Auxiliary Converter for Extended Input Voltage Range
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Solution Overview
Problem
Voltage regulator efficiency is difficult to maximize over a large set of operating conditions due to design trade-offs, especially in 48V-to-PoL systems, which require scalability with respect to input voltage range and output power, while maintaining high power density and minimizing cost.
Innovation Solution
The implementation of an auxiliary converter that extends the low line voltage of the system below the input voltage range of the voltage regulators without sacrificing efficiency, using a comparator-based under- and over-voltage lock-out circuit, and a soft start circuit for controlled turn-on, with optional power management functions like telemetry and output voltage trimming, to maintain efficiency and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the input voltage range of voltage regulators is limited to a narrow range for maximum efficiency, then efficiency is improved, but the system cannot operate over a wide input voltage range including low line conditions
Solution Approach 1:
The power conversion system is divided into two separate converters: a first converter optimized for nominal and high line voltage operation, and a second converter optimized for low line voltage operation. Each converter is designed to operate efficiently within its specific voltage range, allowing the system to maintain high efficiency across the entire wide input voltage range by switching between converters based on input voltage conditions.
2Productivity
If multiple paralleled and interleaved buck converters are used to achieve scalability with respect to output power, then output power scalability is improved, but device complexity increases
Solution Approach 1:
Each converter (first and second) is designed as a self-contained module capable of handling the full range of output power requirements independently. The converters share common control circuitry and can operate autonomously, allowing the system to achieve output power scalability without requiring complex paralleled and interleaved configurations. The universal design allows either converter to serve the entire load within its operating voltage range.
3Reliability
If isolated topology converters are used to improve duty cycle and load protection, then reliability is improved, but device size and cost increase due to additional magnetic components
Solution Approach 1:
The patent uses non-isolated buck converter topologies for both the first and second converters, eliminating the need for heavy magnetic components while maintaining system reliability through intelligent control. The control system provides load protection and manages power distribution without requiring isolated topologies, thereby achieving the same reliability benefits with significantly reduced weight and cost.
Solution Approach 2:
The control system continuously monitors input voltage levels and automatically switches between the first and second converters based on real-time voltage conditions. This feedback mechanism ensures that the appropriate converter is always active, providing load protection and maintaining system reliability without requiring isolated topologies or additional magnetic components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables extended low line operation of voltage regulation systems with minimal impact on efficiency, size, and cost, achieving improved efficiency over a wide input voltage range while maintaining high power density and scalability.
Implementation Method 1
the auxiliary circuit being configured and operative to generate an auxiliary voltage and add it to the DC supply voltage to form a boosted supply voltage
Implementation Method 2
Switching circuitry is configured and operative in response to a level of the DC supply voltage to (1) connect the supply input to the PoL input to apply the DC supply voltage as the PoL input voltage when the DC supply voltage is in the first sub-range, and (2) connect the output of the auxiliary circuit to the PoL input to apply the boosted supply voltage as the PoL input voltage when the DC supply voltage is in the second sub-range
Data Source
AI summary
A DC power supply includes a point-of-load (PoL) regulator providing power to a load with a desired efficiency only when a PoL input voltage is in a first sub-range of a specified larger system input voltage range. The supply has an auxiliary circuit with an output in series with the supply input, generating an auxiliary voltage and adding it to the DC supply voltage to form a boosted supply voltage. Switching circuitry connects the supply input to the PoL input to apply a DC supply voltage as the PoL input voltage when the supply voltage is in the first sub-range, and connects the output of the auxiliary circuit to the PoL input to apply the boosted supply voltage as the PoL input voltage when the supply voltage is outside the first sub-range, maintaining the PoL input voltage within the first sub-range.