Integrated Circuit Power Factor Correction Control

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Solution Overview

Problem

Existing power factor correction circuits in AC-DC converters face challenges in maintaining a high power factor due to distortion in input current when the AC voltage is applied to an input capacitor, leading to dead angles and total harmonic distortion (THD).

Innovation Solution

The integrated circuit incorporates an oscillator circuit, error voltage output circuit, and drive circuit to control the inductor current flowing through an inductor, adjusting the on-time of a transistor based on rectified AC voltage levels, ensuring the input current waveform resembles the AC voltage waveform, thereby improving the power factor and reducing THD.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the AC voltage is applied to an input capacitor of an AC-DC converter, then the power supply circuit can generate output voltage, but distortion occurs in the input current and the power factor is degraded

Engineering Contradiction:
Improvepower factorVSAvoidinput current distortion
Core Design Contradiction:
PowerVSObject-generated harmful factors

Solution Approach 1:

The patent implements a feedback control mechanism where the control circuit continuously monitors the inductor current and adjusts the transistor switching duty cycle accordingly. The control circuit compares the actual inductor current with the desired current waveform and modifies the switching signals to minimize distortion and maintain high power factor. This closed-loop feedback system ensures that the input current waveform follows the AC voltage waveform closely.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent employs dynamic adjustment of the transistor switching duty cycle based on real-time operating conditions. The control circuit dynamically changes the on-time and off-time of the transistor to maintain optimal power factor correction across varying load conditions and AC voltage levels. This dynamic control allows the system to adapt to changing conditions and maintain high power factor performance.

Inventive Principle:
Principle #15Dynamics

2Power

If the transistor on-time is increased to improve power factor, then input current waveform improves, but the circuit complexity increases

Engineering Contradiction:
Improvepower factorVSAvoidcontrol circuit complexity
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

The patent combines multiple control functions into a single integrated control circuit that simultaneously manages oscillation generation, duty cycle control, and power factor correction. The control circuit integrates the oscillator, comparator, and switching control functions in one unit, reducing overall system complexity while maintaining effective power factor correction. This merged approach eliminates the need for separate control modules and simplifies the control architecture.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The control circuit is designed to perform multiple functions simultaneously: generating oscillation signals, monitoring inductor current, comparing with reference waveforms, and controlling transistor switching. This multi-functional control circuit reduces the need for separate dedicated circuits for each function, thereby reducing overall device complexity while maintaining comprehensive power factor correction capability.

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

Data Source

PatentUS11632039B2Integrated circuit and power supply circuit
Publication Date: 2023.04.18 FUJI ELECTRIC CO LTD
  • US11632039B2 patent drawing
  • US11632039B2 patent drawing
  • US11632039B2 patent drawing

AI summary

An integrated circuit for a power supply circuit. The integrated circuit includes an oscillator circuit configured to output an oscillator voltage that rises with a predetermined slope from a first voltage, upon an inductor current of the power supply circuit becoming smaller than a first predetermined value, an error voltage output circuit configured to output an error voltage corresponding to a difference between a reference voltage and a feedback voltage corresponding to the output voltage, a drive circuit configured to turn on and off a transistor of the power supply circuit respectively upon the inductor current becoming smaller than the first predetermined value, and upon the oscillator voltage reaching a second voltage that is based on the error voltage, and an output circuit configured to change the first and/or second voltage based on a rectified voltage obtained by full-wave rectification of the AC voltage, and to output the changed voltage.