Flyback Converter Controller Timing-Based Output Power Measurement

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Solution Overview

Problem

Conventional isolated power converters face measurement inaccuracies in detecting output current and power due to inherent delays in peak detection and sample-hold circuits, especially in continuous current mode, and are unable to accurately measure initial continuous current and output power.

Innovation Solution

The solution involves a power converter with a controller that generates a switching signal based on a current sense signal, taking two measurements during the turn-on period: one at a predefined time delay from the start and another when the current sense signal reaches a threshold voltage, allowing for accurate calculation of average output current and maximum output power without the need for peak detection and hold circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If peak detection and sample-hold circuits are used to detect output current in CCM mode, then output current measurement is enabled, but measurement accuracy deteriorates due to inherent delay and leading edge spikes

Engineering Contradiction:
Improveoutput current measurement accuracyVSAvoidmeasurement circuit complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts the measurement function from complex peak detection and sample-hold circuits to a simplified sampling circuit that takes measurements at specific timing points during the switching cycle. By measuring at the valley point (when current is minimum) and using timing-based sampling, the patent eliminates the need for complex peak detection circuitry while improving accuracy by avoiding leading edge spikes.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent performs preliminary sampling of the current sense signal at predetermined timing points (valley point and specific phase points) before the switching cycle completes. This preliminary action allows the system to capture accurate current values without waiting for peak detection, thereby avoiding delays and improving measurement responsiveness.

Inventive Principle:
Principle #10Preliminary action

2Loss of information

If conventional peak detection circuits are used, then current measurement is possible, but measurement accuracy worsens due to leading edge spikes obscuring initial continuous current

Engineering Contradiction:
Improveinitial continuous current informationVSAvoidcurrent measurement accuracy
Core Design Contradiction:
Loss of informationVSMeasurement precision

Solution Approach 1:

The patent converts the harmful leading edge spike into a useful timing reference. By identifying the valley point (minimum current point) and using it as a reference for subsequent measurements, the system transforms the problematic spike region into a beneficial synchronization point that enables accurate measurement of the continuous current component that would otherwise be obscured.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent employs dynamic timing-based measurement where the sampling points are positioned at specific phases of the switching cycle rather than at fixed time intervals. This dynamic approach allows measurements to be taken at optimal moments (valley point, turn-on phase points) that capture the continuous current information while naturally filtering out the transient leading edge spike effects.

Inventive Principle:
Principle #15Dynamics

3Adaptability or versatility

If conventional measurement approaches are used, then average output current can be measured, but output power measurement capability is lost

Engineering Contradiction:
Improvemeasurement capabilityVSAvoidmeasurement accuracy
Core Design Contradiction:
Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The patent creates a universal measurement system that can determine both average output current and output power using the same sampling circuit and timing-based approach. By measuring the current sense signal at multiple predetermined timing points during the switching cycle, the system can calculate both current and power parameters from the same measurement infrastructure, eliminating the need for separate measurement circuits.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentUS10541618B2Method and apparatus for measuring at least one of output current and output power for isolated power converters
Publication Date: 2020.01.21 INFINEON TECH AUSTRIA AG
  • US10541618B2 patent drawing
  • US10541618B2 patent drawing
  • US10541618B2 patent drawing

AI summary

A flyback converter includes a primary-side switch connected to a primary-side winding of a magnetic device and a secondary-side switch connected to a secondary-side winding of the magnetic device. The flyback converter is operated by controlling the primary-side switch to store energy in the magnetic device during ON periods of the primary-side switch, switching on the secondary-side switch synchronously with switching off the primary-side switch to transfer energy from the magnetic device to the secondary side, determining an off time of the secondary-side switch based on a reflected input voltage measured at the secondary-side winding when the primary-side switch is on, accounting for a settling time of the reflected input voltage when determining the off time of the secondary-side switch so that the settling time has little or no effect on the off time, and switching off the secondary-side switch based on the off time.