Dual Output Power Supply with Integrated Controller
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Solution Overview
Problem
Existing power conversion systems face complexity and cost challenges in designing systems that require both constant voltage and constant current sources for various load devices, such as LED elements, due to the need for multiple power converters and intricate system design.
Innovation Solution
A four-terminal or eight-terminal power supply package is introduced, featuring internal and external power switches with a controller that provides independent control and responsiveness to error signals, allowing for synchronous or asynchronous operation of two power converters optimized for constant voltage and constant current outputs, respectively, within a single integrated circuit or multiple IC elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple power converters are used to provide both constant voltage and constant current outputs, then the system can meet diverse load requirements, but the device complexity and system design difficulty increase
Solution Approach 1:
The patent combines multiple power converter circuits into a single integrated power supply package that can provide both constant voltage and constant current outputs. The controller integrates multiple power switches and control logic in one package, reducing the number of discrete components and simplifying system design while maintaining the ability to support diverse load requirements.
Solution Approach 2:
The power supply package is designed with multi-functionality to serve multiple purposes: it can operate as a constant voltage source for general electronic loads, as a constant current source for LED drivers, and can be configured in various terminal arrangements (four-terminal or eight-terminal) to accommodate different application requirements, all within a single integrated device.
2Adaptability or versatility
If multiple power converters are used to provide both constant voltage and constant current outputs, then the system can meet diverse load requirements, but the cost increases
Solution Approach 1:
By merging multiple power converter functions into a single integrated package with shared components (transformer, controller, power switches), the bill of materials is reduced and manufacturing complexity is lowered, resulting in cost savings compared to using separate discrete power converter modules.
Solution Approach 2:
The universal design allows a single product to replace multiple specialized power supply devices, reducing inventory requirements and simplifying supply chain management, which contributes to overall cost reduction while maintaining versatility for different load types.
3Adaptability or versatility
If multiple power converters are used to provide both constant voltage and constant current outputs, then the system can meet diverse load requirements, but the system size increases
Solution Approach 1:
The integration of multiple power converter circuits into a single compact package with shared magnetic components and control logic significantly reduces the overall volume required compared to using separate discrete power converter modules, enabling smaller form factor applications.
4Device complexity
If a single power supply provides both constant voltage and constant current outputs, then the system design is simplified, but independent control and responsiveness to error signals for each converter becomes more challenging
Solution Approach 1:
The controller is designed with segmented control logic that independently manages each power converter circuit. Each converter has its own control loop that can respond to error signals independently, allowing the controller to provide separate constant voltage and constant current outputs with independent regulation despite the integrated package structure.
Data Source
AI summary
A single power supply provides at least one constant voltage output and at least one constant current output. The single power supply includes two or more switching power converters, such as flyback converters, that are independently controllable based on an error signal corresponding to the associated output. Further, one or more of the switching power converters can implement such control using primary-side feedback. The switching power converters can be flyback converters. Any switching power converters included the in the single power supply can both be part of a single PCB assembly, part of a single IC package, or part of a single monolith semiconductor die.