Primary-side start-up method and circuit arrangement for a series-parallel resonant power converter
A series-parallel resonant power converter comprises a primary-side start-up controller and a secondary-side controller, wherein the primary-side start-up controller sends power to the secondary-side controller when power (voltage) is first applied to the series-parallel resonant power converter. The start-up controller starts up the series-parallel resonant power converter using an open-loop start-up technique wherein the secondary-side closed-loop controller takes over control of the series-parallel resonant power converter once it becomes powered and activated. During light-load or no load conditions, the secondary-side controller sends an off resonance higher frequency or a standby code inhibit (disable) command to the start-up controller. When power needs to be sent to the secondary side of the transformer to charge a secondary side capacitor, the secondary-side controller may send an enable code command to the start-up controller where it is detect to allow the start-up controller to operate in a normal fashion with the secondary side controller.
1. A method for starting up a series-parallel resonant power converter, said method comprising during starting up of the series-parallel resonant power converter:
applying a first DC voltage to a primary-side start-up controller;
turning on and off at least one power switch with the start-up controller at a frequency higher than a resonant frequency of a series-parallel resonant circuit that includes a primary winding of a transformer that is coupled to at least one power switch;
reducing the on and off frequency of the at least one power switch toward the resonant frequency of the series-parallel resonant circuit during said starting up, whereby an AC voltage is produced on a secondary winding of the transformer;
rectifying the AC voltage from the secondary winding of the transformer with first rectifiers to provide a second DC voltage for powering a secondary-side controller and a load; and
transferring control of the at least one power switch from the primary-side start-up controller to the secondary-side controller when the second DC voltage is at a desired voltage value.
2. The method according to claim 1 , wherein the step of turning on and off the at least one power switch with the start-up controller is within a frequency range that lies above said resonant frequency.
3. The method according to claim 2 , wherein the step of turning on and off the at least one power switch with the start-up controller is controlled to drift to a lower end of said frequency range.
4. The method according to claim 1 , wherein the step of turning on and off the at least one power switch with the start-up controller starts at a fixed higher frequency and changes to a lower frequency.
5. The method according to claim 1 , wherein the step of turning on and off the at least one power switch with the start-up controller starts at a fixed lower frequency and changes to a higher frequency.
6. The method according to claim 1 , wherein the step of transferring control of the at least one power switch from the primary-side start-up controller to the secondary-side controller comprises steps of:
sending signals from the secondary-side controller to the primary-side start-up controller when the second DC voltage is at the desired voltage value;
detecting signals from the secondary-side controller with the primary-side start-up controller; and
controlling the at least one power switch with the detected signals from the secondary-side controller.
7. The method according to claim 6 , wherein the second DC voltage is regulated by the secondary-side controller after the primary-side start-up controller detects the signals from the secondary-side controller.
8. The method according to claim 6 , wherein the step of sending signals from the secondary-side controller to the primary-side start-up controller further comprises the step of sending signals through an isolation circuit.
9. The method according to claim 8 , wherein the isolation circuit comprises an optical coupler.
10. The method according to claim 8 , wherein the isolation circuit comprises a pulse transformer.
11. The method according to claim 1 , further comprising a step of applying AC power to a second rectifier for providing the first DC voltage.
12. The method according to claim 1 , further comprising a step of measuring current of the primary winding of the transformer with a current transformer coupled to a current sense input of the secondary-side controller.
13. The method according to claim 1 , further comprising a step of limiting a maximum allowable transformer primary winding current with the primary-side start-up controller.
14. The method according to claim 1 , wherein the first rectifiers are synchronous rectifiers.
15. The method according to claim 14 , wherein the synchronous rectifiers switch at zero voltage.
16. The method according to claim 14 , wherein the synchronous rectifiers switch at zero current.
17. The method according to claim 1 , wherein the at least one power switch is at least one power metal oxide semiconductor field effect transistor (MOSFET).
18. The method according to claim 1 , wherein the series-parallel resonant circuit comprises one inductor, one capacitor and the primary winding of the transformer in a LLC power converter configuration.
19. The method according to claim 1 , wherein the series-parallel resonant circuit comprises two capacitors, one inductor and the primary winding of the transformer in a LCC power converter configuration.
20. The method according to claim 1 , further comprising the steps of:
sending a disable signal from the secondary-side controller to the primary-side start-up controller for inhibiting operation of the power switch when the series-parallel resonant power converter is entering a standby mode; and
sending an enable signal from the secondary-side controller to the primary-side start-up controller for enabling operation of the power switch when the series-parallel resonant power returns to an operating mode.
21. The method according to claim 20 , wherein the disable signal comprises a first coded signal and the enable signal comprises a second coded signal, wherein the primary-side start-up controller comprises decoding logic for decoding the first and second coded signals.
22. The method according to claim 20 , wherein the enable and disable signals are at higher frequencies than pulse control frequencies from the secondary-side controller.
23. The method according to claim 1 , wherein a step of turning on and off the at the least one power switch with the start-up controller further comprises the step of generating a bias voltage from a bias winding of the transformer.
24. The method according to claim 1 , wherein a step of transferring control of the at least one power switch from the primary-side start-up controller to the secondary-side controller comprises the step of the start-up controller accepting switching commands from the secondary-side controller so that the secondary-side controller controls the at least one power switch using the start-up controller in order to achieve substantially linear voltage regulation.
25. The method according to claim 1 , wherein the step of turning on and off at the least one power switch with the start-up controller comprises the step of turning on and off the at least one power switch when the start-up controller is in an open loop mode.
26. The method according to claim 1 , wherein the start-up controller provides over-voltage and under-voltage protection, and a maximum current limit through the transformer primary winding.
27. The method according to claim 1 , wherein a tertiary winding voltage from the transformer is coupled to the start-up controller and enables the start-up controller to regulate the secondary-side voltage in an event the secondary-side controller fails to operate correctly.
28. A series-parallel resonant power converter, comprising:
a primary-side start-up controller coupled to a first DC voltage;
at least one power switch coupled to the primary-side start-up controller;
a transformer having primary and secondary windings;
a series-parallel resonant circuit that includes a primary winding of a transformer that is coupled to the at least one power switch;
a current measurement circuit for measuring current through the primary winding of the transformer and providing the measured primary winding current to the primary-side start-up controller;
a secondary-side rectifier coupled to the transformer secondary winding for providing a second DC voltage;
a secondary-side controller coupled to the primary-side start-up controller and the secondary-side rectifier;
wherein during start-up of the series-parallel resonant power converter:
the primary-side start-up controller is configured to receive the first DC voltage and to start to control the at least one power switch on and off at a frequency higher than a resonant frequency of the series-parallel resonant circuit that includes the primary winding of a transformer;
whereby
a current flows through the transformer primary winding,
an AC voltage develops across the transformer secondary winding,
a second DC voltage from the secondary side rectifier powers up the secondary-side controller, and
the secondary-side controller takes over control of the at least one power switch from the primary-side start-up controller when the second DC voltage reaches a desired voltage level.
29. The power converter according to claim 28 , wherein the at least one power switch is at least one power metal oxide semiconductor field effect transistor (MOSFET).
30. The power converter according to claim 28 , wherein the secondary-side controller is coupled to and controls the primary-side start-up controller through an isolation circuit.
31. The power converter according to claim 30 , wherein the isolation circuit is an optical coupler.
32. The power converter according to claim 30 , wherein the isolation circuit is a pulse transformer.
33. The power converter according to claim 28 , wherein the start-up controller comprises:
a voltage regulator having an input and an output;
internal bias voltage circuits coupled to the voltage regulator output;
an under voltage lockout circuit coupled to the voltage regulator output;
an over voltage lockout circuit coupled to the voltage regulator output;
a voltage controlled oscillator (VCO) and logic circuits for generating a variable frequency control signal;
a fixed off-time circuit coupled to the VCO and the logic circuits;
a power driver coupled to the VCO and the logic circuits for providing the variable frequency control signal to the at least one power switch;
an external gate command detection circuit adapted to receive an external control signal, wherein when the external control signal is detected the external gate command detection circuit causes control of the at least one power switch to change from the logic circuits to the external PWM control signal; and
a voltage comparator having an output coupled to the VCO and the logic circuits for detecting over current through the transformer primary winding.
34. The power converter according to claim 33 , further comprising a blanking circuit coupled between the current sense input and the voltage comparator.
35. The power converter according to claim 33 , wherein a start-up frequency is determined by a capacitance value of a capacitor.
36. The power converter according to claim 35 , wherein a slew rate of a start-up frequency is determined by a resistance value of a resistor.
37. The power converter according to claim 28 , wherein the primary-side start-up controller comprises an open-loop voltage controlled oscillator (VCO) and power switch driver.
38. The power converter according to claim 28 , wherein the secondary-side controller comprises a microcontroller.
39. The power converter according to claim 28 , wherein the primary-side start-up controller is further configured to reduce the on and off frequency of the at least one power switch toward the resonant frequency of the series-parallel resonant circuit during said starting-up.
40. A method for starting up a series-parallel resonant power converter, said method comprising during starting up of the series-parallel resonant power converter:
applying a first DC voltage to a primary-side start-up controller;
during starting-up, turning on and off at least one power switch with the start-up controller at a frequency higher than a resonant frequency of a series-parallel resonant circuit that includes a primary winding of a transformer that is coupled to at least one power switch, whereby an AC voltage is produced on a secondary winding of the transformer;
rectifying the AC voltage from the secondary winding of the transformer with first rectifiers to provide a second DC voltage for powering a secondary-side controller and a load; and
transferring control of the at least one power switch from the primary-side start-up controller to the secondary-side controller when the second DC voltage is at a desired voltage value.
41. The method according to claim 40 , wherein the step of turning on and off the at least one power switch with the start-up controller is within a frequency range that lies above said resonant frequency.
42. The method according to claim 41 , further comprising the step of reducing the on and off frequency of the at least one power switch during said starting-up toward drift to a lower end of said frequency range.