Switch-mode Power Supply Controller Voltage Estimation
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Solution Overview
Problem
Existing switch-mode power supplies face challenges in achieving reliable and universal on-line power processing efficiency optimization due to the need for expensive, power-hungry, and application-specific mixed-signal circuits and algorithms, which are not adequately noise-tolerant and smooth in controller mode transitions.
Innovation Solution
A method for estimating input voltage using a lookup table correlating magnetizing inductance discharge times with input voltages, and generating power efficiency optimization curves for combinations of input and output voltages and flyback cell switching device off-times, allowing for efficient selection of optimal switching times using multi-mode controllers in flyback-based switch-mode power supplies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If expensive, power-hungry mixed-signal circuits and algorithms are used to achieve accurate power processing efficiency optimization, then power processing efficiency is improved, but device complexity and power consumption increase
Solution Approach 1:
The patent replaces complex mixed-signal circuits with a digital processor that executes software algorithms. The controller uses a processor running on-chip software to perform power processing efficiency optimization, substituting hardware complexity with software-based control. This allows accurate efficiency optimization while reducing device complexity and power consumption associated with dedicated mixed-signal circuitry.
Solution Approach 2:
The patent dynamically adjusts controller operating parameters based on real-time measurements of power processing efficiency. The processor monitors efficiency metrics and modifies switching frequencies, duty cycles, and operational modes to optimize performance. This parameter-based approach enables adaptive efficiency optimization without requiring complex dedicated circuits for each adjustment.
2Manufacturing precision
If application-specific mixed-signal circuits are used for precise controller mode transitions, then control precision is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent replaces application-specific mixed-signal circuits with a programmable processor that executes mode transition algorithms. The processor software manages controller mode transitions, providing precise control through software logic rather than dedicated hardware circuits. This reduces device complexity while maintaining manufacturing precision through programmable control sequences.
Solution Approach 2:
The patent employs a universal processor-based controller that can handle multiple functions including mode transitions, efficiency optimization, and parameter adjustments through software. This single programmable unit replaces multiple application-specific circuits, reducing overall device complexity while maintaining precise control across different operational modes through software configuration.
3Reliability
If complex mixed-signal circuits are implemented for noise-tolerant operation, then reliability is improved, but power consumption and device complexity increase
Solution Approach 1:
The patent replaces power-hungry mixed-signal circuits with a digital processor that implements noise filtering and tolerance through software algorithms. The processor executes digital signal processing routines that provide noise immunity without the high power consumption of analog mixed-signal circuitry. This maintains reliability while significantly reducing controller power consumption.
4Measurement precision
If accurate input voltage estimation is implemented using lookup tables and discharge time measurement, then measurement precision is improved, but measurement time and complexity increase
Solution Approach 1:
The patent pre-calculates and stores voltage estimation data in lookup tables during system initialization or manufacturing. The lookup tables contain pre-computed relationships between discharge times and input voltages, allowing the processor to quickly estimate voltage by simple table lookup rather than performing complex real-time calculations. This provides accurate voltage measurement while minimizing measurement time and processor workload.
Solution Approach 2:
The patent uses lookup tables that store pre-computed voltage estimation data as copies of the complex calculation results. Instead of performing time-consuming voltage calculations in real-time, the processor retrieves pre-stored estimation values from the lookup tables based on measured discharge times. This copying approach maintains measurement precision while dramatically reducing the time required for voltage estimation.
Data Source
AI summary
A switch-mode power supply controller controls a circuit that includes a flyback-based, switch-mode power supply in the context of an input voltage source, a USB Type-C PD controller and an output load. The switch-mode power supply controller may be configured to estimate input voltage based on a measured magnetizing inductance discharge time. Furthermore, the switch-mode power supply controller may be configured to estimate output voltage based on the measured magnetizing inductance discharge time and the estimated input voltage. Still further, the estimated voltages may be used by the switch-mode power supply controller to limit certain currents and optimize power efficiency. Even further, the estimated and measured value may be employed by the switch-mode power supply controller to estimate and indicate brownout conditions.