuit diagram of chip U3 in the ideal diode module of the wide voltage seamless switching voltage regulator circuit according to an embodiment of the present invention;

[0037] Figure 11 This is a circuit diagram of chip U11 in the ideal diode module of the wide voltage seamless switching voltage regulator circuit according to an embodiment of the present utility model;

[0038] Figure 12 This is a circuit diagram of chip U8 in the ideal diode module of the wide voltage seamless switching voltage regulator circuit according to an embodiment of the present invention.

[0039] In the picture:

[0040] 1. Voltage input comparator module; 2. Voltage selection module; 3. Buck-boost module; 4. Ideal diode module. Detailed Implementation

[0041] To further illustrate the various embodiments, the present invention provides accompanying drawings, which are part of the disclosure of the present invention. These drawings are mainly used to illustrate the embodiments and can be used in conjunction with the relevant descriptions in the specification to explain the operating principles of the embodiments. With reference to these contents, those skilled in the art should be able to understand other possible implementation methods and the advantages of the present invention. The components in the figures are not drawn to scale, and similar component symbols are usually used to represent similar components.

[0042] According to an embodiment of the present invention, a wide voltage seamless switching voltage regulator circuit is provided.

[0043] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments, such as... Figures 1-12 As shown, Figure 8 Arrows ①-⑦ in the diagram are respectively connected to... Figure 9 Arrows ①-⑦ connect the wide voltage seamless switching voltage regulator circuit according to an embodiment of this utility model, including:

[0044] Voltage input comparison module 1 is used to divide the input voltage range into multiple intervals and perform voltage comparison;

[0045] Voltage selection module 2 is used to select the corresponding voltage range path based on the voltage comparison result;

[0046] The step-up / step-down module 3 is used to boost or buck the input voltage based on a selected voltage range path to output a stable voltage.

[0047] Ideal diode module 4 is used to ensure seamless switching between different voltage range paths and ensure that there is only one output path at any given time;

[0048] Among them, the voltage input comparison module 1 is connected to the step-up / step-down module 3 through the voltage selection module 2, and the step-up / step-down module 3 is connected to the ideal diode module 4.

[0049] By utilizing the above-mentioned technical solution of this utility model, this utility model provides an integrated wide-voltage seamless switching voltage regulator circuit including a voltage input comparison module 1, a voltage selection module 2, a step-up / step-down module 3, and an ideal diode module 4, which can avoid drastic changes in the cell voltage of aluminum electrolysis cells and stably output a 12V voltage.

[0050] In one embodiment, the voltage input comparison module 1 includes a chip U2. The fourth pin of chip U2 is grounded, the third pin of chip U2 is grounded through resistor R8, and the third pin of chip U2 is connected in series with the total input voltage through resistors R52, R7, and R6 in sequence. The second pin of chip U2 is connected to the total input voltage through resistor R6, and the first pin of chip U2 is connected to the total input voltage. The fifth pin of chip U2 is connected to the first shutdown path SHDN1, the sixth pin of chip U2 is connected to the first fault path FAULT1, the seventh pin of chip U2 is grounded through capacitor C5, and the seventh pin of chip U2 is connected to the first output terminal VOUT-1. The eighth pin of chip U2 is connected to the gate GATE1 of the first switching transistor U1.

[0051] In one embodiment, the voltage input comparison module 1 further includes a chip U6. The fourth pin of chip U6 is grounded, the third pin of chip U6 is connected to ground in series with resistors R17 and R54, and the third pin of chip U6 is connected in series with the total input voltage through resistors R16 and R15. The second pin of chip U6 is connected to the total input voltage through resistor R15. The first pin of chip U6 is directly connected to the total input voltage. The fifth pin of chip U6 is connected to the second shutdown path SHDN2. The sixth pin of chip U6 is connected to the second fault path FAULT2. The seventh pin of chip U6 is grounded through capacitor C13 and is connected to the second output terminal VOUT-2. The eighth pin of chip U6 is connected to the gate GATE2 of the second switching transistor U5.

[0052] In one embodiment, the voltage input comparison module 1 further includes a chip U10. The fourth pin of chip U10 is grounded, the third pin of chip U10 is grounded through resistor R28, and the third pin of chip U10 is connected in series with the total input voltage through resistors R56, R27, and R25 in sequence. The second pin of chip U10 is connected to the total input voltage through resistor R25, and the first pin of chip U10 is directly connected to the total input voltage. The fifth pin of chip U10 is connected to the third shutdown path SHDN3, the sixth pin of chip U10 is connected to the third fault path FAULT3, the seventh pin of chip U10 is grounded through capacitor C23, and the seventh pin of chip U10 is connected to the third output terminal VOUT-3. The eighth pin of chip U10 is connected to the gate GATE3 of the third switching transistor U9. The voltage of the first output terminal VOUT-1 is less than the voltage of the second output terminal VOUT-2, and the voltage of the second output terminal VOUT-2 is less than the voltage of the third output terminal VOUT-3.

[0053] The working principle of the voltage input comparison module 1 is as follows: The main control part of the voltage input comparison module 1 is the LTC4376, which is a controller with a wide voltage operating range, integrated overvoltage protection, and reverse power protection. The input voltage range is divided into three parts: 2.5V < voltage < 10V, 9V < voltage < 30V, 25V < voltage < 60V; while ensuring the safety of the circuit, it provides a stable range for the buck-boost of the next-stage circuit.

[0054] When the voltage input comparison module 1 performs voltage detection and comparison, the input voltage (V IN ) is sent to the OV (overvoltage) and UV (undervoltage) detection pins of the chip through an external resistor voltage division network (R1, R2). The internal reference voltage with an accuracy of 0.5% is compared with the divided input voltage; if V IN > OV threshold → trigger overvoltage protection; if V IN < UV threshold → trigger undervoltage protection.

[0055] When the voltage input comparison module 1 performs fast MOSFET switch control, an external N-channel MOSFET (such as Si7137DP) is used as the power switch. During normal operation: LTC4367 provides a gate drive voltage (V IN ) higher than V GATE ≈ V IN + 5V) through an internal charge pump, making the MOSFET fully conductive (R DS(ON) < 10mΩ). When protection is triggered (OV / UV): the charge pump is turned off, the gate voltage is quickly pulled down (< 1μs), the MOSFET is turned off, and the load power supply is cut off.

[0056] When the voltage input comparison module 1 implements a fault recovery mechanism, the automatic recovery mode (default): when the input voltage returns to the safe range (OV / UV threshold ± hysteresis voltage) and remains for 20ms (adjustable), the chip automatically re-enables the MOSFET. The latch mode (optional): an external reset signal (such as a button or MCU control) is required to restore power supply. LTC4367 realizes reliable protection for the 2.5V - 60V power supply through precise voltage detection + fast MOSFET switch + intelligent recovery logic.

[0057] Specifically, the core control chip of the voltage input comparison module 1 uses the LTC4376, which has a wide voltage operating range and integrates overvoltage protection and reverse power protection functions. The module realizes the three-region division of the input voltage (2.5V - 10V, 9V - 30V, 25V - 60V) through three groups of circuits of chips U2, U6, and U10. Each group of circuits is connected to the total input voltage through a specific resistor network. In specific implementation, taking chip U6 as an example, the third pin of the chip is grounded through a voltage-dividing resistor network (such as the series connection of R52 - R7 - R6), and the second pin is directly connected to the input voltage to form a precise voltage-dividing detection circuit. When the input voltage enters different regions, the internal reference voltage comparator with 0.5% accuracy will trigger the enable signal of the corresponding channel.

[0058] Specifically, the switch control of the voltage input comparison module 1 is realized through an external N-channel MOSFET. The gate drive signals (GATE1 / GATE2 / GATE3) output by the eighth pin of the chip control the on-state of the corresponding switch tubes (U1 / U5 / U9). During normal operation, the internal charge pump of the chip provides a gate drive (VIN + 5V) higher than the input voltage to keep the MOSFET in a fully on state (on-resistance < 10mΩ). When overvoltage (VIN > OV threshold) or undervoltage (VIN < UV threshold) is detected, the chip will turn off the gate drive within 1μs, and the output terminals (VOUT-1 / VOUT-2 / VOUT-3) connected through the seventh pin will switch to the path of the adjacent voltage region.

[0059] Specifically, the voltage input comparison module 1 also has an intelligent fault recovery mechanism. When the input voltage returns to the safe range (threshold ± hysteresis voltage) and remains for 20ms, the chip will automatically re-enable the MOSFET of the corresponding channel. Through the shutdown path (SHDN1 / SHDN2 / SHDN3) connected through the fifth pin and the fault signal path (FAULT1 / FAULT2 / FAULT3) of the sixth pin, manual shutdown or latch mode control can be achieved. The voltages of each output terminal strictly follow the hierarchical relationship of VOUT-1 < VOUT-2 < VOUT-3, ensuring that the buck-boost module 3 can obtain a stable interval input voltage.

[0060] It should be noted that in this invention, the voltage selection module 2 uses the LTC4367IMS8PBF power protection controller chip for voltage selection. This chip monitors multiple input voltages (VOUT-1 / VOUT-2 / VOUT-3) from the voltage input comparison module 1 in real time through an internal comparator, and automatically selects the optimal power supply path based on a preset threshold. Its working principle is as follows: when an abnormal voltage (overvoltage / undervoltage) is detected in the current path, the chip quickly shuts off the corresponding MOSFET (response time <1μs), and simultaneously seamlessly switches to the backup path through a logic control circuit, ensuring that the input voltage of the buck-boost module 3 is always within the effective range. Since the automatic switching mechanism and fault protection function of the LTC4367IMS8PBF chip are well-known technologies in the field, the specific implementation details will not be elaborated here.

[0061] In one embodiment, the buck-boost module 3 includes a chip U4. The fifth and fourth pins of the chip U4 are both grounded. The third pin of the chip U4 is grounded through a resistor R10 and connected to the first regulated output terminal VOUT-12V-1 through a resistor R9. The second pin of the chip U4 is grounded through a capacitor C7. The first pin of the chip U4 is connected to the first output terminal VOUT-1 through parallel capacitors C1 and C2. The seventh pin of the chip U4 is connected to the first regulated voltage output terminal VOUT-12V-1. The eighth pin of the chip U4 is connected to the tenth pin through a capacitor C4 and an inductor L1. The ninth pin of the chip U4 is used for mode selection. The tenth pin of the chip U4 is connected to the preamp input (first output terminal VOUT-1) through parallel capacitors C1 and C2.

[0062] In one embodiment, the buck-boost module 3 further includes a chip U7. The fourth pin of the chip U7 is connected to the fifth pin through a capacitor C16. The third pin of the chip U7 is connected to the pre-amplifier input (third output terminal VOUT-3) through capacitors C14 and C15 in parallel. The fifth pin of the chip U7 is connected to the third regulated output terminal VOUT-12V-3 through an inductor L2. The sixth pin and the seventh pin of the chip U7 are connected, and the eighth pin of the chip U7 is grounded.

[0063] In one embodiment, the buck-boost module 3 further includes a chip U12. The sixteenth pin of chip U12 is connected to the second regulated output terminal VOUT-12V-2 via resistor R50. The thirteenth pin of chip U12 is grounded via capacitor C51. The twelfth pin of chip U12 is connected to the preamp input (second output terminal VOUT-2) via resistors R57 and R40. The ninth pin of chip U12 is grounded via resistor R59. The eighth pin of chip U12 is grounded via capacitor C44. The fourth pin of chip U12 is grounded via capacitor C46. The seventeenth pin of chip U12 is connected to the preamp input (second output terminal VOUT-2) via resistor R51. The nineteenth pin of chip U12... Pin 21 of chip U12 is connected to the upper bridge switch Q1 and the lower bridge switch Q2 in series with capacitor C49. Pin 22 of chip U12 is connected to the lower bridge switch Q2. Pin 24 of chip U12 is connected to the lower bridge switch Q2 in series with capacitor C48 and grounded together with pin 23. Pin 25 of chip U12 is connected to the fifth switch U14. Pin 26 of chip U12 is connected to the fourth switch U13 in series with capacitor C45. Pin 27 of chip U12 is connected to the fourth switch U13. Pin 29 of chip U12 is connected to the fourth switch U13. Pin 33 of chip U12 is grounded.

[0064] The working principle of buck-boost module 3 is as follows: For chip U4, chip U4 (such as...) Figure 6 As shown, this embodiment uses an MP3437GRP-Z chip with high-frequency PWM control, synchronous rectification, and intelligent feedback regulation to efficiently boost a 2.7V-10V input to 12V. When forming a boost topology, the MP3437 employs a synchronous boost architecture, controlling the internal MOSFET switch to raise a low input voltage (such as a 3.7V lithium battery) to a stable 12V output. When the switching transistor (Q1) is on: current is stored through the inductor (L), the diode (D) is off, and the load is supplied by the output capacitor (C). OUT Power supply. When the switching transistor (Q1) is turned off: the inductor releases energy, which is superimposed on the input voltage and supplies power to the output through the synchronous rectifier MOSFET (Q2).

[0065] When implementing PWM control and feedback regulation, the U4 chip uses a fixed-frequency PWM (1.5MHz) to control the duty cycle (D) of the switching transistor and adjust the output voltage: the FB pin (feedback) detects the output voltage and compares it with the internal 0.6V reference voltage, dynamically adjusting the PWM duty cycle to maintain a stable 12V output.

[0066] Chip U4 employs synchronous rectification technology. Compared to traditional Boost converters (which use Schottky diodes), the MP3437 uses low R-values.DS(ON) Synchronous rectifier MOSFETs reduce conduction losses and improve efficiency (typically 95%).

[0067] The U4 chip can switch between PWM and PFM operating modes. Under heavy load, it operates in fixed-frequency PWM mode for optimal efficiency. Under light load, it automatically switches to PFM (Pulse Frequency Modulation) to reduce switching losses and improve efficiency.

[0068] For chip U7, chip U7 (such as...) Figure 7 As shown, in this embodiment, the MP9486AGN-Z model is used to efficiently and reliably convert 25V-60V input to 12V output through a high-voltage synchronous Buck architecture, precise PWM control, and multiple protection mechanisms.

[0069] When implementing a buck topology, the MP9486 uses a synchronous buck architecture, employing PWM to control the internal MOSFET switch, thus reducing a high input voltage (e.g., 48V) to a stable 12V output. When the switching transistor (Q1) is on: Input voltage (V... IN The circuit supplies power to the inductor (L) and the load through Q1, with the inductor storing energy. The synchronous rectifier (Q2) is off. When the switching transistor (Q1) is off: the inductor (L) freewheels through Q2 (the low-side MOSFET), maintaining the load current. The output voltage is supplied by the LC filter (L+C). OUT Smoothing. The output voltage is determined by the PWM duty cycle (D).

[0070] When chip U7 is in feedback control mode (FB pin), the FB (feedback) pin detects the output voltage and compares it with the internal 0.8V reference voltage. The duty cycle is dynamically adjusted via an error amplifier (EA) and a PWM modulator to maintain a stable 12V output. An external resistor divider network (R1 / R2) sets the output voltage.

[0071] Chip U7 uses synchronous rectification technology and integrates low R-value. DS(ON) MOSFETs (upper and lower diodes) reduce conduction losses and improve efficiency (typically 92%–95%). Compared to traditional asynchronous Buck diodes (which require an external Schottky diode), they offer higher efficiency and lower temperature rise.

[0072] For chip U12, chip U12 (such as...) Figure 8 and Figure 9As shown, this embodiment uses the MP2980GR-P chip. When implementing a Buck-Boost topology, the MP2980 employs a four-switch Buck-Boost architecture (two high-side MOSFETs + two low-side MOSFETs). PWM control enables Buck, Boost, or pass-through modes: Input voltage > 12V (e.g., 24V): Operates in Buck mode, reducing the voltage to 12V. Input voltage < 12V (e.g., 9V): Operates in Boost mode, increasing the voltage to 12V. Input voltage ≈ 12V: Enters pass-through mode, with all MOSFETs fully turned on, reducing losses.

[0073] When implementing feedback control and voltage regulation, chip U12 uses the FB pin (feedback) to detect the output voltage, compares it with the internal 0.6V reference, and dynamically adjusts the PWM duty cycle. This is achieved through I... 2 The C interface allows for programmable settings of parameters such as output voltage (e.g., 12V) and current limit.

[0074] Chip U12 uses synchronous rectification technology and integrates low R-value. DS(ON) MOSFET drivers reduce conduction losses and improve efficiency (typically 92%-95%).

[0075] Chip U12 implements protection mechanisms, including overvoltage protection (OVP): shutdown when the output exceeds a set value; overcurrent protection (OCP): triggering current limiting mode when the inductor current exceeds the limit; and thermal shutdown (TSD): automatic shutdown when the junction temperature >150℃, and recovery after cooling.

[0076] Specifically, the buck-boost module 3 achieves stable conversion from a wide input voltage range (2.7V-60V) to 12V through three independent circuits (U4 / U7 / U12). Chip U4 (MP3437GRP-Z) handles low-voltage inputs of 2.7V-10V, with its third pin VIN directly connected to the preamp input (VOUT-1). An internal synchronous boost architecture boosts the voltage to 12V. Pin 8 of this chip, along with inductor L1 and capacitor C4, forms an energy storage network. The 12V output from pin 7 is filtered by parallel capacitors C1 / C2 and then sent to VOUT-12V-1. Simultaneously, pin 3, through resistors R9 / R10, forms a feedback voltage divider network to ensure output voltage accuracy.

[0077] Specifically, for the medium-voltage input range (9V-30V), chip U12 (MP2980GR-P) achieves bidirectional switching through a four-switch Buck-Boost topology. Its twelfth pin is connected to the preamp input (VOUT-2) via resistors R57 / R40, the seventeenth pin directly samples the input voltage, and the nineteenth pin drives the upper and lower bridge switches (Q1 / Q2) to form an H-bridge structure. When the input voltage is higher than 12V, the chip automatically switches to Buck mode, stepping down the voltage through the LC network (C49 / L2) connected to the twenty-first pin; when the input is lower than 12V, it switches to Boost mode, boosting the voltage using the synchronous rectifier (Q2) controlled by the twenty-second pin. The output voltage is set to 12V via external resistor R50 connected to the sixteenth pin and dynamically adjusted by the load through the twenty-fifth pin (connected to U14).

[0078] Specifically, the high-voltage input (25V-60V) is handled by chip U7 (MP9486AGN-Z). Its third pin is connected to the preamp input (VOUT-3) via parallel capacitors C14 / C15, and the fifth pin forms a Buck topology through inductor L2. The internal synchronous rectifier MOSFET achieves low-loss freewheeling by shorting pins 6 and 7. The voltage stability of the output VOUT-12V-3 is ensured by the external capacitor C16 connected to pin 4 and the internal 0.8V reference. All three chips use high-frequency PWM control (1.5MHz-2.2MHz), and the output voltage is monitored in real time through the FB pin, dynamically adjusting the duty cycle to maintain an output accuracy of 12V±1% under different input ranges.

[0079] Specifically, the module's intelligent switching function is implemented through the chip's built-in protection mechanism. The MP3437 automatically switches to PFM mode under light load to reduce power consumption; the MP2980 uses I... 2 The C interface (connected to U13 / U14) allows for programmable overcurrent threshold settings; the MP9486 shuts down the drive signal when overheating (>150℃) is detected, and automatically resumes operation after cooling. The enable pins of each chip (such as pin 9 of U4) are controlled by the front-stage voltage selection module 2, ensuring that the corresponding conversion circuit is activated only when the front-stage input voltage is valid.

[0080] In one embodiment, the ideal diode module 4 includes a chip U3. The eighth pin of chip U3 is connected to the tenth pin through resistor R12. The seventh pin of chip U3 is connected to the first fault path FAULT1. The sixth pin of chip U3 is connected to the eleventh pin through resistors R53 and R13. The fifth pin of chip U3 is connected to the pre-stage voltage regulator input (first stable voltage output terminal VOUT-12V-1) through resistor R4. The first, second, and third pins of chip U3 are all connected to the pre-stage voltage regulator input (first stable voltage output terminal VOUT-12V-1). The ninth pin of chip U3 is grounded. The twelfth pin of chip U3 is connected to the pre-stage voltage regulator input (first stable voltage output terminal VOUT-12V-1) in sequence through capacitor C12, resistor R11, and resistor R4. The fifteenth and sixteenth pins of chip U3 are both connected to the output terminal.

[0081] In one embodiment, the ideal diode module 4 further includes a chip U11. The eighth pin of chip U11 is connected to the tenth pin through resistor R41. The seventh pin of chip U11 is connected to the second fault path FAULT2. The sixth pin of chip U11 is connected to the eleventh pin through resistors R58 and R42. The fifth pin of chip U11 is connected to the pre-stage voltage regulator input (second stable voltage output terminal VOUT-12V-2) through resistor R34. The first, second, and third pins of chip U11 are all connected to the pre-stage voltage regulator input (second stable voltage output terminal VOUT-12V-2). The ninth pin of chip U11 is grounded. The twelfth pin of chip U11 is connected to the pre-stage voltage regulator input (second stable voltage output terminal VOUT-12V-2) in sequence through capacitor C47, resistor R38, and resistor R34. The fifteenth and sixteenth pins of chip U11 are both connected to the output terminal.

[0082] In one embodiment, the ideal diode module 4 further includes a chip U8. The eighth pin of chip U8 is connected to the tenth pin through resistor R23. The seventh pin of chip U8 is connected to the third fault path FAULT3. The sixth pin of chip U8 is connected to the eleventh pin through resistors R55 and R24. The fifth pin of chip U8 is connected to the pre-stage voltage regulator input (third stable voltage output terminal VOUT-12V-3) through resistor R21. The first, second, and third pins of chip U8 are all connected to the pre-stage voltage regulator input (third stable voltage output terminal VOUT-12V-3). The ninth pin of chip U8 is grounded. The twelfth pin of chip U8 is connected to the pre-stage voltage regulator input (third stable voltage output terminal VOUT-12V-3) in sequence through capacitor C22, resistor R22, and resistor R21. The fifteenth and sixteenth pins of chip U8 are both connected to the output terminal.

[0083] The working principle of ideal diode module 4 is as follows: Ideal diode module 4 is the last module of this utility model circuit. To ensure seamless voltage switching, there is overlap during voltage selection. Therefore, to ensure a stable output of 12V (or other set voltage), only one output path must be maintained at any given time. Thus, three LM74202 ideal diodes are used. The switching on and off of the ideal diodes is determined by the output potential of the voltage comparator. Through experiments, this circuit can achieve wide-range seamless voltage switching from 2.5V to 100V, and the regulated output value can be freely set between 5V and 30V.

[0084] like Figure 10-12 As shown, in this embodiment, the ideal diode module 4 uses the LM74202 chip. The on / off state of this chip is determined by the SHDN pin. The SHDN pin is connected to the FAULT pin of the first-stage circuit. The on / off state of the ideal diode in the third-stage circuit is determined by whether the circuit corresponding to the first stage is conducting or not.

[0085] Specifically, the ideal diode module 4 uses three LM74202 chips (U3 / U8 / U11) to achieve seamless switching and isolation of multiple power supplies. The fifth pin of chip U3 is connected to the output terminal VOUT-12V-1 of the pre-amplifier via resistor R4, and its first to third pins are directly connected in parallel to the input power path, forming a low-loss (<20mΩ) conduction channel. When the voltage selection module 2 enables the first path, the corresponding FAULT1 signal (connected to the seventh pin of U3) is set to a high level. At this time, the internal MOSFET of the chip is fully turned on, and the twelfth pin monitors the input voltage fluctuation in real time through the RC network (C12 / R11 / R4) to ensure that the output voltage ripple is <50mV.

[0086] Specifically, for the medium-voltage and high-voltage paths, chips U11 and U8 operate with the same architecture. Pin 5 of U11 is connected to VOUT-12V-2 via resistor R34, and the voltage divider network (R58 / R42) externally connected to pin 6, together with pin 11, forms a reverse current blocking detection circuit. When voltage selection module 2 switches to the second path, the FAULT2 signal triggers the internal comparator of U11, causing the MOSFET driven by pin 8 to turn on within <1μs. Simultaneously, the output terminals connected through pins 15 / 16 are powered preferentially over other paths. At this time, U3 and U8 are in a high-impedance state because their SHDN pins (connected to FAULT1 / FAULT3 respectively) are low, achieving electrical isolation.

[0087] Specifically, the module's rapid switching characteristic is achieved through the chip's internal intelligent control logic. Specifically, the LM74202 dynamically adjusts the MOSFET gate drive (output from pin 8) by continuously comparing the potential difference between the IN pins (pins 1-3) and the OUT pins (pins 15 / 16). When the current path voltage is detected to be lower than other paths, the chip automatically reduces the on-resistance (typically 10mΩ) to prevent reverse current flow. When the main path fails, the backup path can switch within 20ms, with the output voltage drop controlled within 5%. External capacitors (such as C12 / C47 / C22) and resistors connected to pin 12 of each chip form a delay circuit to ensure a smooth voltage transition during switching.

[0088] Specifically, the module's wide-range adaptability is achieved through peripheral circuit optimization. Pin 6 of chip U8 is connected to resistors R55 / R24, with the resistance ratio set to allow normal detection even with input voltages up to 100V. Pin 10 of U3 is connected to the internal charge pump via resistor R12, supporting startup from a minimum input voltage of 2.5V. With the output terminals of the three chips connected in parallel, the final voltage regulation accuracy reaches ±1%, and experimental verification shows that the output voltage value can be freely set within the 5-30V range by adjusting the pre-amplifier feedback resistor.

[0089] To facilitate understanding of the above-mentioned technical solutions of this utility model, the working principle or operation method of this utility model in actual process will be described in detail below.

[0090] In practical applications, this circuit can achieve seamless wide-voltage switching through the cooperation of multiple modules. After the voltage input comparator module 1 divides the input range, the three circuits of the buck-boost module 3 handle different ranges respectively: 2.5~10V boost to 12V (U4), 9~30V direct regulation (U12), and 25~60V buck (U12). The ideal diode module 4 ensures that only the effective path is powered through priority control, and the LED indicator shows the current working path in real time. When a path fails due to overcurrent or overheating, the electronic fuse (such as the FAULT signal of LTC4367) will trigger the corresponding ideal diode to turn off, protecting the downstream circuit while other paths seamlessly take over. Experimental verification shows that this circuit can work stably within the 2.5~60V input and 5~30V adjustable output range, which can well meet the requirements of the field and achieve the expected results.

[0091] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A wide-voltage seamless switching voltage regulator circuit, characterized in that, include: The voltage input comparison module is used to divide the input voltage range into multiple intervals and perform voltage comparisons. The voltage selection module is used to select the appropriate voltage range path based on the voltage comparison result. A buck-boost module is used to boost or buck the input voltage based on a selected voltage range path to output a stable voltage. An ideal diode module is used to ensure seamless switching between different voltage range paths and to ensure that there is only one output path at any given time. The voltage input comparison module is connected to the buck-boost module via the voltage selection module, and the buck-boost module is connected to the ideal diode module.

2. The wide voltage seamless switching regulator circuit according to claim 1, characterized in that, The voltage input comparison module includes a chip U2. The fourth pin of the chip U2 is grounded, the third pin of the chip U2 is grounded through a resistor R8, and the third pin of the chip U2 is connected in series with the total input voltage through resistors R52, R7, and R6 in sequence. The second pin of the chip U2 is connected to the total input voltage through a resistor R6, and the first pin of the chip U2 is connected to the total input voltage. The fifth pin of chip U2 is connected to the first shutdown path, the sixth pin of chip U2 is connected to the first fault path, the seventh pin of chip U2 is grounded through capacitor C5 and is connected to the first output terminal, and the eighth pin of chip U2 is connected to the gate of the first switching transistor U1.

3. The wide voltage seamless switching voltage regulator circuit according to claim 2, characterized in that, The voltage input comparison module also includes a chip U6. The fourth pin of the chip U6 is grounded, the third pin of the chip U6 is connected in series with resistors R17 and R54 and then grounded, and the third pin of the chip U6 is connected in series with the total input voltage through resistors R16 and R15. The second pin of the chip U6 is connected to the total input voltage through resistor R15, and the first pin of the chip U6 is directly connected to the total input voltage. The fifth pin of chip U6 is connected to the second shutdown path, the sixth pin of chip U6 is connected to the second fault path, the seventh pin of chip U6 is grounded through capacitor C13 and is connected to the second output terminal, and the eighth pin of chip U6 is connected to the gate of the second switching transistor U5.

4. The wide voltage seamless switching regulator circuit according to claim 3, characterized in that, The voltage input comparison module also includes a chip U10. The fourth pin of the chip U10 is grounded, the third pin of the chip U10 is grounded through a resistor R28, and the third pin of the chip U10 is connected in series with the total input voltage through resistors R56, R27, and R25 in sequence. The second pin of the chip U10 is connected to the total input voltage through a resistor R25, and the first pin of the chip U10 is directly connected to the total input voltage. The fifth pin of chip U10 is connected to the third shutdown path, the sixth pin of chip U10 is connected to the third fault path, the seventh pin of chip U10 is grounded through capacitor C23, and the seventh pin of chip U10 is connected to the third output terminal. The eighth pin of chip U10 is connected to the gate of the third switching transistor U9. Wherein, the voltage of the first output terminal is less than the voltage of the second output terminal, and the voltage of the second output terminal is less than the voltage of the third output terminal.

5. The wide voltage seamless switching regulator circuit according to claim 1, characterized in that, The buck-boost module includes a chip U4, the fifth and fourth pins of which are grounded, the third pin of which is grounded through a resistor R10, and the third pin of which is connected to the first regulated output terminal through a resistor R9. The second pin of which is grounded through a capacitor C7, and the first pin of which is connected to the first output terminal through parallel capacitors C1 and C2. The seventh pin of chip U4 is connected to the first stable voltage output terminal. The eighth pin of chip U4 is connected to the tenth pin through capacitor C4 and inductor L1. The ninth pin of chip U4 is used for mode selection. The tenth pin of chip U4 is connected to the preamp input through capacitors C1 and C2 in parallel.

6. The wide voltage seamless switching regulator circuit according to claim 5, characterized in that, The buck-boost module also includes a chip U7, the fourth pin of which is connected to the fifth pin through a capacitor C16, and the third pin of which is connected to the input of the preamplifier through capacitors C14 and C15 in parallel. The fifth pin of the chip U7 is connected to the third regulated output terminal through inductor L2, the sixth pin of the chip U7 is connected to the seventh pin, and the eighth pin of the chip U7 is grounded.

7. The wide-voltage seamless switching regulator circuit according to claim 6, characterized in that, The buck-boost module also includes a chip U12. The sixteenth pin of the chip U12 is connected to the second regulated output terminal through a resistor R50. The thirteenth pin of the chip U12 is grounded through a capacitor C51. The twelfth pin of the chip U12 is connected to the input of the preamplifier through resistors R57 and R40. The ninth pin of the chip U12 is grounded through a resistor R59. The eighth pin of the chip U12 is grounded through a capacitor C44. The fourth pin of the chip U12 is grounded through a capacitor C46. The seventeenth pin of chip U12 is connected to the input of the front stage through resistor R51. The nineteenth pin of chip U12 is connected to the upper bridge switch Q1 and the lower bridge switch Q2. The twenty-first pin of chip U12 and capacitor C49 are connected in series to the upper bridge switch Q1 and the lower bridge switch Q2. The twenty-second pin of chip U12 is connected to the lower bridge switch Q2. The 24th pin of chip U12 and capacitor C48 are connected in series and then grounded together with the 23rd pin. The 25th pin of chip U12 is connected to the fifth switch U14. The 26th pin of chip U12 and capacitor C45 are connected in series and then connected to the fourth switch U13. The 27th pin of chip U12 is connected to the fourth switch U13. The 29th pin of chip U12 is connected to the fourth switch U13. The 33rd pin of chip U12 is grounded.

8. The wide voltage seamless switching regulator circuit according to claim 1, characterized in that, The ideal diode module includes a chip U3. The eighth pin of the chip U3 is connected to the tenth pin through a resistor R12. The seventh pin of the chip U3 is connected to the first fault path. The sixth pin of the chip U3 is connected to the eleventh pin through resistors R53 and R13. The fifth pin of the chip U3 is connected to the pre-amplifier input through a resistor R4. The first, second, and third pins of the chip U3 are all connected to the pre-amplifier input. The ninth pin of the chip U3 is grounded, the twelfth pin of the chip U3 is connected to the pre-stage voltage regulator input through capacitor C12, resistor R11, and resistor R4 in sequence, and the fifteenth and sixteenth pins of the chip U3 are both connected to the output terminal.

9. The wide voltage seamless switching regulator circuit according to claim 8, characterized in that, The ideal diode module also includes a chip U11. The eighth pin of the chip U11 is connected to the tenth pin through a resistor R41. The seventh pin of the chip U11 is connected to the second fault path. The sixth pin of the chip U11 is connected to the eleventh pin through resistors R58 and R42. The fifth pin of the chip U11 is connected to the pre-amplifier input through a resistor R34. The first, second, and third pins of the chip U11 are all connected to the pre-amplifier input. The ninth pin of the chip U11 is grounded, the twelfth pin of the chip U11 is connected to the input of the pre-stage voltage regulator in sequence through capacitor C47, resistor R38 and resistor R34, and the fifteenth and sixteenth pins of the chip U11 are both connected to the output terminal.

10. The wide-voltage seamless switching regulator circuit according to claim 9, characterized in that, The ideal diode module also includes a chip U8. The eighth pin of the chip U8 is connected to the tenth pin through a resistor R23. The seventh pin of the chip U8 is connected to the third fault path. The sixth pin of the chip U8 is connected to the eleventh pin through resistors R55 and R24. The fifth pin of the chip U8 is connected to the pre-amplifier input through a resistor R21. The first, second, and third pins of the chip U8 are all connected to the pre-amplifier input. The ninth pin of the chip U8 is grounded, the twelfth pin of the chip U8 is connected to the pre-stage voltage regulator input in sequence through capacitor C22, resistor R22 and resistor R21, and the fifteenth and sixteenth pins of the chip U8 are both connected to the output terminal.

Images