Patent Document

CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims benefit of the following patent application which is hereby incorporated by reference: U.S. Provisional Patent Application No. 61/586,541, filed Jan. 13, 2012. 
    
    
     A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to resonant power converters. More particularly, the present invention relates to gain enhancement techniques in resonant power converters through the use of auxiliary components and associated control circuitry. 
     Resonant converters (e.g., LLC converters) have become a popular topology in power conversion applications and can generally meet or exceed high efficiency requirements due to soft switching. However, achieving better performance (e.g., higher efficiency) is difficult because any combination of requirements for a holdup time, peak power, and wide input range regulation must be concurrently satisfied. In other words, any solution which may be provided to meet the requirements for holdup time, peak power, and/or wide regulation range, will generally have undesirable side effects with respect to the efficiency of the converter. As a consequence, the key parameters in resonant converters are designed to fashion a compromise between better performance and sufficient holdup time, peak power, and/or wide input range regulation. 
     Generally stated, a holdup time requirement for a converter is a minimum period of time for which a threshold power output must be maintained after, e.g., an input power failure. 
     As one example in the case of LLC converters, better efficiency may be obtained with larger magnetizing inductance in the power transformer because magnetizing current can accordingly be reduced. This is beneficial with respect to semiconductor conduction losses on the primary side of the transformer. 
     Alternatively, a longer holdup time can be realized with smaller magnetizing inductance in the power transformer according to the gain curve of the LLC converter. Eventually, the key parameters in the LLC converter are a compromise between high efficiency and a required minimum holdup time. 
     It would be desirable to provide a resonant converter design that supported higher efficiency by optimizing the key parameters (e.g., resonant parameters) of the resonant converter while further allowing for sufficient holdup time. 
     BRIEF SUMMARY OF THE INVENTION 
     A resonant converter in accordance with the present invention is designed to controllably adjust one or more key parameters (e.g., resonant parameters) from a first value to a second value only during a holdup time period so as to realize the minimum holdup time requirement, and to return the parameters to the first value when the holdup time period is not in effect so as to provide higher efficiency in the converter. In other words, a particular control mode for a resonant converter of the present invention satisfies the holdup time requirement without negatively affecting the high efficiency of the converter because it only operates in the control mode during the holdup time period. 
     According to the gain curve of the LLC converter, an increase in values for any one or more of a resonant capacitor, a resonant inductor and/or the magnetizing inductance of the power transformer may sufficiently enhance the holdup time of the converter. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a block diagram representing an exemplary resonant converter according to the present invention. 
         FIG. 2  is a circuit block diagram representing an embodiment of the resonant converter of  FIG. 1  having a half-bridge switching converter topology and wherein an auxiliary resonant capacitance is controllably applied. 
         FIG. 3  is a circuit block diagram representing an embodiment of the resonant converter of  FIG. 1  having a half-bridge switching converter topology and wherein an auxiliary resonant inductance is controllably applied. 
         FIG. 4  is a circuit block diagram representing an embodiment of the resonant converter of  FIG. 1  having a half-bridge switching converter topology and wherein an auxiliary magnetizing inductance is controllably applied with respect to the magnetizing inductance integral to a primary winding in the power transformer. 
         FIG. 5  is a circuit block diagram representing an embodiment of the resonant converter of  FIG. 1  having a half-bridge switching converter topology and wherein an auxiliary magnetizing inductance is controllably applied with respect to the magnetizing inductance of a separate magnetizing inductor parallel to the primary winding in the power transformer. 
         FIG. 6  is a circuit block diagram representing an alternative embodiment of the resonant converter of  FIG. 1  having a half-bridge switching converter topology to which an auxiliary resonant parameter may be applied in accordance with the present invention. 
         FIG. 7  is a circuit block diagram representing an embodiment of the resonant converter of  FIG. 1  having a full-bridge switching converter topology to which an auxiliary resonant parameter may be applied in accordance with the present invention. 
         FIG. 8  is a circuit block diagram representing an exemplary embodiment of control circuitry for controllably adjusting resonant parameters. 
         FIG. 9  is a circuit block diagram representing another exemplary embodiment of control circuitry for controllably adjusting resonant parameters. 
         FIG. 10  is a circuit block diagram representing another exemplary embodiment of control circuitry for controllably adjusting resonant parameters. 
         FIG. 11  is a graphical diagram representing performance of an exemplary resonant converter with controllably adjusted resonant capacitance according to a method of the present invention. 
         FIG. 12  is a graphical diagram representing performance of an exemplary resonant converter with controllably adjusted magnetic inductance according to a method of the present invention. 
         FIG. 13  is a graphical diagram representing performance of an exemplary resonant converter with controllably adjusted resonant inductance according to a method of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Throughout the specification and claims, the following terms take at least the meanings explicitly associated herein, unless the context dictates otherwise. The meanings identified below do not necessarily limit the terms, but merely provide illustrative examples for the terms. The meaning of “a,” “an,” and “the” may include plural references, and the meaning of “in” may include “in” and “on.” The phrase “in one embodiment,” as used herein does not necessarily refer to the same embodiment, although it may. 
     The term “coupled” means at least either a direct electrical connection between the connected items or an indirect connection through one or more passive or active intermediary devices. The term “circuit” means at least either a single component or a multiplicity of components, either active and/or passive, that are coupled together to provide a desired function. The term “signal” as used herein may include any meanings as may be understood by those of ordinary skill in the art, including at least an electric or magnetic representation of current, voltage, charge, temperature, data or a state of one or more memory locations as expressed on one or more transmission mediums, and generally capable of being transmitted, received, stored, compared, combined or otherwise manipulated in any equivalent manner. 
     The terms “switching element” and “switch” may be used interchangeably and may refer herein to at least: a variety of transistors as known in the art (including but not limited to FET, BJT, IGBT, JFET, etc.), a switching diode, a silicon controlled rectifier (SCR), a diode for alternating current (DIAC), a triode for alternating current (TRIAC), a mechanical single pole/double pole switch (SPDT), or electrical, solid state or reed relays. Where either a field effect transistor (FET) or a bipolar junction transistor (BJT) may be employed as an embodiment of a transistor, the scope of the terms “gate,” “drain,” and “source” includes “base,” “collector,” and “emitter,” respectively, and vice-versa. 
     The terms “power converter” and “converter” unless otherwise defined with respect to a particular element may be used interchangeably herein and with reference to at least DC-DC, DC-AC, AC-DC, buck, buck-boost, boost, half-bridge, full-bridge, H-bridge or various other forms of power conversion or inversion as known to one of skill in the art. 
     Terms such as “providing,” “processing,” “supplying,” “determining,” “calculating” or the like may refer at least to an action of a computer system, computer program, signal processor, logic or alternative analog or digital electronic device that may be transformative of signals represented as physical quantities, whether automatically or manually initiated. 
     The terms “controller,” “control circuit” and “control circuitry” as used herein may refer to a processor-readable and non-transitory memory medium such as a general microprocessor, application specific integrated circuit (ASIC), microcontroller, or the like as may be designed and programmed with instructions effective to cause specific functions as further defined herein to be performed upon execution by a processing unit, either alone or in combination with a field programmable gate array or various alternative blocks of discrete circuitry as known in the art. 
     Referring generally to  FIGS. 1-13 , various embodiments of a resonant converter are described herein with auxiliary resonant components and control circuitry for controllably adjusting the resonant characteristics of the converter during a holdup time period. Where the various figures may describe embodiments sharing various common elements and features with other embodiments, similar elements and features are given the same reference numerals and redundant description thereof may be omitted below. 
     Referring to  FIG. 1 , an exemplary resonant converter  10  of the present invention includes a switch circuit  12  which may generally define a switching power converter stage coupled to input power terminals Vin+, Vin−. A resonant network  14  is coupled to an output end of the switch circuit  12 . A rectifier and filter circuit  16  is coupled to the resonant network  14  and is further coupled on an output end to output power terminals Vo+, Vo−. An auxiliary resonant circuit  18  is provided which includes one or more auxiliary resonant components which are available to be controllably applied across respective resonant components of the resonant network  14 . A control circuit  20  provides control signals to enable the application of the auxiliary resonant components during, e.g., a holdup time period, which may be determined based on input signals from a feedback circuit  22 . 
     Referring generally to  FIGS. 2-4 , various embodiments may be described with respect to different auxiliary components. It may be understood that any one or more of the auxiliary components may be made available in a resonant converter according to the present invention, although the embodiments described herein only make reference to one at a time. 
     As represented in  FIG. 2 , an embodiment of a resonant converter  10   a  of the present invention includes a switch circuit  12  having first and second switches Q 1 , Q 2 , respectively, arranged in a half-bridge topology as it is known in the art across first and second power input terminals VB+, VB−. A series resonant circuit  14  includes a resonant inductor Lr having a resonant inductance, a primary winding Lm of power transformer TX 1  having a magnetizing inductance, and a resonant capacitor Cr having a resonant capacitance. The series resonant circuit  14  is coupled on a first end to a node between the pair of switches, Q 1 , Q 2 , and on a second end to the second (i.e., negative) power input terminal VB−. 
     A rectifier and filter circuit  16  includes first and second rectifier switches Q 3 , Q 4  coupled to opposing ends of split windings Ls 1 , Ls 2  of a secondary side of the power transformer TX 1 . The rectifier switches Q 3 , Q 4  are further coupled to a first power output terminal Vrtn, with a center node between the split windings Ls 1 , Ls 2  being coupled to a second power output terminal Vo. An output capacitor C 4  is coupled across the power output terminals Vrtn, Vo as a filtering component. The rectifier and filter circuit  16  as represented in  FIG. 2  is intended as merely exemplary, and various alternative topologies on the secondary side (i.e., output end) of the power transformer may be apparent to those of skill in the art and within the scope of the present invention. 
     An auxiliary resonant capacitance branch  18  is provided, with an auxiliary capacitor Ca and a switching element S 1  coupled in series across the resonant capacitor Cr. During normal operation of the converter, the switching element S 1  may be off so as to disable the auxiliary branch and make the capacitance of the resonant capacitor Cr be the sole resonant capacitance for the circuit  14  (i.e., a first resonant capacitance value). During a holdup time condition, the switching element S 1  may be controlled to be turned on very quickly so as to enable the auxiliary branch  18  and apply the auxiliary capacitance from the auxiliary capacitor Ca in parallel with the resonant capacitor Cr, thereby generating an equivalent capacitance (i.e., second resonant capacitance value) which would be increased with respect to the normal (i.e., first) value. According to the gain curve of a typical LLC converter, the holdup time can be enhanced with higher gain due to the higher resonant capacitance. 
     It may be understood that the values of the resonant capacitor Cr and the auxiliary capacitor Ca may be chosen in accordance with component values for the desired transfer function and behavior of the resonant network for each of the normal and holdup time operating conditions, respectively. An auxiliary branch may not necessarily be limited to a single auxiliary capacitor and/or switching element, and various alternative arrangements may be provided within the scope of the present invention for generating an equivalent capacitance during a holdup time condition. 
     Further, as alluded to previously, application of the auxiliary branch is not limited to the occurrence of a holdup time condition, and may in various embodiments be provided in accordance with any one or more of a holdup time condition, a peak power condition, and wide range regulation. A feedback circuit  22  may detect either or both of the input to, and output from, the resonant converter  10   a , wherein the timing may be determined by the controller  20  for applying the auxiliary branch  18  to the resonant circuit  14 . For example, a holdup time condition may be determined in accordance with detection of a loss of power input, or a drop in input power below a predetermined threshold, and the condition may be accordingly programmed to last for a predetermined holdup time period or may be applicable for as long as the input power is determined to be below the threshold value. 
     As represented in  FIG. 3 , another embodiment of a resonant converter  10   a  of the present invention includes substantially the same arrangement as that represented in  FIG. 2 , except that the auxiliary branch  18  is provided with an auxiliary inductor La and a switching element S 1  coupled in series across the resonant inductor Lr. During normal operation of the converter, the switching element S 1  may be on so as to enable the auxiliary branch  18  and apply the auxiliary inductance from the auxiliary inductor La in parallel with the resonant inductor Lr, thereby generating an equivalent inductance for the circuit  14  (i.e., a first resonant inductance value). 
     During a holdup time condition, the switching element S 1  may be controlled to be turned off very quickly so as to disable the auxiliary branch and remove the auxiliary inductance from the auxiliary inductor La, thereby generating a second resonant inductance value which would be increased with respect to the normal (i.e., first) value. According to the gain curve of a typical LLC converter, the holdup time can be enhanced with higher gain due to the higher resonant inductance. 
     It may be understood that the values of the resonant inductor Lr and the auxiliary inductor La may be chosen in accordance with component values for the desired transfer function and behavior of the resonant network for each of the normal and holdup time operating conditions, respectively. An auxiliary branch may not necessarily be limited to a single auxiliary inductor and/or switching element, and various alternative arrangements may be provided within the scope of the present invention for generating appropriate resonant inductance during normal and holdup time operating conditions. 
     Further, as alluded to previously, application of the auxiliary branch is not limited to the occurrence of a holdup time condition, and may in various embodiments be provided in accordance with any one or more of a holdup time condition, a peak power condition, and wide range regulation. A feedback circuit  22  may detect either or both of the input to and output from the resonant converter  10   a , wherein the timing may be determined by the controller for applying the auxiliary branch  18  to the resonant circuit  14 . For example, a holdup time condition may be determined in accordance with detection of a loss of power input, or a drop in input power below a predetermined threshold, and the condition may be accordingly programmed to last for a predetermined holdup time period or may be applicable for as long as the input power is determined to be below the threshold value. 
     As represented in  FIG. 4 , another embodiment of a resonant converter  10  of the present invention includes substantially the same arrangement as that represented in  FIG. 2 , except that the auxiliary branch  18  is provided with an auxiliary inductor La and a switching element S 1  coupled in series across the magnetizing inductance of the primary winding Lm of the power transformer TX 1 . During normal operation of the converter, the switching element S 1  may be off so as to disable the auxiliary branch  18  and make the magnetizing inductance of the primary winding Lm be the sole magnetizing inductance for the circuit  14  (i.e., a first magnetizing inductance value). During a holdup time condition, the switching element S 1  may be controlled to be turned on very quickly so as to enable the auxiliary branch and apply the auxiliary inductance from the auxiliary inductor La in parallel with the primary winding Lm, thereby generating an equivalent magnetizing inductance (i.e., second magnetizing inductance value) which would be decreased with respect to the normal (i.e., first) value. According to the gain curve of a typical LLC converter, the holdup time can be enhanced with higher gain due to the smaller magnetizing inductance. 
     It may be understood that the values of the magnetizing inductance of the primary winding Lm and the auxiliary inductor La may be chosen in accordance with component values for the desired transfer function and behavior of the resonant network for each of the normal and holdup time operating conditions, respectively. An auxiliary branch may not necessarily be limited to a single auxiliary inductor and/or switching element, and various alternative arrangements may be provided within the scope of the present invention for generating an equivalent magnetizing inductance during a holdup time condition. 
     Further, as alluded to previously, application of the auxiliary branch is not limited to the occurrence of a holdup time condition, and may in various embodiments be provided in accordance with any one or more of a holdup time condition, a peak power condition, and wide range regulation. A feedback circuit  22  may detect either or both of the input to and output from the resonant converter  10   a , wherein the timing may be determined by the controller  20  for applying the auxiliary branch  18  to the resonant circuit  14 . For example, a holdup time condition may be determined in accordance with detection of a loss of power input, or a drop in input power below a predetermined threshold, and the condition may be accordingly programmed to last for a predetermined holdup time period or may be applicable for as long as the input power is determined to be below the threshold value. 
     Referring now to  FIG. 5 , to further improve resonant converter efficiency a separate magnetizing inductor Lm may be used with respect to the primary winding P 1  of the power transformer TX 1 , thereby minimizing core loss. In this case, the power transformer TX 1  may be constructed without an air gap, or the parameters of the air gap may reasonably be ignored. An external but smaller core may be used as the magnetizing inductor Lm. Otherwise, application or removal of the auxiliary branch  18  with respect to the magnetizing inductor Lm may be substantially the same as the process described above with respect to  FIG. 4 . 
     Another embodiment of a resonant converter  10   b  according to the present invention may include a symmetrical half-bridge LLC converter as represented in  FIG. 6 . A resonant inductor Lr and primary winding Lm of the power transformer TX 1  are coupled in series to a node between the switches Q 1 , Q 2 . A first capacitor Lc 1  and a first diode D 1  are coupled in parallel with each other on a first end to the primary winding Lm of the power transformer TX 1 , and on a second end to the negative input power terminal VB−. A second capacitor Lc 2  and a second diode D 2  are coupled in parallel with each other on a first end to the primary winding Lm of the power transformer TX 1 , and on a second end to the positive input power terminal VB+. An auxiliary branch  18  and associated control circuitry as previously described with respect to any one or more of  FIGS. 2-5  may be applied in similar fashion with respect to the symmetrical half-bridge topology of  FIG. 6 . 
     Another embodiment of a resonant converter  10   c  according to the present invention may include a full bridge LLC converter as represented in  FIG. 7 . The series resonant network  14  (i.e., resonant inductor Lr, magnetizing inductance Lm and resonant capacitor Cr) is coupled on a first end between a first pair of switches Q 1 , Q 2 , and coupled on a second end between a second pair of switches Q 3 , Q 4 . An auxiliary branch  18  and associated control circuitry as previously described with respect to any one or more of  FIGS. 2-5  may be applied in similar fashion with respect to the full bridge topology of  FIG. 7 . 
     Referring now to  FIG. 8 , an exemplary control circuit  20  as applied to a resonant converter  10   a  such as that represented in  FIG. 2  may now be described. It may be understood that an equivalent control circuit  20  may be utilized with respect to various alternative converter topologies, such as for example those resonant converter topologies  10   a ,  10   b ,  10   c , as represented in  FIGS. 3-7 , and further that various alternative embodiments of a control circuit  20  may be used, such as for example including microcontrollers rather than or in addition to discrete circuitry. 
     In the embodiment shown, a comparator X 1  is utilized to sense the input voltage and determine when the auxiliary component(s) (e.g., the auxiliary resonant capacitor Ca) is enabled and working in parallel with its respective counterpart in the resonant network  14  (e.g., the resonant capacitor Cr) during a holdup time period. A voltage divider defined by resistors R 1  and R 2  provides the input voltage to be sensed against the reference voltage Vref. When the input voltage drops to the setting value, the output of the comparator X 1  will be changed to high, which can drive both of switches Q 5  and Q 6  to be turned on. As a result, the auxiliary capacitor Ca is applied to work in parallel with the resonant capacitor Cr. Note that resistor R 3  and diode D 1  may be included to achieve hysteresis and thereby prevent various glitches in the output of the comparator X 1  during any transition operation. 
     Referring now to  FIG. 9 , the exemplary control circuit  20  as described above with respect to  FIG. 8  may be applied to circuits having a different embodiment for the auxiliary branch  18 . In this case, the auxiliary branch  18  includes a plurality of diodes D 2 , D 3 , D 4 , D 5  in addition to the auxiliary capacitor Ca and a single switching element Q 5 . Note that in  FIG. 8 , the switching elements Q 5  and Q 6  are common source connected. The circuit in  FIG. 9  may typically be more generic in nature as the resonant capacitor Cr is not connected to power return. 
     Referring now to  FIG. 10 , rather than using a bidirectional switch formed by the series connection of switching elements Q 5 , Q 6  (as represented in  FIG. 8 ), another exemplary embodiment of the auxiliary branch  18  may include first and second switching elements Q 5  and Q 6 , respectively, arranged in a parallel configuration with series blocking body diodes D 5  and D 6 , respectively, to realize an equivalent bidirectional switch. 
     The switching elements Q 5  and Q 6  as shown in  FIGS. 8-10  are re-channel Mosfets. However, it may be understood that in various embodiments these switching elements may be replaced with p-channel Mosfets or other equivalent units to achieve substantially the same function. 
     Referring now to  FIGS. 11-13 , graphical simulations are provided of exemplary performance of a resonant converter  10  constructed and operated in accordance with the present invention. The simulations were performed based on a 400 W server powered with a single phase half bridge LLC converter. The optimized key parameters include a resonant inductance Lr=24 μH, a resonant capacitance Cr=44 nF, and a magnetizing inductance Lm=274 μH. The resonant frequency is 126 kHz. The nominal bulk voltage is around 400 Vdc. The minimum bulk voltage is 330 Vdc to maintain 12 Vdc regulation. 
     As represented in the graphs of  FIGS. 11-13 , a holdup time can be enhanced by application of smaller magnetizing inductance, and/or a larger resonant inductance and/or larger resonant capacitance. In each case shown, only a single component is adjusted, although in certain embodiments it may be understood that some combination of components may be adjusted otherwise. 
     In  FIG. 11 , the first curve  11 ( a ) represents the output voltage Vo with a normal bulk voltage of 400 Vdc. The second curve  11 ( b ) represents the output voltage Vo with the normal bulk voltage disabled or removed and an original resonant capacitance of 44 nF at 330 Vdc. The third curve  11 ( c ) represents the output voltage Vo with the resonant capacitance increased by 22 nF to 66 nF, at 330 Vdc. To increase resonant capacitance, a minimum switching frequency has to be reduced synchronously during the hold up time period such that an appropriate gain enhancement is achieved for a longer hold up time. 
     In  FIG. 12 , the first curve  12 ( a ) represents the output voltage Vo with a normal bulk voltage of 400 Vdc. The second curve  12 ( b ) represents the output voltage Vo with the normal bulk voltage disabled or removed and an original magnetizing inductance of 274 μH at 330 Vdc. The third curve  12 ( c ) represents the output voltage Vo with the magnetizing inductance decreased to 175 μH, at 330 Vdc. To decrease the magnetizing inductance, it is unnecessary to adjust the minimum switching frequency during the hold up time period. 
     In  FIG. 13 , the first curve  13 ( a ) represents the output voltage Vo with a normal bulk voltage of 400 Vdc. The second curve  13 ( b ) represents the output voltage Vo with the normal bulk voltage disabled or removed and an original resonant inductance of 24 μH at 330 Vdc. The third curve  13 ( c ) represents the output voltage Vo with the resonant inductance increased to 45 μH, at 330 Vdc. The minimum switching frequency as represented in  FIG. 13  remains substantially unchanged during the hold up time, but the improvement is somewhat limited. 
     The previous detailed description has been provided for the purposes of illustration and description. Thus, although there have been described particular embodiments of the present invention of a new and useful “Resonant Converter with Auxiliary Resonant Components and Holdup Time Control Circuitry,” it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.

Technology Category: 4