Power Converter Stage With Bidirectional Inductive Coupling
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Solution Overview
Problem
Conventional power converters face challenges in providing a reliable auxiliary supply to control circuitry during all operation modes without incurring additional costs, especially when transitioning to stand-by mode, where existing solutions either cut off power or require increased component costs.
Innovation Solution
A power converter stage with a first and second power storing means, primary and secondary inductance, and a controller that enables power transfer between these components through inductive coupling, allowing for internal power storage and supply to the controller during stand-by mode without interfering with the stand-by status, using a synchronous boost converter arrangement with power MOSFET switches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the auxiliary supply is integrated into power converter stages (e.g., PFC stage with auxiliary winding), then the converter structure is simplified and costs are reduced, but the control circuitry loses power supply during stand-by mode
Solution Approach 1:
The power converter stage operates dynamically in different modes (normal mode and stand-by mode) with bidirectional power transfer capability. During normal mode, power flows from input to output; during stand-by mode, power flows bidirectionally between input and output to maintain control circuitry power supply, enabling the system to adapt its operation based on the operational state
Solution Approach 2:
The power converter stage serves multiple functions: it performs power conversion during normal operation and simultaneously functions as an auxiliary power supply during stand-by mode. The same stage and components are utilized for both primary power conversion and control circuitry power supply, eliminating the need for separate auxiliary supply components
2Reliability
If an independent auxiliary supply (e.g., additional flyback converter) is implemented, then continuous power to control circuitry during all modes is achieved, but component count and costs increase
Solution Approach 1:
The existing power converter stage is made multi-functional to serve both primary power conversion and auxiliary power supply purposes. By enabling bidirectional power transfer in the same stage, the patent eliminates the need for separate auxiliary supply components like additional flyback converters, reducing component count while maintaining continuous control power supply
Solution Approach 2:
The auxiliary power supply function is merged with the main power converter stage. The same inductors, switches, and control circuitry are utilized for both power conversion and auxiliary power supply functions, combining multiple functions into a single integrated stage rather than using separate independent supplies
3Reliability
If power transfer between power storing means is enabled during stand-by, then continuous power to controller is achieved, but stand-by losses may increase
Solution Approach 1:
During stand-by mode, power transfer operates periodically rather than continuously. The controller activates power transfer only when needed to maintain the voltage across the output capacitor within acceptable ranges, allowing the system to enter low-loss states when full power transfer is not required, thus minimizing stand-by losses while ensuring continuous controller power supply
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 ensures continuous power supply to the controller during all operation modes while maintaining high efficiency and avoiding increased costs, with stand-by losses comparable to other known solutions, and prevents over-voltage across capacitors.
Implementation Method 1
a secondary inductance inductively coupled to the primary inductance for supplying power to the power converter controller
Data Source
AI summary
The invention relates to a power converter stage (2) for providing power supply to a power converter controller (3), a power converter controller (3) for such power converter stage (2), a power converter (1) including such power converter stage (2) and such power converter controller (3), a method for providing power to a controller (3) of a power converter (1) and a software product for controlling a power converter (1). In order to provide for auxiliary power supply for control circuitry of a power converter (1) during all operation modes of the power converter (1) while avoiding additional costs involved with providing a dedicated control power supply fed from bus voltage, it is proposed that power stored in power storing means (4, 5) included in a power converter stage (2) or more generally in a power converter (1) are used for supply to the controller (3) even if the power converter is in stand-by mode, as a transfer of power between such power storing means (4,5) through a primary inductance (6) may be used for providing also for a power transfer to a secondary inductance (7), which then supplies the controller (3).