Abstract:
A converter with soft start includes a transformer; first and second switches connected to the transformer to supply power to the transformer; a controller connected to the first and second transistors and arranged to, during startup of the converter, switch the first switch with a variable duty cycle and switch the second switch with either a fixed duty cycle or a variable duty cycle with pulses larger than pulses of the variable duty cycle of the first switch; and a bleed device arranged to set initial conditions of the converter before startup of the converter by discharging a capacitor in the converter before startup.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to DC/DC converters. More specifically, the present invention relates to soft-start control schemes for resonant DC/DC converters. 
         [0003]    2. Description of the Related Art 
         [0004]    Known soft-start control schemes with high-side switch Pulse Width Modulation (PWM) control, low-side switch PWM control, or any other asymmetrical PWM control for resonant DC-to-DC converters (e.g., an LLC or an LLCLL resonant converter) requires consideration of the initial conditions in the resonant converter prior to startup. For example, if high-side switch PMW control is used (i.e., the high-side switch operates at a variable duty cycle while the low-side switch operates at a full duty cycle), inrush current will be determined by the initial voltage across the low-side switch. The higher this initial voltage is, the larger the inrush current will be. 
         [0005]    A large inrush current can cause one or more of the following problems during startup of a resonant converter:
       1) A high initial voltage can cause an over-voltage transient in the input capacitors (i.e., resonant capacitors) of a resonant converter, which can decrease the lifetime of the input capacitors.   2) A large inrush current can decrease the lifetime of the input switches (i.e., primary-side switches) of a resonant converter.   3) A large inrush current can also saturate the resonant inductor of a resonant converter. The inrush current can then further increase due to the resonant inductor being saturated.   4) A large inrush current can cause oscillations (e.g., a large ripple voltage) to appear at the output of the resonant converter during an initial stage of soft starting the resonant converter.       
 
         [0010]    Sun et al. (U.S. Pat. No. 8,018,740) teaches operating an LLC resonant converter in a fixed-frequency and variable-pulse duty cycle operation mode during startup of the LLC resonant converter. Sun et al.&#39;s LLC resonant converter switches to a variable-frequency and fixed-pulse duty cycle operation mode once startup is completed (e.g., when a predetermined voltage is reached at a load connected to the output of the LLC resonant converter). That is, during startup, Sun et al.&#39;s LLC resonant converter operates in a PWM mode such that only the duty cycle is controlled and the frequency of the LLC resonant converter remains fixed and then switches to a Pulse Frequency Modulation (PFM) mode after startup. 
         [0011]    Accordingly, one of the drawbacks with Sun et al.&#39;s control scheme is that the implementation of this scheme using commercially available control integrated circuits (ICs) for LLC resonant converters is difficult because conventional control ICs for LLC resonant converters typically do not include a variable-pulse duty cycle capability. Thus, although this scheme can effectively limit inrush current in the LLC resonant converter, an external circuit is needed to control both high-side and low-side switches to operate at a variable pulse duty cycle. Such an external circuit requires a complex implementation to meet isolation requirements for the high-side switch. Another drawback of Sun et al.&#39;s control scheme is a loss of soft switching during startup, which necessitates special considerations for gate drive design. 
         [0012]    Feng et al. (“Optimal Trajectory Control of Resonant LLC Converter for Soft Start-Up”) teaches a control scheme for an LLC resonant converter that uses an asymmetrical current limitation band to settle initial voltage and current levels. Because a startup current in Feng et al. is controlled within the asymmetrical current limitation band, no inrush current exists during startup. Accordingly, one of the drawbacks of Feng et al.&#39;s control scheme is that a resonant current measurement circuit is needed to implement the unsymmetrical current limitation band, which increases the overall cost of a system that includes Feng et al.&#39;s control scheme. Another drawback of Feng et al.&#39;s control scheme is that this control scheme is only applicable for half-bridge LLC resonant converter with a single resonant capacitor, as shown in  FIG. 1 , and not to a half-bridge LLC resonant converter with split resonant capacitors. 
       SUMMARY OF THE INVENTION 
       [0013]    To overcome the problems described above, preferred embodiments of the present invention provide a soft-start control scheme for variable-frequency resonant converters for overcoming the above-described problems that occur during startup of conventional resonant converters. The soft-start control scheme according to the preferred embodiments of the present invention limit inrush current and reduce transient over-voltages by using a bleed device and performing variable duty cycle control for one switch (either high-side or low-side) to set the initial conditions of the resonant converter, which preferably includes setting a capacitor&#39;s voltage to zero or near zero, before startup of the resonant converter. If the bleed device is a bleed resistor, then the bleed resistor R preferably has a very large resistance and thus has a negligible effect on normal operation of the resonant converter. 
         [0014]    A converter with soft start according to a preferred embodiment of the present invention includes a transformer; first and second switches connected to the transformer to supply power to the transformer; a controller connected to the first and second transistors and arranged to, during startup of the converter, switch the first switch with a variable duty cycle and switch the second switch with either a fixed duty cycle or a variable duty cycle with pulses larger than pulses of the variable duty cycle of the first switch; and a bleed device arranged to set initial conditions of the converter before startup of the converter by discharging a capacitor in the converter before startup. 
         [0015]    The bleed device is preferably connected in parallel with the second switch. 
         [0016]    Preferably, either:
       1) the first switch is a high-side switch and the second switch is a low-side switch; or   2) the first switch is a low-side switch and the second switch is a high-side switch.       
 
         [0019]    The converter further preferably includes first and second capacitors connected in series, where the first capacitor is preferably connected to the first transistor and where the second capacitor is preferably connected to the second transistor. Preferably, the bleed device is connected in parallel with the second capacitor, and the second capacitor is the capacitor in the converter discharged by the bleed device before startup. 
         [0020]    Preferably, either:
       1) the first switch is a high-side switch;   2) the second switch is a low-side switch;   3) the first capacitor is a high-side capacitor; and   4) the second capacitor is a low-side capacitor;
 
or
   1) the first switch is a low-side switch;   2) the second switch is a high-side switch;   3) the first capacitor is a low-side capacitor; and   4) the second capacitor is a high-side capacitor.       
 
         [0029]    The bleed device preferably discharges the capacitor in the converter before startup to zero or nearly zero. The converter further preferably includes a resonant inductor. Preferably, the resonant inductor is either a discrete inductor or a leakage inductance of the transformer. Preferably, the bleed device includes either a resistor or a switch. The converter preferably is a resonant converter. The switching of the first switch preferably is center-aligned, left-aligned, or right-aligned. 
         [0030]    A soft-start method for a converter according to a preferred embodiment of the present invention includes the steps of providing a converter that includes a transformer and first and second switches connected to the transformer to supply power to the transformer; before startup of the converter, setting initial conditions of the converter by discharging a capacitor in the converter before startup; and during startup of the converter, switching the first switch with a variable duty cycle and switching the second switch with either a fixed duty cycle or a variable duty cycle with pulses larger than pulses of the variable duty cycle of the first switch. 
         [0031]    The setting initial conditions step preferably is performed using a bleed device connected in parallel with the second switch. 
         [0032]    The converter further preferably includes first and second capacitors connected in series, where the first capacitor is preferably connected to the first transistor and where the second capacitor is preferably connected to the second transistor, and the setting initial conditions step is performed using a bleed device connected in parallel with the second capacitor. 
         [0033]    The discharging of the capacitor in the converter before startup preferably discharges the capacitor to zero or nearly zero. The converter is preferably a resonant converter. 
         [0034]    The above and other features, elements, characteristics, steps, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention with reference to the attached drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0035]      FIG. 1  is a circuit diagram of a conventional half-bridge LLC resonant converter with single resonant capacitor C r . 
           [0036]      FIG. 2  is a circuit diagram of symmetric half-bridge LLC resonant converter with added bleed resistor R. 
           [0037]      FIGS. 3A-3D  show waveforms during soft start using high-side PWM without bleed resistor R. 
           [0038]      FIGS. 4A-4D  show waveforms during soft start using high-side PWM with bleed resistor R. 
           [0039]      FIG. 5  is a circuit diagram of a converter with a bleed resistor R connected in parallel with low-side resonant capacitor C 2  for high-side PWM. 
           [0040]      FIG. 6  is a circuit diagram of a converter with a bleed resistor R connected in parallel with low-side switch Q 2  for high-side PWM. 
           [0041]      FIG. 7A-7C  show gate drive signals with variable duty cycle control for high-side switch Q 1  only.  FIG. 7A  shows a center aligned duty cycle,  FIG. 7B  shows a left-aligned duty cycle, and  FIG. 7C  shows a right-aligned duty cycle. 
           [0042]      FIG. 8  is a circuit diagram of a converter with a bleed resistor R connected in parallel with high-side resonant capacitor C 1  for low-side PWM. 
           [0043]      FIG. 9  is a circuit diagram of a converter with a bleed resistor R connected in parallel with high-side switch Q 1  for low-side PWM. 
           [0044]      FIGS. 10A-10C  show gate drive signals with variable duty cycle control for low-side switch Q 2  only.  FIG. 10A  shows a center aligned duty cycle,  FIG. 10B  shows a left-aligned duty cycle, and  FIG. 10C  shows a right-aligned duty cycle. 
           [0045]      FIG. 11  shows gate drive signals with asymmetrical PWM. 
           [0046]      FIG. 12  is a circuit diagram of half-bridge gate drive using a capacitive bootstrap. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0047]      FIG. 2  is a schematic diagram of an example of an LLC resonant converter according to a preferred embodiment of the present invention. The LLC resonant converter shown in  FIG. 2  is a half-bridge LLC resonant converter that preferably includes at least one high-side switch Q 1  and at least one low-side switch Q 2 . Preferably, the high-side switch Q 1  and the low-side switch Q 2  are metal-oxide-semiconductor field-effect transistors (MOSFETs). Further, the LLC resonant converter shown in  FIG. 2  preferably includes a high-side resonant capacitor C 1  and a low-side resonant capacitor C 2  connected in series, a resonant inductor Lrt, a magnetizing inductor Lmt, and a transformer. The high-side resonant capacitor C 1  and the low-side resonant capacitor C 2  are preferably split resonant capacitors. In particular, split resonant capacitors C 1  and C 2  can be used in medium-power and high-power applications to help reduce the input current ripple. 
         [0048]    The resonant inductor can be a discrete inductor as shown, for example, in  FIGS. 5 ,  6 ,  8 , and  9  as resonant inductor Lre or can be created by the leakage inductance of the transformer as shown, for example, in  FIGS. 2 ,  5 ,  6 ,  8 , and  9  as resonant inductor Lrt. The magnetizing inductor can be a discrete inductor as shown, for example, in  FIGS. 5 ,  6 ,  8 , and  9  as magnetizing inductor Lme or can be created by the magnetizing inductance of the transformer as shown, for example, in  FIGS. 2 ,  5 ,  6 ,  8 , and  9  as magnetizing inductor Lmt. Further, the resonant and magnetizing inductors can each include both discrete inductors and leakage inductors as shown, for example, in  FIGS. 5 ,  6 ,  8 , and  9 . Secondary switches Q 3  and Q 4 , together with the output capacitor Co, preferably define a secondary-side synchronous rectification circuit of the LLC resonant converter shown in  FIG. 2 . It is possible to used diode rectifiers instead of secondary switches Q 3  and Q 4 . 
         [0049]    In the preferred embodiment shown in  FIG. 2 , the switching of the high-side switch Q 1  is controlled with a variable duty cycle, while the switching of the low-side switch Q 2  is controlled with a full duty cycle. In other words, only the high-side switch Q 1  is in PWM mode during startup of the LLC resonant converter. 
         [0050]    A bleed resistor R is connected in parallel with the low-side resonant capacitor C 2 . Accordingly, the initial voltage across the low-side switch Q 2  and the low-side resonant capacitor C 2  is nearly zero before startup of the resonant converter. Because the bleed resistor R preferably has a large resistance, the bleed resistor R may not completely discharge the low-side resonant capacitor C 2 ; however, the bleed resistor R can discharge the low-side resonant capacitor C 2  to an acceptable low voltage. 
         [0051]    When the low-side switch Q 2  is turned on with a full duty cycle at startup, no large inrush current spike is generated because the voltage applied to the resonant inductor Lrt is small because the small initial voltage on the low-side resonant capacitor C 2 . When the high-side switch Q 1  is turned on, the voltage applied to the resonant inductor Lrt is close to the input voltage Vi which causes a rapid increase in current. However, the high-side switch Q 1  is PWM controlled such that the current can be easily controlled to be an acceptable level by changing the duty cycle of the high-side switch Q 1 . Thus, by properly setting initial conditions before the startup of the resonant converter, inrush current can be avoided. 
         [0052]    The transient over-voltage problem on the high-side resonant capacitor C 1  and the low-side resonant capacitor C 2  can also be eliminated because the inrush current is limited by this control scheme. In addition, a smooth soft-start can be achieved, and oscillations during the initial stage of the soft start can be significantly reduced and prevented. 
         [0053]      FIGS. 3A-3D  are graphs of simulated voltage and current measurements for high-side PWM control of the LLC resonant converter of  FIG. 2  without the bleed resistor R, and  FIGS. 4A-4D  are graphs of simulated voltage and current measurements for high-side PWM control of the LLC resonant converter of  FIG. 2  with the bleed resistor R. As shown in the graph of  FIG. 3B  without the bleed resistor R, the resonant current Ires through the resonant inductor Lrt, Lre exhibits a large inrush current spike during startup of the resonant converter. Further, this large inrush current also results in a high-voltage spike across the high-side resonant capacitor C 1 , as shown in the graph of  FIG. 3C . 
         [0054]    As seen in  FIGS. 4A-4D  with the bleed resistor R, both the inrush current and the initial voltage spike across the high-side resonant capacitor C 1  are significantly reduced, which reduces stress on the components of the resonant converter. 
         [0055]    Another benefit of this control scheme is that the low-side switch Q 2  is turned on at zero voltage. Thus, zero-voltage switching (ZVS) losses only occur in the high-side switch Q 1  during startup of the resonant converter. Accordingly, switching noise is reduced as compared with a conventional PWM scheme. 
         [0056]    Implementation of the control scheme is relatively simple because high-voltage half-bridge gate drivers can be used to drive the gate terminals of the high-side switch Q 1  and the low-side switch Q 2  to eliminate the need for bulky pulse transformers used in conventional resonant converters. 
         [0057]    A commercial high-voltage half-bridge Gate Drive IC, which acts as buffer for the gate drive signals provided by a controller IC, is able to drive the high-side switch Q 1  because of the use of a capacitive bootstrap, an example of which is shown in  FIG. 12 . The high-voltage half-bridge Gate Drive IC typically includes the following terminals: high-side power supply VB, high-side output HO, high-side ground or voltage offset VS, low-side power supply VCC, low-side output LO, and low-side ground COM. The low-side switch Q 2  preferably is turned on with an appropriate minimum time interval to properly charge the bootstrap capacitor CB for the high-side gate driver power supply. The bootstrap capacitor CB is connected to the low-side power supply VCC, which is typically supplied by an auxiliary power supply at about 12 volts, through diode DB, which prevents the high voltage from the input voltage Vi from damaging the low-side power supply VCC. By using this arrangement, the low-side switch Q 2  turns on with a full duty cycle, which allows the bootstrap capacitor CB for the high-side gate driver power supply to be fully charged at every cycle. As shown in  FIG. 12 , a low-side buffer capacitor CL provides a low-side output voltage buffer and recharges the bootstrap capacitor CB. The capacitance of the low-side buffer capacitor CL is preferably about ten times the capacitance of the bootstrap capacitor CB. 
         [0058]    For high-side gate drive using a capacitive bootstrap, the low-side switch Q 2  preferably turns on prior to the high-side switch Q 1  to pre-charge the bootstrap capacitor CB. This arrangement charges the low-side resonant capacitor C 2  and discharges the high-side resonant capacitor C 1  to some extent. Thus, the voltage across the high-side resonant capacitor C 1  increases before the high-side switch Q 1  turns on, which results in larger inrush current. Reducing the capacitance of the bootstrap capacitor reduces the inrush current caused by the voltage across the high-side resonant capacitor C 1  increasing before the high-side switch Q 1  turns on. However, the capacitance of the bootstrap capacitor should be carefully selected to ensure reliable operation of the gate driver. 
         [0059]    According to a preferred embodiment of the present invention, high-side PWM control is used in a resonant converter that includes the bleed resistor R connected in parallel with the low-side switch Q 2  as shown in  FIG. 6 . According to another preferred embodiment of the present invention, the bleed resistor R is connected in parallel with the low-side resonant capacitor C 2 , as shown in  FIG. 5 . The bleed resistor R is preferably connected to the low-side resonant capacitor C 2  because it will have less effect during normal operation. Further, the effect during normal operation can be reduced by properly selecting the bleed resistor R. 
         [0060]    During startup of the resonant converters shown in  FIGS. 5 and 6 , the high-side switch Q 1  is controlled with a variable duty cycle, while the low-side switch Q 2  operates with a full duty cycle.  FIGS. 7A-7C  show gate drive waveforms for the resonant converters of  FIGS. 5 and 6 . A high-side gate drive signal Vgs 1  for the high-side switch Q 1  and a low-side gate drive signal Vgs 2  for the low-side switch Q 2  can be center-aligned as shown in  FIG. 7A , left-aligned as shown in  FIG. 7B , or right-aligned as shown in  FIG. 7C . Preferably, the gate drive signals are right-aligned to provide ZVS for the low-side switch Q 2 . 
         [0061]    The resonant converters shown in  FIGS. 5 and 6  and the gate drive signals shown in  FIGS. 7A-7C  reduce the inrush current and the initial voltage spike across the high-side resonant capacitor C 1  so as to reduce stress on the components of the resonant converter. 
         [0062]    According to a preferred embodiment of the present invention, low-side PWM control is used in a resonant converter that includes the bleed resistor R connected in parallel with the high-side switch Q 1 , as shown in  FIG. 9 . According to another preferred embodiment of the present invention, the bleed resistor R is connected in parallel with the high-side resonant capacitor C 1 , as shown in  FIG. 8 . The bleed resistor R is preferably connected to the high-side resonant capacitor C 1  because it will have less effect during normal operation. Further, the effect during normal operation can be reduced by properly selecting the bleed resistor R. 
         [0063]    During startup of the resonant converters shown in  FIGS. 8 and 9 , the low-side switch Q 2  is controlled with a variable duty cycle while the high-side switch Q 1  operates with a full duty cycle.  FIGS. 10A-10C  are gate drive waveforms for the resonant converters of  FIGS. 8 and 9 . A high-side gate drive signal Vgs 1  for the high-side switch Q 1  and a low-side gate drive signal Vgs 2  for the low-side switch Q 2  can be center-aligned as shown in  FIG. 10A , left-aligned as shown in  FIG. 10B , or right-aligned as shown in  FIG. 10C . Preferably, the gate drive signals are right-aligned to provide ZVS for high-side switch Q 1 . 
         [0064]    The resonant converters shown in  FIGS. 8 and 9  and the gate drive signals shown in  FIGS. 10A-10C  reduce the inrush current and the initial voltage spike across the high-side resonant capacitor C 2  so as to reduce stress on the components of the resonant converter. 
         [0065]    Accordingly, the resonant converters shown in  FIGS. 5 ,  6 ,  8 , and  9  can be easily implemented using commercially available control ICs for LLC resonant converters with high-side gate drive capability using a capacitive bootstrap, an example of which is shown in  FIG. 12  and described above. Because commercially available control ICs for LLC resonant converters can only operate at frequency modulation mode, the duty cycles of the high-side switch Q 1  and the low-side switch Q 2  are not directly controllable. However, low-side PWM control can be easily implemented by adding a simple external circuit to selectively filter out a portion of each of the pulses included in low-side gate drive signals output by the control IC to provide the low-side gate drive signal Vgs 2 . High-side PWM control is difficult to implement with commercially available control ICs for LLC resonant converters because isolation between the circuit that provides pulse blanking (i.e., filtering or zeroing out a portion of each of the voltage pulses in the low-side gate drive signal Vgs 2 ) and the circuit that generates the high-side gate drive signal should be considered. In particular, a bulky pulse transformer can be required. Thus, low-side PWM control provides an easier implementation of soft startup in a resonant converter when commercially available control ICs for LLC resonant converters are used. 
         [0066]    The bleed resistor R, when connected in parallel with the high-side switch Q 1  or the high-side resonant capacitor C 1 , can pre-discharge the high-side resonant capacitor C 1  such that the voltage across the high-side resonant capacitor C 1  is nearly zero before startup of the resonant converter. When the high-side switch Q 1  is turned on with full duty cycle at startup, no large inrush current spike is generated because the voltage across the resonant inductor Lrt, Lre is small because of the small initial voltage on the high-side resonant capacitor C 1 . The low-side PWM control can achieve similar soft-start performance as that of the high-side PWM control described above. Thus, by properly setting initial conditions before the startup of the resonant converter, inrush current can be avoided. 
         [0067]    For a high-side gate drive using a capacitive bootstrap, the low-side switch Q 2  preferably turns on prior to the high-side switch Q 1  to pre-charge the bootstrap capacitor CB. This arrangement charges the low-side resonant capacitor C 2  and discharges the high-side resonant capacitor C 1  to some extent. Thus, the voltage across the high-side resonant capacitor C 1  increases before the high-side switch Q 1  turns on, which results in larger inrush current. Reducing the capacitance of the bootstrap capacitor can reduce the inrush current caused by the voltage across the high-side resonant capacitor C 1  increasing before the high-side switch Q 1  turns on. However, the capacitance of the bootstrap capacitor should be carefully selected to ensure reliable operation of the gate driver. 
         [0068]    Other devices or circuits can be added to a resonant converter to achieve similar results as those achieved with the bleed resistor R. For example, a transistor or switch can be used in place of the bleed resistor R to selectively charge or discharge the high-side resonant capacitor C 1  or the low-side resonant capacitor C 2 . For example, before startup, the transistor or switch can be turned on to discharge the high-side resonant capacitor C 1  or the low-side resonant capacitor C 2 , and then the transistor or switch can be turned off so that the converter can startup. 
         [0069]    Asymmetrical PWM control can be used in the resonant converters described above and controlled in a similar manner as high-side PWM control and low-side PWM control described in the preferred embodiments of the present invention.  FIG. 11  shows gate drive waveforms for asymmetrical PWM control, including a high-side gate drive signal Vgs 1  for the high-side switch Q 1  and a low-side gate drive signal Vgs 2  for the low-side switch Q 2 . If the high-side gate drive signal Vgs 1  initially has a wider pulse width than the low-side gate drive signal Vgs 2 , the bleed resistor R is preferably connected in parallel with the high-side switch Q 1  or the high-side resonant capacitor C 1 . However, if the low-side gate drive signal Vgs 2  initially has a wider pulse width than the high-side gate drive signal Vgs 1 , the bleed resistor R is preferably connected in parallel with the low-side switch Q 2  or the low-side resonant capacitor C 2 . 
         [0070]    The preferred embodiments of the present invention are described above with respect to analog circuits. However, the preferred embodiments of the present invention can also be implemented with digital circuits. In particular, the control IC for the resonant converters can be a digital IC or an analog IC. Further, the preferred embodiments of the present invention can be applied to any type of DC-to-DC converter, including LLCLL resonant converters and LLC resonant converters. 
         [0071]    If a single resonant capacitor is used instead of split resonant capacitors C 1  and C 2 , then the bleed resistor R can be placed in parallel with the single resonant capacitor. 
         [0072]    It should be understood that the foregoing description is only illustrative of the present invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variances that fall within the scope of the appended claims.