Multi-output power supply with dual power-on control

According to an aspect, a power supply is provided. The power supply includes a plurality of voltage converters including a first voltage converter and one or more other voltage converters. The power supply also includes a power supply control configured to perform a plurality of operations including enabling the first voltage converter during a start-up mode of operation, monitoring and regulating an output of the first voltage converter, reconfiguring the power supply control to enable the one or more other voltage converters based on determining that the output of the first voltage converter meets a regulation threshold, and transitioning from the start-up mode of operation to a regular mode of operation based on enabling the one or more other voltage converters to output one or more regulated voltages by the power supply.

FOREIGN PRIORITY

This application claims priority to India Patent Application No. 202011019857 filed May 11, 2020, the entire contents of which is incorporated herein by reference.

BACKGROUND

The subject matter disclosed herein generally relates to the field of electronic systems, and more particularly to a multi-output power supply with dual power-on control.

Electronic systems, such as control systems, may require multiple voltage rails to be regulated at predetermined levels to maintain proper operation. Further, in safety-critical systems, there can be multiple power conditioning requirements defined across a range of operating conditions. Such systems may be powered by different sources, such as a generator, a battery, a supercapacitor, an ultracapacitor, a thermal electric system, a fuel cell, ground-based power, and the like. Power demands of electronic systems can also vary and may be required to accommodate short interruptions in power and various changes in loads during start-up, normal, and diagnostic modes of operation.

In systems with greater power demands that supply multiple regulated voltages, high-power rated and bulky components may be needed. Multiple output power supplies often require multiple controllers. The initial bias voltage to these controllers is generally provided by a bootstrap start-up circuit at the time of power on operation. The power required for initial biasing of multiple controllers can make the bootstrap startup circuits bulky. To meet system power requirements, power supply conditioning circuitry can impact the total weight, heat generation, and power consumption of the system into which the power supply conditioning circuitry is integrated. In applications, such as aerospace applications, these factors as well as safety and reliability can constrain the overall system design.

BRIEF SUMMARY

According to one embodiment, a power system is provided. The power supply includes a plurality of voltage converters including a first voltage converter and one or more other voltage converters. The power supply also includes a power supply control configured to perform a plurality of operations including enabling the first voltage converter during a start-up mode of operation, monitoring and regulating an output of the first voltage converter, reconfiguring the power supply control to enable the one or more other voltage converters based on determining that the output of the first voltage converter meets a regulation threshold, and transitioning from the start-up mode of operation to a regular mode of operation based on enabling the one or more other voltage converters to output one or more regulated voltages by the power supply.

In addition to one or more of the features described above, or as an alternative, further embodiments may include a non-volatile storage device including a first set of configuration data and at least a second set of configuration data.

In addition to one or more of the features described above, or as an alternative, further embodiments may include where enabling the first voltage converter is based on the power supply control receiving the first set of configuration data from the non-volatile storage device.

In addition to one or more of the features described above, or as an alternative, further embodiments may include where reconfiguring the power supply control to enable the one or more other voltage converters is based on the power supply control receiving the second set of configuration data from the non-volatile storage device.

In addition to one or more of the features described above, or as an alternative, further embodiments may include where the power supply control is configured to transition from the regular mode of operation to the start-up mode of operation prior to depowering based on detecting a power shutdown event.

In addition to one or more of the features described above, or as an alternative, further embodiments may include where the regular mode of operation includes the first voltage converter meeting the regulation threshold and the one or more other voltage converters meeting one or more corresponding regulation thresholds.

In addition to one or more of the features described above, or as an alternative, further embodiments may include a diode-or circuit coupled to the output of the first voltage converter, where an output of the diode-or circuit is coupled to a local regulator configured to power the power supply control, and a start-up bootstrap circuit coupled to the diode-or circuit and a power input.

In addition to one or more of the features described above, or as an alternative, further embodiments may include where the power supply control is configured to monitor and regulate each output of two or more voltage converters.

In addition to one or more of the features described above, or as an alternative, further embodiments may include where the power supply control includes an independent pulse width modulation controller for each of the first voltage converter and the one or more other voltage converters, and the power supply control comprises at least one analog-to-digital converter configured to monitor the output of the first voltage converter and the one or more other voltage converters.

In addition to one or more of the features described above, or as an alternative, further embodiments may include where the output of the first voltage converter provides input power to at least one of the one or more other voltage converters.

According to an embodiment, a method includes enabling, by a power supply control of a power supply, a first voltage converter during a start-up mode of operation. An output of the first voltage converter is monitored and regulated. The power supply control is reconfigured to enable one or more other voltage converters based on determining that the output of the first voltage converter meets a regulation threshold. The power supply control can transition from the start-up mode of operation to a regular mode of operation based on enabling the one or more other voltage converters to output one or more regulated voltages by the power supply.

In addition to one or more of the features described above, or as an alternative, further embodiments may include accessing a non-volatile storage device including a first set of configuration data and at least a second set of configuration data.

In addition to one or more of the features described above, or as an alternative, further embodiments may include transitioning from the regular mode of operation to the start-up mode of operation prior to depowering based on detecting a power shutdown event.

In addition to one or more of the features described above, or as an alternative, further embodiments may include delivering power from a power input to a start-up bootstrap circuit coupled to a diode-or circuit, delivering power from the first voltage converter to the diode-or circuit, and providing power from an output of the diode-or circuit to a local regulator configured to power the power supply control.

In addition to one or more of the features described above, or as an alternative, further embodiments may include monitoring and regulating each output of two or more voltage converters by the power supply control.

Technical effects of embodiments of the present disclosure include a power supply with dual power-on control that reduces power consumption during start up bootstrap operation.

DETAILED DESCRIPTION

FIG. 1is a schematic representation of a control system100including a plurality of controller line replaceable units (LRUs)102operable to control one or more effectors104and monitor one or more sensors106. The term “LRU” refers to a component that is designed to be rapidly replaced at an operating location in the field with an equivalent component to restore operational performance, typically with quick-release fittings and minimal tooling requirements. The example ofFIG. 1is a dual-channel control system, where the controller LRUs102can exchange data with each other on a cross-channel data link and cross-channel status discretes108. Power exchange between the controller LRUs102can be performed through the cross-channel status discretes108or through one or more power exchange links109. In some embodiments, one of the controller LRUs102can provide a regulated or converted voltage to other LRUs102and/or other subcomponents. The controller LRUs102may also interface with one or more external systems (not depicted) via communication links110to receive and send data and commands external to the control system100. The controller LRUs102can receive power inputs112, which may include power and status discrete signals. As one example, the control system100can be part of an aircraft, such as a flight control system, propulsion control system, environmental control system, or other such system. Alternatively, the control system100can be incorporated in industrial machinery, an elevator system, a vehicle system, or other such systems with safety-critical applications.

The power inputs112can be, for example, various direct current (DC) and/or alternating current (AC) sources. As one example, the power inputs112can include aircraft power regulated at about 28 volts DC and various power supply status signals, such as a power supply reset, a power-on reset, a power shutdown, and other such signals. Various power sources of the power inputs112can come from other components of the higher-level system into which the control system100is integrated. For example, power sources can include one or more of a generator, a battery, a supercapacitor, an ultracapacitor, a thermal electric system, a fuel cell, ground-based power, and the like.

The effectors104can be any type of electrical or electro-mechanical actuation devices/systems. For instance, the effectors104, can be solenoids, relays, motors, pumps, valves, indicators, or other such devices capable of controlling position, pressure, or motion, including discrete, linear, rotary, and/or oscillatory responses. One or more of the effectors104can be a single channel effector controlled by one of the controller LRUs102, and one or more of the effectors104can be a multi-channel effector controlled by two or more of the controller LRUs102. For instance, a multi-channel effector104may be controlled by two or more controller LRUs102providing a partial command/current source or a single one of the controller LRUs102providing a full command/current source.

The sensors106can be any type of sensing device to observe feedback and conditions for control and monitoring purposes. For example, the sensors106can include linear position sensors, rotatory position sensors, pressure sensors, flow rate sensors, current sensors, voltage sensors, level sensors, accelerometers, photovoltaic sensors, discrete inputs, and other such sensing devices known in the art. The sensors106can include substantially redundant information provided to each of the controller LRUs102to support voting or blending of multiple observed values, for instance, where cross-channel data values are exchanged between the controller LRUs102on the cross-channel data link and cross-channel status discretes108.

The communication links110can report data and status observed by the controller LRUs102to a higher-level control or data management system. For example, in the context of an aircraft, the communication links110can interface with an air data computer, cockpit instrumentation, a vehicle system bus, and/or other interfaces operable to command actions by the controller LRUs102and process data and status generated by the controller LRUs102.

Referring now toFIG. 2, a portion of a channel200of the control system100ofFIG. 1including an exemplary controller LRU102of the present disclosure is shown. The controller LRU102can include a memory202which can store executable instructions and/or data associated with operation of various systems, such as aircraft systems. The executable instructions can be stored or organized in any manner and at any level of abstraction, such as in connection with one or more applications, processes, routines, procedures, methods, etc. As an example, at least a portion of the instructions and associated data can be initially stored in non-volatile memory204of the memory202and transferred to volatile memory206of the memory202for faster execution, record creation, and the like. Volatile memory206typically loses its state upon a shutdown or absent sufficient memory refreshing. Non-volatile memory204is persistent and maintains state between shutdown and startup.

Further, as noted, the memory202may store data. The data may include, but is not limited to, sensor data, event data, time history data, fault data, or any other type(s) of data as will be appreciated by those of skill in the art. The instructions stored in the memory202may be executed by one or more processors, such as a processor208. The processor208may be operative on the data.

The processor208, as shown, is coupled to one or more input/output (I/O) device interfaces210operable to receive sensor data from sensors106and/or command one or more effectors104. The sensors106and effectors104can include any types known in the art for controlling and/or monitoring the health of aircraft components and systems, for instance.

The components of the controller LRU102may be operably and/or communicably connected through a communication interface216by one or more buses that can include, for instance, cross-channel status discretes108and communication links110ofFIG. 1in some embodiments. The controller LRU102may further include other features or components as known in the art. For example, the controller LRU102may include one or more transceivers and/or devices configured to transmit and/or receive information or data from sources external to the controller LRU102(e.g., through the I/O device interface210). Information received over the communication links110can be stored in the memory202and/or may be processed and/or employed by one or more programs or applications and/or the processor208.

Power inputs112can be further processed by a multi-output power supply220of the controller LRU102to provide various voltage levels needed within the controller LRU102. For example, various voltage rails at different levels may be needed to support the memory202, processor208, I/O device interface210, and communication interface216. Further, these regulated voltages may supply the other sub component of another LRU102through a power exchange link109. Further, the multi-output power supply220may have changing current demands depending on a mode of operation and the ability of another channel200to control effectors104in an active-active or active-standby configuration.

FIG. 3is an example of the multi-output power supply220ofFIG. 2in more detail. In the example ofFIG. 3, a power supply control302is depicted that is configurable to control a plurality of voltage converters304. The voltage converters304can be, DC-DC, AC-DC, or DC-AC converters that produce regulated voltage or current outputs at different levels to support operation of the channel200ofFIG. 2. Further, outputs of the voltage converters304may be used for motor drives, front-end converters, other LRUs102, and various subcomponents, for instance, as output on one or more power exchange links109ofFIGS. 1 and 2. Each of the voltage converters304can include known components, such as a half-bridge circuit306and a filter308. The voltage converters304can receive power from the power inputs112. Control signals from the power supply control302can determine a percentage of the power from the power inputs112to pass through and condition as regulated voltage outputs. For example, the power supply control302can independently control each of the pulse width modulation signals having duty cycles corresponding to a desired voltage level of each regulated voltage output. Rather than enabling all of the voltage converters304upon start-up, the power supply control302can initially enable a first voltage converter304A in a start-up mode of operation while one or more other voltage converters304B remain disabled. A diode-or circuit310can be coupled to an output305A of the first voltage converter304A. A start-up bootstrap circuit312can be coupled to the diode-or circuit310and a power input of the power inputs112. The start-up bootstrap circuit312can supply initial bias voltage with a passively controlled voltage to an output314of the diode-or circuit310until the output305A of the first voltage converter304A meets a regulation threshold, such as being above a minimum voltage threshold to deliver power to the diode-or circuit310and output314.

The output314of the diode-or circuit310can be coupled to a local regulator316configured to power the power supply control302with a plurality of local voltage levels318. In embodiments, the power supply control302can be an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or the like, which includes basic logic functions and/or gates to rapidly configure the voltage converters304without extended delays or complexity that may be associated with a microprocessor-based solution. The power supply control302can include a plurality of modulation controllers320with configurable digital pulse-width modulation circuits322. The power supply control302can include at least one analog-to-digital converter324configured to monitor the output305A of the first voltage converter304A and outputs305B of the one or more other voltage converters304B. The output305A and outputs305B are examples of regulated voltages output by the multi-output power supply220. Buffer circuits326A and326B can be respectively coupled between the outputs305A,305B and analog-to-digital converters324A,324B to condition the signals to be monitored by the modulation controllers320.

In the example ofFIG. 3, there are four independently controlled voltage converters304; however, it will be understood that there can be any number of voltage converters304at or above two. Further, although four analog-to-digital converters324are depicted within the power supply control302to independently monitor the outputs305A,305B in parallel, it will be understood that other configurations can be implemented, such as one or more multiplexed analog-to-digital converters internal or external to the power supply control302. Further, the power supply control302can include other support elements, such as a clock328that receives input from an oscillator330. The power supply control302can also include an interface332coupled to a non-volatile storage device334. The non-volatile storage device334can store a first set of configuration data336and a second set of configuration data338. The non-volatile storage device334can be part of the non-volatile memory204ofFIG. 2or a dedicated device accessible through a local bus340, such as a serial peripheral interface bus. The first set of configuration data336may be referred to as BOOT configuration1that can enable modulation controller320A, configurable digital pulse-width modulation circuit322A, the first voltage converter304A, and analog-to-digital converter324A. The second set of configuration data338may be referred to as BOOT configuration2that can enable all of the modulation controllers320, configurable digital pulse-width modulation circuits322, voltage converters304, and analog-to-digital converter324. Therefore, when the power supply control302is configured with BOOT configuration1, the multi-output power supply220operates with reduced power consumption as compared with BOOT configuration2. Notably, with BOOT configuration1, the output314of the diode-or circuit310is powered by the bootstrapping circuit312until the first voltage converter304A provides a stable regulated value at output305A. Upon transitioning from BOOT configuration1to BOOT configuration2, the first voltage converter304A continues to power the output314. Further details are provided with respect toFIGS. 4-8. Although only two sets of configuration data336,338are depicted inFIG. 3, it will be understood that additional configuration data sets can be used to support additional configurations. Similarly, in some embodiments, different numbers of supporting interfaces can be included, such as different numbers of modulation controllers320, configurable digital pulse-width modulation circuits322, analog-to-digital converters324, and the like. Further, there can be spare interfaces to support reconfiguration across multiple designs.

Referring now toFIG. 4, with continued reference toFIGS. 1-3.FIG. 4shows a method400of configuring the multi-output power supply220ofFIGS. 2 and 3according to an embodiment. The method400is also described with respect to timing diagram500ofFIG. 5, state transition diagram600ofFIG. 6, and timing diagram700ofFIG. 7.

At block402, the multi-output power supply220is powered on by receiving power inputs112as depicted at power-on502transition from power-off state602to power-on state604. At block404, the power supply control302is booted with BOOT configuration1as depicted at BOOT_1504with a transition from power-on state604to BOOT_1state606. At block406, the power supply control302enables modulation controller320A, configurable digital pulse-width modulation circuit322A, and analog-to-digital converter324A, which results in the first voltage converter304A transitioning from OFF to ON as depicted at Controller_1508and state transition from BOOT_1state606to Controller_1active state608.

At block408, the modulation controller320A can monitor the output305A using the analog-to-digital converter324A. The modulation controller320A can continue to monitor the output305A at block410as part of a start-up mode of operation412until the output305A meets a regulation threshold, such as reaching a predetermined minimum voltage level. At block414, upon determining that the output305A meets the regulation threshold, the power supply control302is booted with BOOT configuration2as depicted at BOOT_2506with a transition from Controller_1active state608to BOOT_2state610. At block416, the power supply control302enables all of the modulation controllers320, configurable digital pulse-width modulation circuits322, and analog-to-digital converters324as depicted with Controller_2510, Controller_3512, and Controller_4514switching from OFF to ON while Controller_1508remains ON. The transition is further illustrated as transitioning from BOOT_2state610to Controller_1234active state612. The multi-output power supply220can transition to a regular mode of operation at block418upon outputs305B reaching regulated states, as illustrated in the transition from Controller_1234active state612to voltage regulation state614. Upon detecting a power shutdown event at the power supply control302, the power supply control302can transition back through Controller_1active state608and BOOT_1state606to power-off state602.

The timing diagram700ofFIG. 7further illustrates how a BOOT configuration1power requirement702is reduced in the start-up mode of operation412during a start-up mode period until a bootstrap transition704to a regular mode of operation706is reached, where the regular mode of operation706corresponds to block418ofFIG. 4. In the regular mode of operation706, a BOOT configuration2power requirement708is higher than the BOOT configuration1power requirement702. In the example ofFIG. 7, the BOOT configuration1controller power requirement702is about 25% of the BOOT configuration2power requirement708. It will be understood that other power ratios are possible depending upon the number of voltage converters304ofFIG. 3and other factors. The controller power consumption profile depicted inFIG. 7illustrates an example of a power requirement for the power supply control302ofFIG. 3. Reduced power consumption for the power supply control302can be supplied by the start-up bootstrap circuit312in start-up mode until the BOOT_1state. Subsequently in regular operating mode, the full power requirement for the power supply control302is supplied by the regulated voltage of output305A. This reduces the power requirements for the start-up bootstrap circuit312, which enables the start-up bootstrap circuit312to be designed with less bulky and lower power rated components than would otherwise be needed.

FIG. 8is a flow diagram of a method800, according to an embodiment of the present disclosure. The method800further summarizes a start-up sequence of a multi-output power supply, such as the multi-output power supply220ofFIG. 2and is described with respect toFIGS. 1-8. The power supply control302can be configured to perform a plurality of operations as described with respect to the method800.

At block802, the power supply control302of the multi-output power supply220can enable the first voltage converter304A during the start-up mode of operation412. At block804, the power supply control302can monitor and regulate the output305A of the first voltage converter304A. At block806, the power supply control302can be reconfigured to enable one or more other voltage converters304B based on determining that the output305A of the first voltage converter304A meets a regulation threshold. At block808, the power supply control302can transition from the start-up mode of operation412to a regular mode of operation706based on enabling the one or more other voltage converters304B to output one or more regulated voltages.

In embodiments, the power supply control302can access the non-volatile storage device334that includes a first set of configuration data336and at least a second set of configuration data338, which may include multiple subsets of data. The first voltage converter304A can be enabled based on the power supply control302receiving the first set of configuration data336from the non-volatile storage device334. The power supply control302can be reconfigured to enable the one or more other voltage converters304B based on the power supply control302receiving the second set of configuration data338from the non-volatile storage device334. The regular mode of operation706can include the first voltage converter304A meeting the regulation threshold and the one or more other voltage converters304B meeting one or more corresponding regulation thresholds. Transitioning from the regular mode of operation706to the start-up mode of operation412can be performed prior to depowering the multi-output power supply220based on the power supply control302detecting a power shutdown event. Further, the power supply control302can be configured to monitor and regulate each output of two or more voltage converters304, for instance, as part of turn-on/turn-off sequence.

While the above description has describedFIGS. 4-8in a particular order, it should be appreciated that unless otherwise specifically required in the attached claims that the ordering of the steps may be varied.

FIG. 9is a block diagram of a motor drive900, according to an embodiment of the present disclosure. The example ofFIG. 9illustrates an alternate embodiment where the power supply control302ofFIG. 3can be used to sequence start-up bootstrap power control for an effector902, such as an electric motor. Similar to the example ofFIG. 3, the motor drive900includes a voltage converter304A that provides output305A to diode-or circuit310. The diode-or circuit310can also receive supply initial bias voltage from start-up bootstrap circuit312, which may be powered by a power input of the power inputs112. Buffer circuit326A can provide feedback to the power supply control302. In the example ofFIG. 9, a DC-AC converter904can also be controlled by the power supply control302with method800, for example to power the effector902, which can be one of the effectors104ofFIGS. 1 and 2. The DC-AC converter904can receive input power from a DC power source906. In some embodiments, the DC power source906can be the output305A or can be based on the output305A.

FIG. 10is a block diagram of a front-end converter1000, according to an embodiment of the present disclosure. The example ofFIG. 10illustrates an alternate embodiment where the power supply control302ofFIG. 3can be used to sequence start-up bootstrap power control for a load1002, which may require a regulated DC voltage. Similar to the example ofFIGS. 3 and 9, the front-end converter1000includes a voltage converter304A that provides output305A to diode-or circuit310. The diode-or circuit310can also receive supply initial bias voltage from start-up bootstrap circuit312, which may be powered by a power input of the power inputs112. Buffer circuit326A can provide feedback to the power supply control302. In the example ofFIG. 10, an AC-DC converter1004can also be controlled by the power supply control302with method800, for example to power the load1002. The AC-DC converter1004can receive input power from an AC power source1006. Other variations are contemplated with additional converter types and configurations.