Switching Power Supply Parallel Leg Control for Loss Distribution

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Solution Overview

Problem

Switching power supplies face increased power losses and cooling demands due to higher power ratings and switching frequencies, leading to uneven distribution of losses among paralleled switching devices, which can result in premature failure of individual devices.

Innovation Solution

A system and method for controlling paralleled switching devices by generating a carrier signal at a first frequency and a reference signal based on input voltage to create control signals for each device, enabling switching devices in a sequence at a second frequency, which is a fraction of the carrier frequency, to distribute losses evenly and reduce switching and conduction losses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple switching devices are connected in parallel to increase overall power rating, then power handling capability is improved, but uneven distribution of power losses occurs leading to premature device failure

Engineering Contradiction:
Improveoverall power ratingVSAvoiddevice lifespan
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The patent implements periodic action by sequentially enabling switching devices in different legs at different times within each switching cycle. The controller enables switching devices in a rotating sequence across multiple legs, where each leg is enabled for one switching cycle and then skipped for the next cycle. This periodic sequential enabling ensures that power losses are evenly distributed among all paralleled devices over time, preventing any single device from bearing excessive losses and failing prematurely, while maintaining the increased overall power rating provided by the parallel configuration.

Inventive Principle:
Principle #19Periodic action

2Productivity

If switching frequency is increased to improve power conversion efficiency, then productivity is improved, but switching losses increase requiring increased cooling capacity

Engineering Contradiction:
Improvepower conversion efficiencyVSAvoidswitching losses
Core Design Contradiction:
ProductivityVSLoss of energy

Solution Approach 1:

The patent applies segmentation by dividing the switching operation across multiple separate legs, each with its own switching device. Instead of having all devices switch simultaneously at high frequency, the controller segments the switching duty by enabling one leg at a time in sequence. This segmentation reduces the cumulative switching losses because not all devices are transitioning simultaneously, thereby reducing the total switching losses even at high switching frequencies while maintaining efficient power conversion.

Inventive Principle:
Principle #1Segmentation

3Reliability

If synchronization routines are implemented to equalize switching times of paralleled devices, then reliability is improved, but device complexity increases

Engineering Contradiction:
Improvesynchronized switchingVSAvoidcontrol circuit complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent inverts the conventional synchronization approach. Instead of attempting to synchronize all switching devices to turn on and off simultaneously through complex feedback and timing adjustment circuits, the controller deliberately enables devices in a simple sequential pattern where each leg is enabled for one cycle and skipped the next. This inverted approach achieves reliable power loss distribution without requiring complex synchronization routines, thereby improving reliability while minimizing control circuit complexity.

Inventive Principle:
Principle #13The other way round (Inversion)

Data Source

PatentEP3174188B1System and method for controlling parallel legs in a switched mode power supply
Publication Date: 2019.05.15 ROCKWELL AUTOMATION TECH INC
  • EP3174188B1 patent drawingFigure 1~2
  • EP3174188B1 patent drawingFigure 3~4
  • EP3174188B1 patent drawingFigure 5~6

AI summary

An improved system and method for controlling multiple, paralleled switching devices (32) in a switching power supply (30) is disclosed. The switching power supply (30) includes parallel legs (31) between voltage rails (42, 44) on the input where each leg is connected to a common output. Each leg (31) may have a single switching device (32) or pairs of switching devices. According to one embodiment of the invention, the switching device(s) (32) for each leg (31) is enabled during one carrier period (D1) and the leg (31) having switching devices enabled is alternated during subsequent carrier periods (D1). According to another embodiment of the invention, the switching device(s) (32) for each leg (31) are enabled during each carrier period (D1); however, the switching device(s) (32) for one leg (31) are enabled within the carrier period (D1) prior to the switching device(s) (32) for the other legs (31) and the first leg (31) to be enabled is alternated during successive carrier periods (D1).