Abstract:
The present invention relates to an AC/DC converter ( 1 ) of the type having an AC/DC conversion stage ( 2 ) and a DC/DC conversion stage ( 3 ), the AC/DC conversion stage ( 2 ) comprising an input filter stage ( 4 ), an input rectifier stage ( 5 ) and a tracking boost converter stage. The boost converter stage in turn comprises an input choke ( 10 ), a boost diode ( 16 ) and a bulk capacitor ( 17 ). The bulk capacitor ( 17 ) is arranged to store a range of voltages substantially proportional to the input voltage of the converter. The DC/DC stage ( 3 ) is arranged to receive the range of voltages from the bulk capacitor ( 17 ) and is controllable to provide a desired DC output regardless of the voltage received from the bulk capacitor ( 17 ). This is achieved through careful combination of components and use of output feedback control to control the voltage applied to an isolated transformer ( 41 ) in the DC/DC stage.

Description:
INTRODUCTION  
       [0001]     The present invention relates to an AC/DC converter of the type comprising an AC/DC conversion stage and a DCIDC conversion stage, the AC/DC conversion stage comprising a dual mode input stage having an input filter and an input rectification circuit, the AC/DC conversion stage further comprising a pre-regulator tracking boost converter stage having an input boost choke, a boost diode and a bulk capacitor, the bulk capacitor being capable of storing a range of DC voltages thereon substantially proportional to the input AC voltage.  
         [0002]     AC/DC converters have been known for many years and are used extensively particularly throughout the electronics industry. These converters take power from a utility line or mains supply and deliver a predetermined DC output, typically at the lower voltages required by electronic circuitry as used in industrial, communications, computing, medical and general applications. Typically, an AC/DC converter comprises a pre-regulator which performs a “power factor correction”, namely, it draws current largely proportional to the input voltage and then feeds a boosted line voltage, typically at 400V, which it feeds to a capacitor which stores energy during the low voltage parts of the AC input cycle. This capacitor then feeds a DC/DC converter which provides the required DC voltage for the circuitry in question.  
         [0003]     There are however problems associated with the known types of AC/DC converters. First of all, many of these converters experience problems with the filtering of electromagnetic interference (EMI) caused by the operation of the converter. Every switching stage of the converter generates interference. Modern power converters operate with switching at a frequency typically in the range of 20 KHz to 1 MHz or higher, and such switching can generate significant interference to other electrical equipment. This interference must be reduced by using more suitable switching techniques and/or filtering. Particular challenges in this area lie in filtering the current ripple in the input boost choke or flyback stage as typically used in power-factor correction stages and also in limiting the common-mode noise generated in the isolation transformer between the line/mains and the electronic circuitry being fed by the supply. Industry-led and regulatory standards apply to EMI performance and safety isolation in power converters and it is important to provide a power converter that adheres to these standards.  
         [0004]     The other main design problem associated with the known types of AC/DC converters concerns the efficiency of the converters. In particular, there is a design challenge in getting optimum efficiency from power converters across the wide range of input voltages, where the input voltage cycle peak varies from typically 1.414*85V to 1.414*265V depending on the country. Furthermore, one must maximise efficiency at the different points of the operating cycle between 0V and the peak input voltage value. Design of AC/DC converters with an approximately fixed value of bulk capacitor voltage typically involves compromises in optimising efficiency across the differing line voltages.  
         [0005]     In many instances, AC/DC converters have to be capable of operating in dual mode, namely, be capable of taking both low-line voltages (nominally 110V, as is common in the US and Japan) and high-line voltages (nominally 220V to 240V as is common in Europe). It has been known to implement an AC/DC converter having a dual mode input stage whereby either low-line or high-line input voltages can be handled adequately and converted to provide power to a piece of equipment. However, there are various problems with these types of converters including those outlined above.  
         [0006]     It is an object therefore of the present invention to provide an AC/DC converter of the type comprising a dual mode input stage which will overcome at least some of the problems associated with the known constructions of AC/DC converters.  
       STATEMENTS OF INVENTION  
       [0007]     According to the invention, there is provided an AC/DC converter comprising an AC/DC conversion stage and a DC/DC conversion stage, the AC/DC conversion stage comprising a dual mode input stage having an input filter and an input rectification circuit, the AC/DC conversion stage further comprising a pre-regulator tracking boost converter stage having an input boost choke, a boost diode and a bulk capacitor, the bulk capacitor being capable of storing a range of DC voltages thereon substantially proportional to the input AC voltage, characterised in that the DC/DC conversion stage comprises a controller, a pre-regulator buck converter stage and an output isolation transformer stage, the pre-regulator buck converter stage being controlled using a feedback from the output of the converter.  
         [0008]     By having such a converter, it is possible to provide a converter that is efficient across a wide range of different input voltages. The tracking boost converter will operate to provide a voltage across the bulk capacitor approximately proportional to the input voltage. This voltage across the bulk capacitor is then used by the buck converter to provide the input to the output isolation transformer. By having the feedback control from the output, the converter will be able to operate the isolation transformer stage with a fixed voltage ratio and the buck converter can adapt the voltage received from the bulk capacitor to give a quasi-fixed input voltage to the isolation transformer. This will result in a highly efficient controller across the range of input voltages.  
         [0009]     In one embodiment of the invention there is provided an AC/DC converter in which the controller has means to operate the converter in discontinuous mode at high input voltages and in predominantly continuous mode at low input voltages.  
         [0010]     By operating the converter in this fashion, the converter may be operated in an efficient manner across the range of input voltages. At low input voltages, switching losses are reduced by a factor of between 2 and 4 compared with a typical AC/DC converter mainly due to the fact that the converter is operating with a lower bulk capacitor voltage (approximately 200V as opposed to 430V) than would normally be the case. At high voltages, conduction losses are also lower due to lower input current for the required power. The dominant loss component at high voltages tends to be associated with the reverse recovery properties of the boost diode and a freewheeling diode. If the converter is operated in discontinuous mode, the boost diode and the freewheeling diode are normally not conducting current at the time the main switch turns on, thus eliminating this reverse recovery problem and reducing losses. The converter will operate in predominantly continuous mode at low voltages. This will depend on the requirement of the load and for particularly light loads the converter may not be required to operate in continuous mode.  
         [0011]     In another embodiment of the invention there is provided an AC/DC converter in which the pre-regulator tracking boost converter stage is further provided with a hold-up extension circuit comprising an auxiliary capacitor. In this way, it is possible to ensure that the converter can provide sufficient hold-up power in the event of a power interruption at low-line voltages. The auxiliary capacitor can be switched in to the circuit as and when deemed necessary.  
         [0012]     In a further embodiment of the invention there is provided an AC/DC converter in which the hold-up extension circuit further comprises a standby circuit to charge the auxiliary capacitor. Alternatively, the hold-up extension circuit may further comprise a separate boost circuit to charge the auxiliary capacitor.  
         [0013]     In another embodiment of the invention there is provided an AC/DC converter in which there is provided an inrush current limiting circuit comprising a resistive element. By having such a device, it will be possible to protect the converter components from the inrush current typically experienced on power up of the converter.  
         [0014]     In a further embodiment of the invention there is provided an AC/DC converter in which the inrush current limiting circuit further comprises a semi-controlled bypass circuit operable to bypass the resistive element after start up. This is seen as particularly suitable as the inrush current limiting circuit resistive element will have a loss associated therewith which is undesirable when attempting to achieve maximum efficiency of the converter during normal operating conditions. Once the protection against the inrush current is no longer required, the resistive element may be bypassed thereby effectively avoiding the loss associated therewith, optimizing the operating efficiency of the converter.  
         [0015]     In one embodiment of the invention there is provided an AC/DC converter in which the semi-controlled bypass circuit further comprises a pair of semi-controlled rectifying elements connected to the input rectification circuit. Preferably, the semi controlled rectifying elements comprise semi-controlled diodes. By having semi-controlled diodes, these diodes can be configured so they effectively form part of the full bridge rectifier on the input when they are switched on, shorting out a second pair of diodes that form part of the full bridge on start-up as well as shorting out the resistive element. This is seen as an efficient way of by-passing the resistive element that is both reliable and relatively simple to operate.  
         [0016]     In a further embodiment of the invention there is provided an AC/DC converter in which the resistive element further comprises a negative temperature co-efficient (NTC) thermistor.  
         [0017]     In one embodiment of the invention there is provided an AC/DC converter in which there is provided a ripple current filtering circuit, the ripple current filtering circuit comprising an additional winding on the input boost choke in series with an inductor and a capacitor arranged in series electrically with respect to each other. This is seen as a particularly simple way of eliminating the ripple current on the input choke thereby providing a more efficient converter.  
         [0018]     In another embodiment of the invention there is provided an AC/DC converter in which the isolation transformer is operated as a full duty-cycle isolation stage. By operating the isolation transformer as a full duty-cycle isolation stage it is possible to reduce the EMI as well as improve utilization of the transformer.  
         [0019]     In a further embodiment of the invention there is provided an AC/DC converter in which the isolation transformer further comprises a planar transformer with windings integrated in a printed circuit board (PCB). By using a planar transformer the transformer will be well matched and it will be possible to eliminate most of the common mode currents in the transformer which is of significant benefit.  
         [0020]     In one embodiment of the invention there is provided an AC/DC converter in which there are provided balanced saturable reactors connected at each terminal of the isolation transformer&#39;s secondary winding. By having balanced saturable reactors, it will be possible to limit the EMI as well as reduce the ringing on the output and contain the reverse recovery effects in the body diodes of the output synchronous rectifiers.  
         [0021]     In another embodiment of the invention there is provided an AC/DC converter in which there is provided a protection circuit operable by the controller, the protection circuit comprising a dump resistor connected across the output of the pre-regulated buck converter stage. By having such a protection circuit, it will be possible to prevent damage to the capacitors, transformer elements and the switching devices that may be caused in the event of a transient excess voltage such as that caused by a reverse power flow from the converter output towards the input. The dump resistor will provide a path for the excess power to dissipate.  
         [0022]     In a further embodiment of the invention there is provided an AC/DC converter in which the protection circuit further comprises a switching element to allow the converters to be operated in parallel without reverse power flow from one or more other converters. In this way, reverse power flow is avoided that could potentially cause damage to the converter components.  
         [0023]     In one embodiment of the invention there is provided an AC/DC converter in which the bulk capacitor voltage is adapted to provide an output DC voltage approximately proportional to the input AC voltage so that at low input line AC and low output line DC voltages in the order of 200V, the inductance of the input choke of the pre-regulator boost converter stage is so chosen that the boost converter operates in continuous mode and at a high input line AC voltage and high output DC voltages of the order of 400V operates in discontinuous mode. The inductance value of the input choke will affect the manner in which the controller operates the boost converter. By choosing an appropriate value of inductance, the controller will vary the duty cycle appropriately so that the converter operates the boost converter in discontinuous mode at high voltage. This will help to overcome the losses associated with the reverse recovery properties of the boost diode. Furthermore, by choosing the appropriate value of inductance, the controller can operate the boost converter in continuous mode at higher loads at low voltages without significant conduction losses.  
         [0024]     In another embodiment of the invention there is provided an AC/DC converter in which the hold-up capacitor is chosen to have a capacitance with a hold-up time of the order of 20 milliseconds.  
         [0025]     In a further embodiment of the invention there is provided an AC/DC converter in which the DC/DC conversion stage further comprises a full bridge output stage and output rectifying elements having rectifying voltage after spike adjustments and normal de-rating slightly greater than the output voltage.  
         [0026]     In one embodiment of the invention there is provided an AC/DC converter in which the DC/DC conversion stage comprises a centre tapped rectifier whose rectifying voltage, after spike adjustments and normal de-rating, is slightly greater than twice the output voltage.  
         [0027]     In another embodiment of the invention there is provided an AC/DC converter in which there is provided a current sensing device monitoring the output of the converter.  
         [0028]     In a further embodiment of the invention there is provided an AC/DC converter in which there is provided a voltage sensing device monitoring the output of the converter. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0029]     The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which:  
         [0030]      FIG. 1  is a circuit diagram view of an AC/DC converter in accordance with the invention,  
         [0031]      FIG. 2  is an enlarged view of portion of  FIG. 1  showing the AC/DC conversion stage of the AC/DC converter,  
         [0032]      FIG. 3  is an enlarged view of portion of  FIG. 1  showing the DC/DC conversion stage of the AC/DC converter,  
         [0033]      FIG. 4  is a circuit diagram of a full duty transformer stage in accordance with the invention, and  
         [0034]      FIG. 5  is a circuit diagram of a multiple output winding configuration for a transformer used in accordance with the invention. 
     
    
       [0035]     Referring to the drawings and initially to FIGS.  1  to  3  thereof, there is provided an AG/DC converter, indicated generally by the reference numeral  1 , having an AC/DC conversion stage  2  comprising a dual mode input stage and a DC/DC conversion stage  3 .  
         [0036]     Now referring specifically to  FIG. 2 , the AC/DC conversion stage  2  comprises input terminals  70  feeding an input EMI filter  4 . The EMI filter  4  in turn feeds a rectifying bridge, indicated generally by the reference numeral  5  which in turn feeds a negative temperature coefficient thermistor (NTC)  6  in turn combined with semi- controlled rectifying elements  7  and  8  in the rectifying bridge  5 . These in turn feed an input tracking boost converter choke, namely, an input choke  10  having an additional winding  11  feeding a shim inductor  12  and a capacitor  13  across a switch  15 . A boost diode  16  is provided and finally a bulk capacitor  17  is also provided. A hold-up extension circuit  20  is connected across the bulk capacitor  17  for charging an auxiliary capacitor  21 . The hold-up extension circuit  20  includes a hold-up extension feed  22 .  
         [0037]     It is advantageous to discuss the operation of the AC/DC conversion stage  2  prior to discussing the operation of the rest of the AC/DC converter  1 . The bulk capacitor voltage  17  is adapted to provide an output DC voltage in approximate proportion to the input AC voltage so that at low-line AC and low output DC voltage of the order of 200V, the induction of the input choke, namely, the input choke  10  operates in continuous mode, and at high-input AC and high output DC of the order of the 400V, the input choke  10  operates in discontinuous mode. Thus, here the input capacitor, namely, the bulk capacitor  17 , operates with continuous current to the input choke  10  at voltages such as low-line, typically 110V as is common in the US and Japan. Because one is operating with a bulk capacitor voltage, that is to say, a voltage at the capacitor  17  of typically 200V as compared with typically 400V in a conventional power factor connected converter, switching losses are reduced by a factor of between 2 and 4. Some components of the switching loss are proportional to the bulk capacitor voltage and others are proportion to the square of the bulk capacitor voltage and thus the reduction is between approximately twice and four times in this instance. At higher line, typically 220V up to 240V, as found in Europe, the operation of the boost stage is primarily in discontinuous mode. At such voltages, conduction losses are lower, due to lower input current for the required power and the dominant loss component tends to be associated with the reverse recovery properties of the boost diode. If the converter is operated in discontinuous mode, the boost diode is normally not conducting current at the time the main switch turns on, thus eliminating this reverse recovery problem. When current ceases to flow in the boost diode, it is normal for the voltage on the switching device to oscillate and there is an opportunity to turn on the switch close to a “valley” in the voltage across it, thus minimising losses in this component.  
         [0038]     The purpose of this tracking boost stage is to get full benefit of dual-mode approach and allow the usage of less expensive components, in particular the boost diode. As is well appreciated to those skilled in the art, usage of the approaches developed in this area have been limited by among other things the difficulty in filtering the increased ripple current at high line and by the difficulty in designing the subsequent DC/DC conversion stage. A further difficulty is the greater challenge in obtaining effective holdup performance—i.e. the ability to maintain the output voltage with regulation for a period typically corresponding to loss of an input cycle of the AC line, as is increasingly been mandated by performance requirements. This requirement may also be in conflict with requirements in the area of inrush current limitation.  
         [0039]     With the present circuit, the difficulty in filtering the increased ripple current is addressed by the usage of the ripple-cancellation approaches between the input EMI filter  4  and the additional winding  11 .  
         [0040]     Since the capacitor is placed after the rectifying and voltage limiting elements, it does not have to have the surge requirements associated with a capacitor placed directly across the line—typically known as an “X2” capacitor.  
         [0041]     A so-called hold-up issue occurs because the energy to run the DC load during the missing cycle of input line/mains voltage is provided by the bulk capacitor  17 , and operating at typically 200V in the mode of operation associated with a low-line condition means that the holdup energy in this capacitor is one fourth of the energy stored at 400V, the approximate voltage corresponding to high-line operation. While it would be possible to address this issue by fitting a somewhat larger capacitance capacitor  17  than would be normal, as in the case of conventional boost power factor correction stage which is more practical at power levels up to 400 watts with present equipment, the problem is overcome with the present invention by fitting the hold-up extension circuit  20  which allows for the auxiliary capacitor  17  to be charged. This can be typically done by a standby circuit provided in many converter types or by a separate boost circuit and then used to provide the bulk energy to maintain the output DC voltage at the required level during absence of the input mains/line voltage by switching in hold-up extension feed  22 . This approach is more suited to higher power levels where the extra cost of the holdup control circuitry is justified.  
         [0042]     Increased capacitance values also require a more advanced inrush-current limiting circuit than required in the traditional power factor correction circuits. Inrush current limiting has historically used NTC thermistors, as in the present circuit, whose resistance drops as current is drawn, corresponding to normal operation. Initially—when cold—such devices have a high resistance which limits inrush current charging the bulk capacitors through the rectifying elements. However, the on-resistance of the NTC element causes further losses, defeating the objective of maximising efficiency. This is overcome in the present invention by combining the NTC device  6  with the semi-controlled rectifying elements  7 ,  8  in the rectifier bride  5 , as illustrated. These elements, when switched on, have losses similar to those of conventional elements and thus there is no loss penalty.  
         [0043]     It will be appreciated that alternatively the NTC element may be bypassed by a semiconductor device such as a triac, which however typically has a material forward voltage drop resulting in losses. An alternative is usage of an electromechanical element such as a relay, with reliability issues typically associated with electromechanical devices and frequently with the need for power-consuming control circuitry to maintain the relay “on” in normal operation or indeed, a fixed resistor could be used in the position, as shown in the drawings, but usage of an NTC device usually allows a smaller element to be used and is more effective in brownout conditions and in recovery from a brief mains “outage”.  
         [0044]     Referring to  FIG. 3 , the DC/DC conversion stage  3  comprises an input buck converter stage, indicated generally by the reference numeral  30 , having an input buck drive FET  31  feeding a free-wheeling diode  32  connected to an inductor  33  which in turn feeds an intermediate voltage level stage, indicated generally by the reference numeral  35 , to a pair of output capacitors  36  and  37  which in turn feed a full duty cycle stage, indicated generally by the reference numeral  40 . The full duty cycle stage  40  in turn feeds a planar transformer, indicated generally by the reference numeral  41 , which in turn feeds output inductors  42  and  43  of an output rectifying stage  44 . A feedback controller  50  connects the input buck converter stage  30  with the output for both current and voltage sensing by means of a current sensor  51  and a voltage sensor, namely, a FET diode  52 .  
         [0045]     With use of a dual-mode input stage as described above, the DC/DC conversion stage has to handle bulk capacitor voltage (spanning the range of typically 200V to 400V in most current requirements) to the fixed level ordinarily required in most load applications. The challenge of wide-range conversion at high efficiency is more complex in this case than when converting from an approximately fixed level such as the nominal 400V as obtained in the conventional converter approach. One also has the requirement for low EMI generation from the transformer.  
         [0046]     The input buck converter stage  30 , which is controlled in a feedback loop by the controller  50 , measures the output voltage with a full duty cycle isolation stage. This is achieved by the use of the planar transformer  41  which facilitates a balanced construction, and along with full-duty cycle operation results in almost perfect cancellation of the common-mode currents than can be introduced in these transformers. The output rectifying elements  42  and  43  can also be limited in voltage while adjusted for spike effects and normal derating, to just over the output voltage in the case of full-bridge output stages and to just over twice the output voltage in the case of centre-tapped rectifiers. Deriving a gate drive signal, if synchronous rectification is used, from the main winding is also feasible, given that this voltage can be made proportional to the output voltage, which is normally adjustable over a relatively narrow range.  
         [0047]     The implementation described in this specification permits the leakage inductance energy in the main transformer to be used to achieve very efficient zero-voltage switching. The small balanced saturable reactors  42  and  43  in series with the main transformer winding maintain the balance necessary to limit EMI and serve to reduce ringing on the output and to contain reverse recovery effects in the body diodes of the output synchronous rectifiers. Further operational and design aspects of this circuit are described below.  
         [0048]     The input buck converter stage  30  operates typically at full load in discontinuous mode, i.e. with discontinuous inductor current, at high line voltage. This limits the reverse recovery effects in the freewheeling diode  32 . It will be noted that a synchronous rectifier can also be used. At low-line voltage, the inductor current  33  is designed to be continuous. This limits conduction loss, and reverse recovery effects are materially less given the reduced voltage applied.  
         [0049]     The capacitance on the output of the input buck converter stage  30 , namely, the capacitors  36  and  37 , is selected to allow the full-duty cycle stage to operate either as a current-fed stage or as a voltage-fed stage. In practice a relatively low value of capacitance is selected here to allow for quasi-voltage fed operation of the full-bridge stage, resulting in easier containment of voltage spikes at switching under some load conditions through clamping of the voltage across the output rectifiers.  
         [0050]     When a centre-tapped output section is used, the output windings are closely coupled—i.e. the leakage inductance between these windings is minimal as compared with the leakage inductance between either secondary winding and the primary.  
         [0051]     The output choke is positioned such that the centre tap of the output stage is connected to the positive output, with an inductor in the -ve “leg”, when using conventional n-type FET switches or when using diodes in the conventional fashion.  
         [0052]     It is important in this circuit that very close control be maintained on the intermediate capacitance of the capacitors  36  and  37 . A protection circuit immediately switches in a power dump resistor  71  on detection of a fault condition, and simultaneously removes drive from the input buck converter stage  30  high-side switching element  31 . Further protection against reverse power flow is provided by use of a switched device, typically used also to allow converters to be operated in parallel without reverse power flow from one or more other converters into the converter in question.  
         [0053]     Referring to  FIG. 4 , there is illustrated portion of the primary winding of a transformer, indicated generally by the reference numeral  60 , that may be used in accordance with the invention. In this embodiment, the approach to overcome the deficiency of the tracking boost converter, namely, that it has variable output voltage, has been to use a buck converter stage with a subsequent full duty cycle transformer stage. This full duty cycle stage is optimal also for providing self-driven control of synchronous rectifiers, with minimal deadtime and consequently minimal losses.  
         [0054]     An extension of this approach is to connect additional sets of output windings and synchronous rectifiers, also self driven, which can provide further output voltages which closely track the main output. These voltages can be isolated from each other or may be combined in the established “stacking” approach. If it is desired to optimise cross regulation between such outputs, then using common tracking or windings for the output inductors on a single core is possible, as in  FIG. 4 . Given the much closer tracking between output voltages than is the norm with diode rectifiers, this approach can be particularly effective in reducing ripple and in improving cross-regulation.  
         [0055]     This approach also lends itself very well to use of approaches suited to get fractional turns. For example, a common requirement is one of getting 3.3V, 5V and 12V nominal output voltages as required in computer systems. An illustrative implementation is as in  FIG. 6 . This shows only the secondary turns - the primary winding is implemented as conventionally, going through both ferrite sections.  
         [0056]     Throughout this specification, the converter has been described as being operated in discontinuous mode at high voltages and in continuous mode at low voltages. It will be understood however that although the controller may be capable of operating the converter in continuous mode at low voltages, practically speaking it may not in fact be required to do so in the case of a light load on the converter. In this instance, the controller will have the ability to operate in either continuous or discontinuous mode at low voltages depending on the requirements of the load on the converter. Furthermore, the converter may be required to operate in continuous mode at high voltages at least over parts of the cycle if not the entire cycle if there is a particularly large load on the converter.  
         [0057]     In the specification the terms “comprise, comprises, comprised and comprising” or any variation thereof and the terms “include, includes, included and including” or any variation thereof are considered to be totally interchangeable and they should all be afforded the widest possible interpretation and vice versa.  
         [0058]     The invention is not limited to the embodiment hereinbefore described, but may be varied in both construction and detail.