Interleaved Resonant Converter Current Sharing Control
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Solution Overview
Problem
Interleaved resonant converters face current-sharing challenges due to fabrication and process tolerance mismatches, leading to inefficiencies, thermal stability issues, and potential system damage from variations in output current amplitudes across phases.
Innovation Solution
A switching controller adjusts the duty-cycle of switching signals across phases based on feedback currents to equalize output currents and voltages, using a duty-cycle and frequency controller to dynamically compensate for differences in resonant converter gains, thereby ensuring balanced interleaving without additional circuitry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple phases of resonant converters are interleaved to meet high power requirements, then power output is improved, but current-sharing problems occur due to fabrication and process tolerance mismatches
Solution Approach 1:
The patent implements a feedback mechanism where the controller monitors output currents from multiple resonant converter phases and dynamically adjusts duty cycles to equalize current distribution. This closed-loop control compensates for fabrication and process tolerance mismatches, ensuring reliable current sharing across all phases while maintaining high power output capability.
Solution Approach 2:
The patent employs dynamic duty cycle adjustment for each phase based on real-time current measurements. Rather than using fixed duty cycles, the controller continuously adapts the switching parameters to balance current distribution, allowing the system to maintain optimal performance despite variations in component characteristics and loading conditions.
2Reliability
If duty cycles are adjusted to compensate for current mismatches, then current-sharing balance is improved, but control complexity increases
Solution Approach 1:
The patent uses a single integrated controller that performs multiple functions: monitoring output currents from all phases, comparing current levels, calculating appropriate duty cycle adjustments, and generating switching signals. This multi-functional approach consolidates what could be multiple separate control circuits into one device, managing complexity while achieving precise current balancing.
Solution Approach 2:
The control system automatically detects current mismatches and adjusts duty cycles without external intervention. The controller continuously monitors the system state and self-corrects imbalances, eliminating the need for manual calibration or complex external control circuitry while maintaining reliable current sharing.
3Reliability
If tight manufacturing tolerances are enforced to reduce current variations, then current-sharing balance is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the operational parameters (duty cycles) of each phase dynamically to compensate for fixed manufacturing variations. Instead of requiring tight control of physical parameters during manufacturing, the system adjusts electrical parameters during operation, allowing standard manufacturing tolerances while achieving balanced current distribution through software-based compensation.
Solution Approach 2:
The patent replaces mechanical/physical precision requirements with electronic control. Rather than relying on precisely matched physical components, the system uses digital control algorithms to equalize current distribution, substituting manufacturing precision with computational compensation and reducing dependency on tight manufacturing tolerances.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach achieves balanced interleaving, enhances efficiency, maintains thermal stability, and reduces manufacturing costs by eliminating the need for tight manufacturing tolerances, while being scalable and versatile across multiple phases and power settings.
Implementation Method 1
Each of the resonant converter circuits includes a transformer configured to induce a switching current from a primary winding of the transformer to a secondary winding of the transformer, wherein the output voltage is generated via the induced switching current through the secondary winding of the transformer.
Data Source
AI summary
One example includes an interleaved resonant converter circuit. The circuit includes a plurality of resonant converter circuits that are each coupled to an output node and are configured to collectively generate an output voltage on the output node in response to a respective plurality of sets of switching signals at each of a respective plurality of phases. The circuit also includes a switching controller configured to generate each of the plurality of sets of switching signals having a variable duty-cycle relative to each other at each of the plurality of phases.