Patent Document

FIELD OF INVENTION 
   The present invention relates to power converters, and more particularly, to a circuit that controls synchronous rectifier back bias in non-isolated DC-DC buck converters. 
   BACKGROUND OF THE INVENTION 
   Increasingly, synchronous rectifiers are replacing freewheeling diodes in non-isolated DC-DC buck converters in order to increase the power conversion efficiency of the converters. One feature of non-isolated DC-DC converters with synchronous rectification is that current is enabled to flow not only to the output terminals through the synchronous rectifier but also in a reverse direction from the output terminals back into the converter, i.e., a non-isolated dc-dc converter with synchronous rectification can have both current-sourcing and current-sinking capability. 
   A conventional buck converter is shown in FIG.  1 . As is well known, a basic buck converter comprises a switch  6 , an input filter capacitor  8 , a freewheeling diode  12 , an inductor  14 , and a capacitor  16 , connected in a conventional way between an input terminal  2  to which is coupled an input voltage V in  relative to ground, and an output terminal  22  at which the buck converter generates a regulated output voltage V o  relative to ground. An exemplary load  20  is shown coupled to the output of converter  10 . The switch  6  is typically an electronic switch, such as a MOSFET, that is controlled in a known manner by a control circuit, e.g., a pulse width modulator (PWM) (not shown in  FIG. 1 ) that is responsive to the output voltage V o . When the switch  6  is closed, the capacitor  16  is charged via switch  6  and inductor  14  from the input voltage V in  to produce the output voltage V o , which is consequently less than the peak input voltage V in . When switch  6  is open, current through the inductor  14 , identified as I o , is maintained via diode  12 . 
   In order to boost power conversion efficiency, the freewheeling diode  12  is preferably replaced with a MOSFET, defined as a synchronous rectifier, identified as  18  in FIG.  1  and shown connected using dotted lines. In operation, synchronous rectifier  18  lowers the voltage drop across nodes  7  and  5  that otherwise exists with diode  12 . Only uni-directional current flow is permitted through the freewheeling diode  12 . By contrast, the synchronous rectifier  18  permits bi-directional current flow. As a result, inductor current, I o , can flow in reverse through synchronous rectifier  18  from the output. Synchronous rectifier  18  is preferably controlled directly by a PWM (not shown). Although switch  6  and synchronous rectifier  18  are both driven by a PWM, it is well known that the control signals from the PWM for these elements are complementary signals such that switch  6  and synchronous rectifier  18  are never turned on at the same time, in order to prevent the shorting of the input terminal  2  to ground. 
   The bi-directional current flowing capability of the synchronous rectifier  18  may pose a serious problem when such rectifiers are used in paralleled power converters. The paralleling of power converters provides a way for two or more individual, small, high density power converter modules to supply the higher power required by current generation loads and/or to provide redundancy. Applications may also require various configurations of paralleled converters. A known application, e.g., for a digital signal processor, requires paralleled converters to be configured for sequential operation, wherein the converters are powered on sequentially according to a predetermined sequence.  FIG. 2  is a block diagram of a prior art system having two paralleled power modules connected in a sequencing configuration to supply power to two loads. The parallel sequencing system  30  in  FIG. 2  includes a converter  32  connected in parallel with a converter  34 . According to the sequencing for an embodiment of system  30 , converter  32  is always turned on before converter  34  is turned on. Each converter  32 ,  34  is a buck converter having a synchronous rectifier in place of the freewheeling diode, as shown in FIG.  1 . As shown in  FIG. 2 , power is supplied to converters  32 ,  34  from a single power input, V in , at input terminals  2 ,  4 . It will be recognized by those skilled in the art that it is not necessary that power be supplied to the converter at a single power input port. Rather, each power module may receive power from a separate power source such as separate AC-DC converters (not shown). Converter  32  is coupled to output terminals  42  and  44  to supply an output voltage V A0  to a load, shown schematically as  28 . Converter  34  is coupled to output terminals  38 ,  40  to supply an output voltage V B0  to a load, shown schematically as  26 . The output of each converter  32 ,  34  is also coupled to the output terminals of the other converter via a diode  36 . Diode  36  has an anode coupled to output terminal  42  of converter  32  and a cathode coupled to the output terminal  38  of converter  34 . The corresponding negative output terminals  44 ,  40  of each converter are also connected as shown in FIG.  2 . 
   In operation, converter  32  is turned on first while converter  34  remains off. During this time, the synchronous rectifier in converter  34  remains in an off state. At this time, converter  32  supplies an output voltage V A0  to a load  28 . However, since converter  34  is off, diode  36  is in a conduction state. As a result, converter  32  also provides power to a load  26 . At this point in the sequence, converter  34  is turned on. As converter  34  begins to operate, its synchronous rectifier, now turned on, will pull down the paralleled outputs to a level corresponding to the programmed soft-start level for converter  34 . This pulling-down effect causes a short circuit operation of converter  32  during the soft-start period for converter  34 . This effect is one example of an effect commonly referred to as the “synchronous rectifier back bias” problem of non-isolated dc-dc buck converters. The synchronous rectifier of converter  34  will continue this “pulling-down” effect until the output voltage of converter  34  becomes equal to the output voltage of converter  32 , at which point diode  36  no longer conducts and the two converter outputs become uncoupled from one another. In practice, a short circuit protection will be triggered and the system  30  cannot remain in operation without special attention. A need therefore exists for overcoming this synchronous rectifier back bias problem for the system of  FIG. 2 , while having the benefits provided by the use of a synchronous rectifier, namely reduced cost and higher density, as demanded for modern devices. 
     FIG. 3  is a block diagram of another configuration of a system of parallel converters (also referred to herein as “power modules”). For the paralleled converter configuration shown in  FIG. 3 , power is supplied to a common output voltage bus and thereby to a load. As shown in  FIG. 3 , power module  1 , power module  2 , . . . power module N are each coupled to a single power output port  320  for supplying power to a load. An exemplary load  330  is shown coupled to output port  320  of system  300 . In a preferred embodiment, power is supplied to power modules  1  through N at a single power input port  340 . It will be recognized by those skilled in the art that it is not necessary that power be supplied to power modules  1  through N at a single power input port. Rather, each power module may receive power from a separate power source such as separate AC-DC converters (not shown). 
   In one exemplary system, the power modules  1  through N are buck converters having a synchronous rectifier in place of the freewheeling diode, as shown in FIG.  1 . For this exemplary system, because the synchronous rectifier allows reverse current flow, a system failure may result, e.g. from recycling one or more modules while the system is already in operation, and powering on each of paralleled modules at different times, etc. 
   A need therefore exists for a circuit that actively and efficiently controls the synchronous rectifier in the respective power converters in a system having paralleled power converters in order to eliminate the synchronous rectifier back bias problem. There is also a need for a circuit that provides this function during the soft start period of a power converter in a paralleled converter configuration. 
   SUMMARY OF THE INVENTION 
   The present invention solves the problems of prior art devices by providing, in a system comprising a plurality of paralleled converters, a control circuit that efficiently prevents the turning on of the synchronous rectifier in a buck converter during a predetermined condition, so as to prevent current reversing through the synchronous rectifier during that time. In one embodiment, the present invention provides control of the synchronous rectifier during the soft-start time for a non-isolated DC-DC buck converter, thereby preventing current reversing (sinking) during its soft start process. In another embodiment of the present invention, a circuit uses a signal indicative of a soft-start condition for a converter to prevent the turning on of the synchronous rectifier during the soft-start time. The present invention also solves the synchronous rectifier back bias problem during the soft-start of a converter used in a paralleled converter configuration. 
   Consequently, embodiments of the present invention have the advantage of preventing the synchronous rectifier back bias problem and doing so at reduced cost using fewer components than known devices. 
   Broadly stated, the present invention provides, in a system having a buck converter comprising a switch, an inductor, a capacitor and a synchronous rectifier, the buck converter having two input terminals to which an input DC voltage is coupled and two output terminals where the output DC voltage is provided, the synchronous rectifier having a control input and being controlled such that when the switch is open, current through the inductor is maintained by a path provided by the synchronous rectifier, and having a pulse width modulator (PWM) having an output designed to provide control of the state of the synchronous rectifier; a control circuit coupled between the PWM output and the control input of said synchronous rectifier for controlling the synchronous rectifier during a predetermined condition, comprising a comparator circuit for comparing a feedback signal indicative of the predetermined condition to a predetermined reference voltage, such that said comparator circuit outputs a control signal when the predetermined condition is active; a driver circuit responsive to the control signal to turn off the synchronous rectifier when the predetermined condition is active so as to prevent the PWM from controlling the state of the synchronous rectifier and so as to enable the PWM to control the synchronous rectifier when said predetermined condition is not active. 
   Broadly stated the present invention also provides, a power system having a plurality of DC-DC converter modules, each having an input terminal to which an input DC voltage is coupled and an output terminal where the output DC voltage is provided, said converter modules being connected in parallel through their output terminals to a common bus connected to a load, each said converter module comprising: a buck converter for converting said input DC voltage to a regulated output DC voltage, said buck converter having a switch and an inductor connected in series between its respective input terminal and output terminal, said inductor having one end connected to its respective output terminal, a synchronous rectifier connected between said other end of said inductor and ground, and a capacitor connected between its respective output terminal and ground; a pulse width modulator (PWM) having an output designed to provide control of the state of said synchronous rectifier; a control circuit coupled between said PWM output and said control input of said synchronous rectifier for controlling said synchronous rectifier during a predetermined condition, comprising: a comparator circuit for comparing a feedback signal indicative of said predetermined condition to a predetermined reference voltage, such that said comparator circuit outputs a control signal when said predetermined condition is active; and a driver circuit responsive to said control signal to turn off said synchronous rectifier when said predetermined condition is active so as to prevent said PWM from controlling the state of said synchronous rectifier and so as to enable said PWM to control said synchronous rectifier when said predetermined condition is not active. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The forgoing aspects and the attendant advantages of the present invention will become more readily appreciated by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein: 
       FIG. 1  illustrates a typical prior art non-isolated DC-DC buck converter; 
       FIG. 2  is a block diagram of a prior art system having two power modules connected in a sequencing configuration to supply power to separate loads; 
       FIG. 3  is a block diagram of a prior art system of power modules connected in parallel through their output terminals to a common bus connected to a load; 
       FIG. 4  shows an embodiment of the circuit according to the present invention for use in a system that does not provide a signal indicative of the soft-start condition; and 
       FIG. 5  shows a preferred embodiment of the circuit according to the present invention for a system having an accessible soft-start indication. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention overcomes the drawbacks of known prior art circuits. A preferred embodiment of the circuit for each converter in a paralleled system of converters is shown in FIG.  5 . The converter  200  has an input terminal  104  to which an input DC voltage V in  is coupled relative to ground and an output terminal  122  where the output DC voltage V O  of each converter module is provided relative to ground. Converter  200  includes a control circuit  250  coupled to a buck regulator  102  having a synchronous rectifier  118 . The buck regulator  102  comprises a switch  106 , an inductor  114 , and a capacitor  116 , connected in a conventional way between input terminal  104  and output terminal  122 . An exemplary load R L  is shown coupled to the output of converter  200 . Switch  106  is typically a power MOSFET which is controlled in a known manner by a PWM  166  that is responsive to the output voltage V o . When the switch  106  is closed, the capacitor  116  is charged via switch  106  and inductor  114  from the input voltage to produce the output voltage V o , which is consequently less than the peak input voltage. When switch  106  is open, current through the inductor  114  is maintained via synchronous rectifier  118 . 
   In buck regulator  102 , the synchronous rectifier  118  replaces a conventional freewheeling diode, as is shown in  FIG. 1 , in order to boost power conversion efficiency. Synchronous rectifier  118  has a control input and is preferably a MOSFET whose control input is the gate of the MOSFET. The synchronous rectifier  118  permits bi-directional current flow. As a result, the inductor current can flow in reverse through synchronous rectifier  118  from the output. The synchronous rectifier  118  is conventionally controlled directly by a pulse width modulator PWM  146 . Switch  106  and synchronous rectifier  118  may be driven by the same pulse width modulator. It is well known conventionally that the control signals from the pulse width modulator for the control inputs of switch  106  and synchronous rectifier  118  must be complementary signals such that both devices are not turned on at the same time, so as to avoid shorting the input terminal  104  to ground. As seen in  FIG. 5 , for converter  200 , however, a control circuit  250  is coupled between a PWM  146  and the gate input of the synchronous rectifier  118 . Thus, for the present invention, a PWM is not directly coupled to the control input of the synchronous rectifier  118 . According to the embodiment of the present invention shown in  FIG. 5 , control circuit  250  provides direct control of the on and off state of synchronous rectifier  118 . 
   Control circuit  250  includes a comparator circuit  204  coupled to a driver circuit  170  that is coupled directly to the gate input of synchronous rectifier  118 . The driver circuit  170  comprises a PNP transistor  120 , an NPN transistor  130 , and a resistor  126 . Transistor  120  has a base and collector, both coupled to PWM  146  at node  125 , and an emitter coupled to the control input of synchronous rectifier  118 . Transistor  130  has a collector coupled to PWM  146  at node  125 , an emitter coupled to the control input of synchronous rectifier  118 , and a base coupled through resistor  126  to node  125 . The base of transistor  130  is also coupled to the comparator circuit  104  at a node  135 . 
   Comparator circuit  204  includes a transistor  128 . Transistor  128  is shown as an NPN transistor in FIG.  5 . Transistor  128  is preferably a bipolar transistor type. As shown in  FIG. 5 , transistor  128  has a collector connected to node  135 , an emitter coupled to ground, and a base. The base of transistor  128  is coupled to the output of a comparator  110 . 
   The comparator  110  has a positive input and a negative input. A reference signal  236  is coupled to the positive input of comparator  110 . The reference signal  236  is preferably generated by a conventional voltage divider circuit coupled to a voltage reference V ref . The voltage divider is preferably formed by a resistor  142  and a resistor  144  connected in series between V ref  and ground. 
   For the preferred embodiment of the circuit of the present invention shown in  FIG. 5 , a soft-start indication signal  210  is fed back to the negative input of comparator  110  in control circuit  250 . The soft-start indication signal  210  is preferably provided by PWM  146 . As described above with reference to  FIG. 2 , it is during the soft-start period of the buck converter when the synchronous rectifier back bias problem is experienced. Thus, preferably a signal indicative of this soft-start period is used by the control circuit of the present invention to eliminate this problem. Once the soft-start sequence is completed, and the buck converter is outputing the required output voltage for normal operation, the soft-start indication signal is not longer active. 
   The operation of the converter  200  will now be described in further detail. During the soft-start period of the buck converter  102 , control circuit  250  operates to block the PWM from controlling the synchronous rectifier  118 . When the buck converter  102  is not in the soft-start period, control circuit  250  enables the PWM to control the synchronous rectifier  118  of the buck converter  102 . 
   For the embodiment in  FIG. 5 , comparator  110  compares the soft-start indication signal  210  to the reference signal  236 . During the soft-start period, signal  210  is active. Preferably, the reference signal  236  is set to a predetermined level such that signal  236  is higher than the level of the soft-start indication signal  210  when the converter is in soft-start mode, and reference signal  236  is not higher than the soft-start signal when the converter is not in soft-start mode. As a result, comparator  110  outputs a “high” signal during the soft-start period of the converter, and a “low” signal otherwise. 
   Thus, during soft-start mode of the converter, comparator  110  sets the base of transistor  128  high, thereby causing transistor  128  to switch to a conductive state. During this conductive state, because the emitter is coupled to ground, the voltage at the collector of transistor  128  is also pulled down to a low voltage level near ground. The base of transistor  130  at node  135  is coupled to the collector of transistor  128 , and so is also pulled down to a low voltage level near ground. As a result, transistor  130  is nonconductive. 
   Conventionally, the PWM outputs a high level signal, preferably 5V, at signal line  138  in order to set the synchronous rectifier  118  in an “on” conductive state. When transistor  130  is non-conductive, it prevents signal  138  from being coupled to the control input of the synchronous rectifier. 
   Transistor  120  is a PNP transistor having a base and collector connected to the PWM at node  125 , and an emitter connected to the control input of the synchronous rectifier  118 . Thus, transistor  120  does not provide a path for the PWM  146  to set the control input of the synchronous rectifier  118 . As a result, during the soft-start period of the buck converter  102 , the circuit of the present invention blocks PWM  146  from controlling the synchronous rectifier  118 . If the synchronous rectifier  118  was on during the soft-start period, transistor  120  functions to turn synchronous rectifier  118  off by discharging the gate charge at the its control input. Control circuit  250  holds synchronous rectifier  118  in the off state until the soft-start indication signal  210  indicates the converter is no longer in soft-start. 
   When the converter is not in soft-start mode, the output of comparator  110  is low, the base of transistor  128  is low, making transistor  128  non-conductive. This causes the collector of  128  to present a floating level to the base of transistor  130  at node  135 . As a result, driver circuit  170  no longer blocks the PWM from the control input of the synchronous rectifier  118 , thereby allowing the PWM to control the state of the synchronous rectifier  118 . Thus, during the soft-start period the control circuit  250  turns off synchronous rectifier  118  and keep it off during this period, thereby preventing reverse current flow through the synchronous rectifier  118  and solving the back bias problem. 
     FIG. 4  shows an alternate embodiment of the circuit according to the present invention for use for a system that does not provide a signal indicative of the soft-start condition. As seen in  FIG. 4 , the converter  100  differs from the embodiment in  FIG. 5 , since in  FIG. 4 , the output voltage at terminal  122  is fed back for comparison to a reference by comparator  110  rather than a soft-start indication signal. For converter  100 , a suitable reference signal  136  is provided by a voltage divider circuit formed by a resistor  132  and  134  in order to output a signal from comparator  110 , such that the comparator output is active during the soft-start period. 
   For another alternate embodiment, any suitable signal can be fed back to the control circuit  250 , in order to disable the synchronous rectifier  118  during a predetermined condition. 
   According to another embodiment, the present invention provides a system that solves the aforementioned synchronous rectifier back bias problem for a converter used in a paralleled converter configuration, wherein each converter corresponds to converter  100  in FIG.  4 . Two embodiments of the paralleled configuration of converters are shown in  FIGS. 2 and 3 . Alternately, the present invention provides a system of paralleled converters wherein each converter corresponds to converter  200  in  FIG. 5   
   The foregoing detailed description of the invention has been provided for the purposes of illustration and description. Although exemplary embodiments of the present invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to the precise embodiments disclosed, and that various changes and modifications to the present invention are possible in light of the above teaching.

Technology Category: 4