PSR Controller with Non-Volatile Shift Register for Output Regulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Primary-side regulation (PSR) power supplies often operate outside specified bounds due to variations in semiconductor manufacturing and packaging processes, leading to inconsistent output voltage and current levels across different units, despite adjustments and trimming at the final test stage.
Innovation Solution
A novel PSR controller integrated circuit with a non-volatile shift register is used, allowing for in-circuit testing and programming to adjust output voltage and current settings, compensating for variations in transformer inductance, line input voltage, efficiency, and cord resistance, ensuring all units operate within specified limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adjustments and trimming are performed at the final test stage, then some compensation for component variations can be achieved, but output voltage and current still operate outside specified bounds due to manufacturing variations
Solution Approach 1:
The patent applies preliminary action by measuring and storing compensation values during the manufacturing process for each individual power supply unit. These compensation values are programmed into non-volatile memory before the product leaves the factory, allowing the unit to self-correct for its specific component variations throughout its operational life, ensuring consistent output within specified bounds across all units.
2Manufacturing precision
If in-circuit testing and programming is implemented, then all units can be ensured to operate within specified limits, but the manufacturing process complexity increases
Solution Approach 1:
The patent implements self-service by having each power supply unit automatically measure its own component variations during manufacturing and program its own compensation values into its non-volatile memory. The controller measures the actual output characteristics, calculates the necessary compensation, and stores these values in the shift register, eliminating the need for complex external programming equipment and reducing manufacturing process complexity.
3Reliability
If compensation for component variations is implemented, then output consistency is improved, but additional circuitry and programming capability are required
Solution Approach 1:
The patent applies universality by designing the controller to perform multiple functions: it controls the primary switch, measures output voltage and current, calculates compensation values, and programs the non-volatile memory. The non-volatile shift register is also multi-functional, serving as both a programming interface during manufacturing and a storage medium for compensation values during operation, reducing the need for separate dedicated circuits.
Data Source
AI summary
A primary-side regulation (PSR) controller integrated circuit includes a PSR CC/CV controller and a non-volatile shift register. An assembled power supply that includes the integrated circuit is in-circuit tested to determine errors in power supply output voltage and/or current. Programming information is determined and shifted into the shift register. During programming, the power supply regulates to a different output voltage, and the different voltage is used for shift register programming. After programming, the power supply operates in a normal mode so that the output voltage and current are within specification. The voltage and current to which the power supply regulates are set by some of the bits of the programming information. Other of the bits set error correction circuits of the PSR CC/CV controller such as a primary inductance variation compensation circuit, a line input voltage variation compensation circuit, an efficiency variation compensation circuit, and a cord resistance compensation circuit.