Switching Voltage Regulator Charging Control for Overvoltage Prevention
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Solution Overview
Problem
Charging systems for energy storage devices often result in overvoltage due to high effective series resistance (ESR), leading to reduced lifespan and inefficient charging, as conventional linear regulators have high power dissipation and slow charging times.
Innovation Solution
A charging system with a controller that monitors output voltage and current, generating a PWM control signal to adjust the output current of a switching voltage regulator, reducing the current in a step-by-step manner when the voltage exceeds a predetermined threshold, mimicking constant current charging while preventing overvoltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a switching voltage regulator is used for charging, then charging speed is improved, but overvoltage occurs due to high ESR leading to reduced device lifespan
Solution Approach 1:
The patent implements a feedback mechanism where the charging controller continuously monitors the output voltage of the switching voltage regulator. When the output voltage exceeds a predetermined threshold, the controller generates a control signal to reduce the output current. This closed-loop feedback system prevents overvoltage conditions while maintaining fast charging speeds, thereby extending energy storage device lifespan without sacrificing charging productivity.
2Reliability
If a linear regulator is used for charging, then overvoltage is reduced, but power dissipation increases and charging time becomes slower
Solution Approach 1:
The patent replaces the traditional linear regulator (which dissipates excess voltage as heat) with a switching voltage regulator controlled by a charging controller. The switching regulator uses pulse-width modulation (PWM) to efficiently transfer power, reducing power dissipation significantly. The controller adds intelligence to the switching regulator by monitoring output voltage and dynamically adjusting current, providing overvoltage protection that was previously only available from linear regulators, while maintaining the efficiency advantages of switching regulation.
3Reliability
If a linear regulator is used for charging, then overvoltage condition is reduced, but charging time increases
Solution Approach 1:
The patent substitutes the slow linear regulator with a switching voltage regulator that operates at high frequency, enabling much faster charging. The charging controller compensates for the switching regulator's tendency toward overvoltage by implementing real-time voltage monitoring and dynamic current adjustment. This combination achieves both the speed advantage of switching regulators and the overvoltage control of linear regulators, significantly reducing charging time while maintaining reliability.
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 extends the lifespan of energy storage devices by preventing overvoltage, achieving faster charging times (30%-40% faster) with reduced power dissipation compared to conventional linear regulators.
Implementation Method 1
a switching voltage regulator 120
Implementation Method 2
generating a PWM control signal to adjust the output current
Data Source
AI summary
Charging systems and related methods are disclosed for switching voltage regulators. A charging controller may be configured to generate a control signal indicating a first level of an output current generated by a switching voltage regulator for charging an energy storage device, determine that an output voltage exceeded a predetermined threshold, and generate the control signal indicating a new level of the output current that is reduced from the first level. A method of controlling charging of an energy storage device may comprise monitoring an output voltage charging an energy storage device, comparing a reference signal and a current sense signal to generate a PWM control signal that determines an output current for a switching voltage regulator generating the output voltage, and decrementing the reference signal in response to the output voltage exceeding a predetermined level for a maximum charging voltage for the energy storage device.