Multi-Level Buck Converter Control for Constant Ripple Current

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Solution Overview

Problem

Conventional power conversion systems in data centers face inefficiencies, particularly in voltage distribution and conversion, which leads to energy losses and reduced power density, necessitating improved methods to manage energy usage and reduce environmental impact.

Innovation Solution

A novel power supply system incorporating a controller that adjusts the switching frequency of a multi-level buck converter based on a target ripple current value, ensuring efficient energy conversion by maintaining a constant or controlled ripple current magnitude across varying input voltages, thereby optimizing power conversion efficiency and reducing switching losses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional power conversion systems are used with fixed switching frequency, then the system structure is simple, but power conversion efficiency is reduced and energy losses increase

Engineering Contradiction:
Improveenergy lossesVSAvoidsystem complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent implements dynamic switching frequency adjustment in the power converter controller. The switching frequency is varied based on operating conditions (input voltage, output voltage, load current) to optimize power conversion efficiency. This dynamic adaptation allows the system to maintain high efficiency across different operating points while managing energy losses effectively.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes the switching frequency parameter adaptively based on operating conditions. By adjusting this critical parameter according to input voltage levels, output voltage requirements, and load demands, the system achieves optimal power conversion efficiency without requiring complete system redesign, thus balancing efficiency improvement with acceptable complexity.

Inventive Principle:
Principle #35Parameter changes

2Productivity

If switching frequency is increased to improve power conversion efficiency, then power conversion efficiency is improved, but switching losses increase

Engineering Contradiction:
Improvepower conversion efficiencyVSAvoidswitching losses
Core Design Contradiction:
ProductivityVSLoss of energy

Solution Approach 1:

The controller dynamically adjusts switching frequency based on real-time operating conditions. At light load conditions, lower switching frequencies are used to minimize switching losses. At heavy load conditions, higher switching frequencies maintain power conversion efficiency. This dynamic balancing act optimizes the trade-off between conversion efficiency and switching losses throughout the operating range.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The switching frequency parameter is changed adaptively according to load conditions and voltage levels. The system selects optimal frequency values that maximize power conversion efficiency while keeping switching losses within acceptable limits, achieving the best compromise between these two competing factors.

Inventive Principle:
Principle #35Parameter changes

3Loss of energy

If multi-level buck converter is used to improve voltage conversion efficiency, then power conversion efficiency is improved, but device complexity increases

Engineering Contradiction:
Improvepower conversion efficiencyVSAvoidconverter topology complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The multi-level buck converter topology is segmented into multiple voltage levels (e.g., three-level with Vin/2 and Vin/3 nodes). This segmentation allows the converter to achieve higher power conversion efficiency by distributing voltage stress across multiple switches and capacitors, reducing individual component stress and enabling softer switching transitions that minimize losses.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Flying capacitors are introduced as intermediary elements in the multi-level converter topology. These capacitors mediate voltage transfer between different levels, enabling efficient voltage conversion while distributing the conversion stress across multiple stages. This intermediary approach improves overall efficiency while managing the complexity through modular architecture.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Stability of the object's composition

If constant ripple current is maintained across varying input voltages, then power conversion stability is improved, but switching frequency must be continuously adjusted

Engineering Contradiction:
Improveripple current stabilityVSAvoidswitching frequency control complexity
Core Design Contradiction:
Stability of the object's compositionVSExtent of automation

Solution Approach 1:

The controller implements feedback mechanisms to monitor output ripple current and adjust switching frequency accordingly. This closed-loop control ensures that ripple current remains constant despite variations in input voltage, maintaining power conversion stability. The automatic frequency adjustment based on feedback signals manages the complexity through intelligent control algorithms.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The switching frequency parameter is continuously adjusted to compensate for input voltage variations and maintain constant ripple current. This adaptive parameter change approach ensures stable power conversion characteristics while the control system automatically manages the frequency adjustment complexity through programmed response curves and compensation algorithms.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS12051977B2Multi-level power converter and control
Publication Date: 2024.07.30 INFINEON TECH AUSTRIA AG
  • US12051977B2 patent drawing
  • US12051977B2 patent drawing
  • US12051977B2 patent drawing

AI summary

An apparatus such as a power supply or other suitable entity includes a controller. The controller receives a target ripple current value indicative of a ripple current associated with an output voltage and corresponding output current of a power converter powering a load. The controller selects a switching frequency of operating the power converter as a function of a magnitude of the received target ripple current value. The controller applies the selected switching frequency to switches in the power converter to produce the output current with a magnitude of the ripple current as indicated by the target ripple current value.