PWM Controller Green Mode Transition for Power Loss Reduction

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Solution Overview

Problem

Conventional pulse width modulation controllers fail to efficiently transition between normal and green modes, leading to significant power wastage during light load or no load conditions, as they continue to operate at a fixed frequency regardless of load, resulting in reduced efficiency and increased power dissipation.

Innovation Solution

A pulse width modulation controller that smoothly transitions between normal and green modes by adjusting the ON-time of the drive signal, entering green mode when the ON-time falls below a threshold, and releasing a drive signal when the total ON-time reaches a predetermined threshold or the output voltage drops, thereby reducing switching frequency and power consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the controller continues driving the power converter at a fixed frequency during light load or no load conditions, then the controller operates simply without complex mode switching, but power consumption increases significantly and efficiency drops

Engineering Contradiction:
Improvecontroller operation simplicityVSAvoidpower consumption
Core Design Contradiction:
Ease of operationVSLoss of energy

Solution Approach 1:

The controller dynamically adjusts the switching frequency based on load conditions. During heavy load, it operates at a higher frequency to meet power demands, while during light load or no load conditions, it automatically reduces the switching frequency to minimize power consumption. This dynamic frequency adjustment resolves the contradiction by making the controller adapt its operation complexity and power usage to actual load requirements rather than maintaining a fixed simple operation mode.

Inventive Principle:
Principle #15Dynamics

2Loss of energy

If the controller switches to green mode with reduced switching frequency during light load, then power consumption decreases and efficiency improves, but the transition between normal mode and green mode becomes complex to design

Engineering Contradiction:
Improvepower consumptionVSAvoidcircuitry transition design
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The controller uses parameter changes to manage the transition between normal mode and green mode. Specifically, it monitors the pulse width of drive signals and compares it against a threshold value. When the pulse width falls below the threshold, indicating light load conditions, the controller automatically transitions to green mode with reduced switching frequency. This parameter-based transition mechanism simplifies the circuitry design compared to complex mode-switching circuits, while still achieving effective power consumption reduction.

Inventive Principle:
Principle #35Parameter changes

3Loss of energy

If the controller reduces switching frequency to low value in green mode, then efficiency increases during light load, but the ON time of pulses must remain constant which limits control flexibility

Engineering Contradiction:
Improveswitching lossesVSAvoidcontrol flexibility
Core Design Contradiction:
Loss of energyVSAdaptability or versatility

Solution Approach 1:

The controller implements periodic action by accumulating pulse widths over multiple switching cycles in green mode. Instead of maintaining a constant ON time which would limit control flexibility, the controller sums up the pulse widths of multiple individual pulses and compares the accumulated value against a threshold. This periodic accumulation approach allows each individual pulse to be short (reducing switching losses), while the cumulative effect over multiple cycles maintains the necessary total energy transfer, thus preserving control flexibility while achieving efficiency improvements.

Inventive Principle:
Principle #19Periodic action

Data Source

PatentUS7436233B2Normal mode and green mode pulse width modulation controller
Publication Date: 2008.10.14 SYNC POWER CORP
  • US7436233B2 patent drawing
  • US7436233B2 patent drawing
  • US7436233B2 patent drawing

AI summary

A PWM controller that effectively transitions between normal mode and green power mode is disclosed. A driver provides a normal drive signal during normal operation. A pulse width detector detects the pulse width of the PWM signal and if the pulse width drops below a threshold the normal mode drive signal will be turned off and a pulse ON time measurer will begin storing the pulse ON time. When the total ON time reaches a total ON time threshold or the output voltage drops below a voltage limit, a green mode drive signal will be output to the power converter. During green mode the driver will continue sending the green mode drive signal at intervals until a heavy load condition when the green mode drive signal will be shut off and the driver will resume sending the normal mode drive signal.