High Density Isolated DC-to-DC Converter Startup Control
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Solution Overview
Problem
High input voltage DC-to-DC power converters require large, low-frequency bias supplies for secondary side control, leading to increased space consumption on printed circuit boards due to the need for additional isolated bias voltage generators, which is undesirable for compact designs.
Innovation Solution
A DC-to-DC power converter system where a primary microcontroller initiates a start-up sequence and transfers control to a secondary microcontroller upon completion, allowing the exclusion of separate isolated bias voltage generators by using a transformer and microcontrollers to manage energizing signals, enabling efficient high-density conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate isolated bias voltage generators are added to power the secondary microcontroller, then the converter can achieve secondary side control functionality, but the physical footprint and space consumption on the PCB increase
Solution Approach 1:
The patent merges the bias voltage generation function with the existing primary side power converter by using the primary microcontroller to control the power stage during startup, eliminating the need for a separate isolated bias voltage generator. The primary microcontroller directly energizes the power circuitry to generate the bias voltage needed by the secondary microcontroller, combining multiple functions into a single integrated solution that reduces PCB space while maintaining secondary side control capability.
2Measurement precision
If high input voltage DC-to-DC power converters are designed with secondary side control, then control precision and monitoring capability are improved, but device complexity increases due to additional components
Solution Approach 1:
The patent makes the primary microcontroller multi-functional by having it perform both the traditional primary side control functions and the additional function of generating bias voltage for the secondary microcontroller during startup. This universal approach allows a single component to serve multiple purposes, reducing the total component count while maintaining the control precision and monitoring capabilities provided by secondary side control.
Solution Approach 2:
The primary microcontroller serves itself by using its existing control capabilities to generate the bias voltage needed by the secondary microcontroller. Instead of requiring an external dedicated bias supply, the system uses the primary controller's own power stage to create the necessary voltage, allowing the system to be self-sufficient and reducing overall complexity.
3Volume of moving object
If the converter is designed for high density with reduced physical footprint, then space efficiency is improved, but the ability to accommodate separate bias supplies is compromised
Solution Approach 1:
The patent extracts the bias voltage generation function from the traditional separate isolated bias supply and integrates it into the primary side power converter control. By removing the need for dedicated bias supply components and using the primary microcontroller to directly control power stage energization, the design achieves high density with reduced footprint while maintaining the flexibility to provide bias voltage to the secondary microcontroller.
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 solution reduces the physical footprint of DC-to-DC power converters by eliminating the need for separate bias supplies, allowing for compact and efficient high-density isolated DC-DC conversion, especially in applications requiring secondary side control.
Implementation Method 1
a transformer including a primary side and a secondary side
Data Source
AI summary
A DC-to-DC power converter includes a transformer having a primary side and a secondary side, and a primary circuit electrically coupled to the primary side of the transformer. The primary circuit includes a primary microcontroller configured to generate a first energizing signal that energizes a portion of the primary circuit. The DC-to-DC power converter also includes a secondary circuit electrically coupled to the secondary side of the transformer. The secondary circuit includes a secondary microcontroller communicatively coupled to the primary microcontroller, wherein the secondary microcontroller is configured to provide an instruction to the primary microcontroller that causes the primary microcontroller to relinquish control of the primary circuit to the secondary microcontroller, and wherein the secondary microcontroller is further configured to provide a second energizing signal to the portion of the primary circuit.