PFC Stage Voltage Control for Switching Power Supply Start-Up

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Solution Overview

Problem

Off-line switching power supplies face challenges in maintaining operation when AC input voltage exceeds the target level set for the PFC stage, leading to premature cessation of switching and insufficient auxiliary power generation, causing the entire power converter to shut down.

Innovation Solution

The PFC stage is configured to temporarily set its target level higher than the steady-state level during start-up, allowing the power supply to commence operation even when AC input voltage is higher than the normal range, and then returns to the steady-state level once operational, with additional target levels for light loading conditions to optimize efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the PFC stage target level is set to the steady-state level during start-up, then the power supply cannot operate when AC input voltage exceeds the target level, but if the target level is set higher during start-up, then the power supply can operate with higher AC input voltages but requires additional control complexity

Engineering Contradiction:
Improvestart-up operation reliabilityVSAvoidcontrol circuit complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The PFC stage target level is made dynamic rather than fixed. During start-up, the target level is temporarily increased to allow operation with higher AC input voltages. Once the power supply reaches steady-state operation, the target level returns to the normal steady-state level. This dynamic adjustment resolves the contradiction by adapting the target level to the operational phase, ensuring reliable start-up without permanently increasing control complexity.

Inventive Principle:
Principle #15Dynamics

2Reliability

If the PFC stage target level is fixed at steady-state level, then the power supply shuts down when AC input voltage is too high, but if the target level is increased, then efficiency decreases under normal operating conditions

Engineering Contradiction:
Improveoperation continuityVSAvoidenergy efficiency
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The PFC stage target level is adjusted periodically based on the operational phase. During the transient start-up phase, the target level is increased to prevent shutdown from high AC input voltage. During steady-state operation, the target level returns to the optimal steady-state level for maximum efficiency. This periodic adjustment between different target levels resolves the contradiction by applying the appropriate target level at the appropriate time.

Inventive Principle:
Principle #19Periodic action

3Productivity

If a single target level is used for all operating conditions, then the power supply cannot optimize efficiency under light loading conditions, but if multiple target levels are implemented, then the control system becomes more complex

Engineering Contradiction:
Improveoperational efficiencyVSAvoidcontrol system complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

Different target levels are applied to different operational phases and loading conditions. The system implements a first target level for start-up conditions, a second target level for steady-state full loading conditions, and a third target level for light loading conditions. This local optimization of target levels for specific operating conditions resolves the contradiction by improving efficiency where needed without requiring complete system redesign.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS11228237B2Switching power supply and start-up improvements thereof
Publication Date: 2022.01.18 CHAMPION MICROELECTRONICS CORP
  • US11228237B2 patent drawing
  • US11228237B2 patent drawing
  • US11228237B2 patent drawing

AI summary

The present invention is directed toward a switching power supply and improvements thereof. In accordance with an embodiment, a switching power supply is provided. The switching power supply comprises: a first power supply stage that forms an intermediate regulated voltage; and a second power supply stage configured to accept the intermediate regulated voltage and configured to form a regulated output voltage, wherein the intermediate voltage is set to an initial target level upon start-up of the power supply and wherein the intermediate regulated voltage is set to a second target level during steady-state operation of the power supply.