Universal Digital PWM Controller for DC-DC Converters
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Solution Overview
Problem
Existing digital pulse width modulators (DPWMs) for multi-phase converters face high power consumption, limited flexibility, and inefficiency at high switching frequencies, making them unsuitable for low-power applications and requiring significant redesign for changing electronic device characteristics.
Innovation Solution
A universal, fault-tolerant digital controller architecture with programmable digital pulse width modulators that can operate with 1 to 4 phases, adjust phase shifts, and output voltages, featuring low power consumption and the ability to automatically switch to reduced phase operation in case of failures, utilizing programmable counters, delay lines, and sigma-delta modulators to achieve efficient and flexible control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If digital pulse width modulators are used for multi-phase converters, then control flexibility and matching accuracy are improved, but power consumption increases linearly with switching frequency
Solution Approach 1:
The digital controller is segmented into multiple independent phase modules, each handling a specific phase of the multi-phase converter. This modular architecture allows the controller to scale power consumption with the number of phases rather than switching frequency, and enables selective activation of phases based on load requirements, thereby reducing overall power consumption while maintaining control flexibility.
Solution Approach 2:
The digital controller is designed as a universal multi-functional platform that can control different numbers of phases (1-4 phases) and different converter topologies using the same hardware architecture. This universality eliminates the need for multiple specialized controllers, reducing total power consumption while maintaining adaptability through programmable control algorithms.
2Use of energy by moving object
If traditional analog controllers are used, then power consumption is lower, but stability problems occur when operating with parallel converters
Solution Approach 1:
The patent replaces traditional analog control circuits with a digital control system. The digital controller uses discrete logic elements, counters, and state machines to generate PWM signals, eliminating the analog circuits that cause stability problems in parallel converter configurations. This substitution maintains low power consumption while providing superior stability through precise digital timing and control algorithms.
3Measurement precision
If application specific digital architectures are used, then control precision is improved, but chip area increases and flexibility is reduced
Solution Approach 1:
The digital controller employs dynamic reconfiguration capabilities where the control architecture can be programmatically adjusted to match different operating conditions and converter configurations. The controller uses programmable counters, delay lines, and phase-shift registers that can be dynamically configured to achieve precise control for 1-4 phase operations, maintaining both precision and flexibility through software-defined behavior rather than fixed hardware.
Solution Approach 2:
The controller achieves different control characteristics by changing operational parameters such as counter modulus, delay line length, and phase shift values rather than changing the physical hardware architecture. This parameter-based configuration allows the same chip to provide application-specific precision control for different converter types and phase numbers, eliminating the need for multiple specialized designs.
4Reliability
If the number of phases is reduced in case of failure, then fault tolerance is improved, but control complexity increases
Solution Approach 1:
The digital controller incorporates self-diagnosis and automatic reconfiguration capabilities. Phase detection circuits continuously monitor the status of each phase, and upon detecting a failure, the controller automatically reconfigures itself to operate with the remaining healthy phases. This self-service approach to fault tolerance eliminates the need for complex external fault management circuits while providing automatic adaptation to failure conditions.
Data Source
AI summary
A multiphase hybrid digital pulse width modulator can comprise a counter that is selectable between at least two different numbers of states to indicate a first portion of a switching period. Unclocked logic can indicate a second portion of the switching period. The unclocked logic can include a delay line.