Power Converter Adaptive Output Control via Single Opto-Coupler
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Solution Overview
Problem
Current power converter control methods, such as Primary Side Regulation (PSR), Secondary Side Regulation (SSR), and combined regulation, face challenges including high costs, inefficiencies, and complexity due to the use of sensing resistors and multiple opto-couplers, which affect the precision and reliability of controlling output voltages and currents for adaptive devices.
Innovation Solution
The use of a single opto-coupler and supporting circuitry to communicate load requests from adaptive devices to the primary side of a power converter, allowing sophisticated control of output currents and voltages without the need for sensing resistors and additional opto-couplers, by encoding communication requests into feedback signals and adjusting transformer coils to meet desired output levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If Secondary Side Regulation (SSR) with sensing resistor and multiple opto-couplers is used, then output voltage and current control precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the sensing resistor from the system by using the existing feedback signal from the secondary side. Instead of adding a separate sensing resistor to measure output current, the invention utilizes the feedback signal already present in SSR circuits, thereby removing the harmful component while maintaining measurement capability.
Solution Approach 2:
The patent merges the functions of multiple opto-couplers into a single opto-coupler. By combining the feedback signal processing and communication functions into one opto-coupler, the system achieves the same control precision with reduced component count, lower cost, and decreased complexity.
2Measurement precision
If sensing resistor is used for output current sensing, then current measurement precision is improved, but power consumption and cost increase
Solution Approach 1:
The patent removes the sensing resistor from the circuit by extracting the current measurement function from a separate physical component. Instead, the current measurement is performed using the feedback signal that already exists in the SSR system, eliminating the power consumption associated with the sensing resistor while maintaining measurement precision.
3Measurement precision
If multiple opto-couplers are used for controlling output voltage and current, then control precision is improved, but cost and device complexity increase
Solution Approach 1:
The patent combines the functions of multiple opto-couplers into a single opto-coupler. The single opto-coupler processes both the feedback signal and communication requests, integrating the control functions for both output voltage and current into one component. This merging maintains control precision while significantly reducing device complexity and cost.
Solution Approach 2:
The single opto-coupler in the patent performs multiple functions: it transmits feedback signals from the secondary side, communicates load requests from adaptive devices, and enables both voltage and current control. This multi-functionality eliminates the need for separate opto-couplers while maintaining full control capability.
4Device complexity
If Primary Side Regulation (PSR) without opto-couplers is used, then device complexity is reduced, but output voltage and current control precision deteriorates
Solution Approach 1:
The patent introduces a single opto-coupler as an intermediary between the primary and secondary sides. This opto-coupler enables precise communication of feedback signals and load requests, providing the measurement precision needed for accurate control while maintaining the simplicity of PSR architecture. The opto-coupler acts as a mediator that bridges the two sides without adding significant complexity.
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 reduces costs, energy consumption, and complexity while achieving precise control of output voltages and currents, improving efficiency and reliability in adapting to varying load requests from adaptive devices.
Implementation Method 1
an opto-coupler configured to communicate a communication request in a feedback signal generated by the secondary controller
Data Source
AI summary
Embodiments of devices, systems, and methods for controlling the output voltages and currents of a power converter as requested by an adaptive device are described. In one embodiment, a power converter includes a primary controller, a secondary controller, and an opto-coupler configured to communicate a communication request, including a load request, by a secondary controller to a primary controller in a feedback signal. A method may include the operations of: executing a request cycle, by extending an “ON” state for a secondary switch, detecting a slope change in a scaled primary voltage signal, entering a communication-ready mode, converting a load request into communication information communicated in a feedback signal using an opto-coupler, decoding the communication information, and adjusting at least one of a reference voltage for output current and a reference voltage.