Power Control Module Sequential Startup Circuit

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Solution Overview

Problem

Power control circuits face challenges in minimizing board space, cost, and startup time due to the need for larger capacitors to supply initial power to microprocessors and other circuits simultaneously, leading to delayed operation and increased complexity.

Innovation Solution

A power control device with a startup circuit that generates a drive power supply and provides current to the controller and drive unit based on signals, featuring a PFC and DC-DC converter that operate sequentially to optimize power distribution, reducing initial current demand and allowing earlier microprocessor activation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a larger capacitor is used to supply initial power to the microprocessor and other circuits simultaneously, then the microprocessor can be powered up reliably, but the board space increases and the startup time increases

Engineering Contradiction:

Improvemicroprocessor power-up reliabilityVSAvoidboard space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The power-up process is segmented into sequential phases: first the PFC circuit is powered and stabilized, then the DC-DC converter is activated, and finally the microprocessor is powered up. This segmentation allows each component to draw power in sequence rather than simultaneously, reducing the peak current requirement and enabling the use of a smaller capacitor while maintaining reliable microprocessor power-up.

Inventive Principle:

Principle #1Segmentation

2Reliability

If a larger capacitor is used to supply initial power to the microprocessor and other circuits simultaneously, then the microprocessor can be powered up reliably, but the startup time increases

Engineering Contradiction:

Improvemicroprocessor power-up reliabilityVSAvoidstartup time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The PFC circuit is activated in advance to establish a stable intermediate voltage before the microprocessor is powered up. This preliminary action ensures that when the microprocessor does start, the power supply infrastructure is already in place and stable, reducing the startup time while maintaining reliability without requiring a larger capacitor.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If all circuits are powered up simultaneously, then the power distribution is simple, but the initial current demand increases and delays operation

Engineering Contradiction:

Improvepower distribution complexityVSAvoidinitial current demand

Core Design Contradiction:

Device complexityVSPower

Solution Approach 1:

The power distribution system transitions from a static simultaneous power-up approach to a dynamic sequential power-up approach. Control signals dynamically enable the PFC circuit first, then the DC-DC converter, and finally the microprocessor. This dynamic control manages peak current demand while the added control logic complexity is minimal, involving only a few control signals and timing circuits.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10637361B2Power control module with improved start requirements

Publication Date: 2020.04.28 SANKEN ELECTRIC CO LTD

AI summary

Circuits and devices are described that provide power to appliances and other devices via a power correction circuit and an LLC converter, which may for example include resonant series converters and flyback converters. The circuits and devices economize on board space, part size and power start up time by separately powering up the controller circuit portion prior to powering up the LLC converter.