Auxiliary Power Supply Switching for Flat Efficiency Across Loads

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Solution Overview

Problem

AC-DC power supplies experience a significant drop in efficiency at low loading conditions due to overhead power that does not scale down with reduced load, leading to lower overall efficiency in IT systems like data centers and network routing/switching systems.

Innovation Solution

The implementation of an interleaved power supply system with an auxiliary power supply and a controller that dynamically adjusts the number of phases and power modules based on loading conditions, using soft or hard switching devices to optimize efficiency by directing the auxiliary power supply to provide output power when sufficient, thereby reducing unnecessary overhead power consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the power supply operates at peak loading conditions with all subsystems designed for optimal performance, then the peak efficiency is maximized, but the efficiency drops sharply at lower loading conditions due to overhead power requirements

Engineering Contradiction:

Improvepower efficiencyVSAvoidloading condition adaptability

Core Design Contradiction:

Loss of energyVSAdaptability or versatility

Solution Approach 1:

The power supply is divided into multiple independent phases (first phase, second phase, third phase) that can operate independently or in combination. Each phase can be selectively activated based on loading conditions, allowing the system to segment its operation to match actual power demands and maintain efficiency across varying loads.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The controller dynamically adjusts the number of active phases based on real-time loading conditions. At low loading, fewer phases are activated to reduce overhead power consumption; at high loading, more phases are activated to meet power demands. This dynamic adaptation resolves the contradiction between peak efficiency and loading condition versatility.

Inventive Principle:

Principle #15Dynamics

2Power

If all output modules are activated to meet high power demands, then the power supply capacity is sufficient, but the overhead power consumption increases unnecessarily at low loading conditions

Engineering Contradiction:

Improveoutput power capacityVSAvoidoverhead power consumption

Core Design Contradiction:

PowerVSUse of energy by moving object

Solution Approach 1:

Instead of always activating all output modules, the system applies partial action by activating only the necessary number of phases based on current loading requirements. The controller selectively engages phases to provide sufficient power capacity while avoiding the excessive overhead consumption that would result from activating all modules unnecessarily.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system changes the operational parameters by adjusting the number of active phases according to loading conditions. This parameter change allows the power supply to scale its overhead power consumption proportionally with the actual power delivery requirements, resolving the contradiction between maintaining power capacity and reducing energy waste.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If a single auxiliary power supply is used to provide output power at low loading conditions, then the efficiency is improved, but the power rating of the auxiliary power supply must be sufficient to cover the maximum possible output power requirement

Engineering Contradiction:

Improveefficiency at low loadingVSAvoidpower supply architecture

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The auxiliary power supply is designed with multi-functionality, serving dual purposes: providing output power directly at low loading conditions and supporting the main output modules at higher loading conditions. This universal design allows a single auxiliary unit to handle multiple operational scenarios, improving efficiency without requiring separate dedicated supplies for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The auxiliary power supply is configured to autonomously provide output power when loading conditions are low and its power rating is sufficient, without requiring intervention from the main output modules. This self-service capability allows the auxiliary supply to independently optimize efficiency at low loads, while the controller manages the transition between auxiliary and main module operation.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20230344329A1Modular power supply architecture optimized for flat efficiency across loadings

Publication Date: 2023.10.26 CISCO TECHNOLOGY INC

AI summary

A control method improves the efficiency profile of a power supply across a wide range of output loading. The method includes obtaining a measure of output power for a power supply, which includes one or more output modules and an auxiliary power supply. The method determines whether a maximum power rating of the auxiliary power supply is sufficient to provide the measure of output power. Responsive to a determination that the maximum power rating of the auxiliary power supply is sufficient to provide the measure of output power, the controller of the power supply directs the auxiliary power supply to provide the output power.