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ADAPTIVE PHASE SHEDDING AND SWITCHING FREQUENCY CONTROL FOR MULTIPHASE DC-DC CONVERTERS BASED ON LOAD CURRENT

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ADAPTIVE PHASE SHEDDING AND SWITCHING FREQUENCY CONTROL FOR MULTIPHASE DC-DC CONVERTERS BASED ON LOAD CURRENT

ORDINARY APPLICATION

Published

date

Filed on 12 November 2024

Abstract

Disclosed herein is a multiphase DC-DC converter system (100) for adaptive phase shedding and switching frequency control based on load current. The system (100) comprises a DC-DC converter (102) configured to operate with individual phases (106) connected in parallel. The system (100) also includes an input capacitor (104) connected to the DC-DC converter (102) configured to filter voltage fluctuations at the input. The system (100) also includes an output capacitor (108) connected to the DC-DC converter (102) configured to filter output voltage fluctuations and maintain consistent output ripple at the output. The system (100) also includes a digital controller (110) connected to the DC-DC converter (102) and configured to manage adaptive phase shedding and switching frequency. The digital controller (110) further comprises a voltage controller (112), positioned at the outer voltage loop and configured to regulate output voltage by generating a reference current based on load conditions.

Patent Information

Application ID202441087011
Invention FieldELECTRICAL
Date of Application12/11/2024
Publication Number47/2024

Inventors

NameAddressCountryNationality
SWATHI HATWAR HDEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING, NMAM INSTITUTE OF TECHNOLOGY, NITTE (DEEMED TO BE UNIVERSITY), NITTE- 574110, KARNATAKA, INDIAIndiaIndia
ANUP SHETTYDEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING, NMAM INSTITUTE OF TECHNOLOGY, NITTE (DEEMED TO BE UNIVERSITY), NITTE- 574110, KARNATAKA, INDIAIndiaIndia
DR. SURYANARAYANA KDEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING, NMAM INSTITUTE OF TECHNOLOGY, NITTE (DEEMED TO BE UNIVERSITY), NITTE- 574110, KARNATAKA, INDIAIndiaIndia

Applicants

NameAddressCountryNationality
NITTE (DEEMED TO BE UNIVERSITY)6TH FLOOR, UNIVERSITY ENCLAVE, MEDICAL SCIENCES COMPLEX, DERALAKATTE, MANGALURU, KARNATAKA 575018IndiaIndia

Specification

Description:FIELD OF DISCLOSURE
[0001] The present disclosure generally relates to a multiphase DC-DC converter system, more specifically, relates to a system for adaptive phase shedding and switching frequency control based on load current.
BACKGROUND OF THE DISCLOSURE
[0002] Multiphase DC-DC converters are power conversion systems designed to distribute electrical load across multiple phases to efficiently convert direct current (DC) from one voltage level to another. By splitting the load between several phases, these converters are able to reduce the stress on individual components, lower the overall thermal load, and achieve higher efficiency, particularly in applications that require high current and stable voltage outputs.
[0003] Multiphase converters are widely used in areas like telecommunications, data centers, automotive systems, and computing, where reliable power supply and high efficiency are critical. The ability to handle large currents without increasing switching losses or compromising stability makes them an ideal solution for powering modern electronic devices.
[0004] Traditional multiphase DC-DC converters typically use static or open-loop control systems to manage the addition or removal of phases based on load requirements. These conventional systems often suffer from several limitations, including inefficient switching at light loads, difficulty in balancing phase currents due to circuit parasitic, and increased power losses during phase transitions. Furthermore, traditional converters commonly rely on silicon-based switching devices, which tend to have higher switching losses compared to newer materials. This can result in lower overall efficiency, especially at varying load conditions, and may lead to issues such as thermal imbalance and reduced reliability over time.
[0005] The present disclosure relates to the field of multiphase DC-DC converters and specifically addresses the challenges associated with efficient phase shedding and switching frequency control based on load current. Multiphase DC-DC converters are widely used in various applications due to their ability to distribute the load across multiple phases, reducing stress on individual components and improving overall system efficiency. However, conventional methods for managing the addition and removal of phases in these converters often face several drawbacks, such as increased switching losses, imbalances in phase currents, and reduced reliability due to the temporary disabling of overload protection mechanisms.
[0006] Conventional systems, such as those using methods for phase dropping and adding, rely heavily on adjusting the duty cycle to redistribute phase currents. This approach introduces complexity during phase transitions, potentially causing temporary imbalances in current distribution, leading to output voltage glitches during phase shedding or adding.
[0007] Existing inventions focus on improving steady-state efficiency, particularly in systems for multiphase ripple voltage regulation. However, these systems often lack adaptive control to optimize efficiency across a wide range of load currents, especially under light-load conditions, which can lead to higher switching losses.
[0008] The present disclosure introduces an advanced method for adaptive phase shedding and switching frequency control that dynamically responds to varying load currents. Unlike traditional systems, which operate with fixed phase settings or require manual adjustments, this invention continuously monitors the load current and adjusts the number of active phases to match the current demand. This not only ensures higher efficiency across both light and heavy loads but also reduces energy wastage during low power demand periods. The ability to dynamically modify the phase count and switching frequency ensures that the system operates at its optimal point of efficiency, minimizing unnecessary power losses and improving the overall performance of the DC-DC converter.
[0009] Unlike conventional systems, which typically depend on direct duty cycle adjustments to add or remove phases, this invention employs a novel reference current control technique for phase transitions. Traditional systems often face challenges in maintaining smooth transitions during phase addition or removal, leading to current imbalances and output voltage glitches. In contrast, this invention gradually adjusts the reference current of each phase, ensuring that transitions are seamless and current distribution remains balanced. This not only prevents disruptions in the power output but also ensures that overload protection remains active throughout the process, enhancing both the safety and reliability of the system under varying operating conditions.
[0010] The system is designed to incorporate wide bandgap semiconductor devices, which offer significant advantages over conventional silicon-based devices. By utilizing WBG technology, the system is able to operate with lower switching losses, allowing for higher switching frequencies without sacrificing efficiency. This reduces the size and cost of passive components such as capacitors, further improving system compactness and performance. The use of WBG devices also enhances thermal performance, allowing the system to handle higher power densities while maintaining cooler operation, thus extending the lifespan of the converter and reducing the need for extensive cooling solutions.
[0011] The system solves a critical issue of phase current imbalance faced by many existing multiphase converters. In conventional systems, due to circuit parasitic and a shared duty cycle across all phases, individual phase currents can become imbalanced over time, leading to degraded performance and reduced efficiency. This invention addresses that problem by implementing individual current compensators for each phase, ensuring that current is evenly distributed across all active phases. This balanced load sharing not only improves efficiency but also reduces thermal stress on switches, extending its operational life and ensuring consistent performance even in applications with varying load conditions.
[0012] Thus, in light of the above-stated discussion, there exists a need for an adaptive phase shedding and switching frequency control based on load current in multiphase DC-DC converters.
SUMMARY OF THE DISCLOSURE
[0013] The following is a summary description of illustrative embodiments of the invention. It is provided as a preface to assist those skilled in the art to more rapidly assimilate the detailed design discussion which ensues and is not intended in any way to limit the scope of the claims which are appended hereto in order to particularly point out the invention.
[0014] According to illustrative embodiments, the present disclosure focuses on a system for adaptive phase shedding and switching frequency control based on load current, which overcomes the above-mentioned disadvantages or provide the users with a useful or commercial choice.
[0015] An objective of the present disclosure is to improve the efficiency of multiphase DC-DC converters by dynamically optimizing phase addition or removal based on load current. This reduces unnecessary power losses and ensures consistent output voltage ripple during phase transitions. The system adapts to varying load conditions, maintaining high performance and stability while minimizing energy consumption across different operating states.
[0016] Another objective of the present disclosure is to ensure smooth phase transitions by adjusting reference currents rather than directly varying the duty cycle. This approach maintains system reliability and overload protection, preventing sudden disruptions during phase changes while ensuring stable power flow and balanced phase currents.
[0017] Another objective of the present disclosure is to increase efficiency by incorporating wide bandgap (WBG) power semiconductor devices. These devices reduce switching losses, enabling the converter to operate at higher frequencies and withstand greater voltages and temperatures. This significantly improves overall system performance, particularly in high-power applications, while minimizing heat generation and energy loss.
[0018] Another objective of the present disclosure is to address phase current imbalances using individual current controllers for each phase. This ensures balanced current distribution, overcoming the limitations of traditional converters where common duty cycles lead to uneven phase currents. Maintaining current balance improves system reliability and prevents long-term performance degradation.
[0019] Another objective of the present disclosure is to implement adaptive switching frequency control and phase shift selection. This ensures consistent output voltage ripple and allows the use of smaller, more cost-effective filter capacitors. By adjusting frequency based on load conditions, the system enhances efficiency, reduces switching losses, and improves overall performance across various operating states.
[0020] Yet another objective of the present disclosure is to improve thermal management through a phase rotation technique. By alternating active phases in a round-robin manner, the system prevents prolonged overheating of any single phase, ensuring even thermal distribution and extending the operational life of the converter components in high-power applications
[0021] In light of the above, in one aspect of the present disclosure, a multiphase DC-DC converter system for adaptive phase shedding and switching frequency control based on load current is disclosed herein. The system comprises a DC-DC converter configured to operate with individual phases connected in parallel, each phase comprising wide bandgap power semiconductor devices designed to minimize switching losses. The system also includes an input capacitor connected to the DC-DC converter configured to filter voltage fluctuations at the input. The system also includes an output capacitor connected to the DC-DC converter configured to filter output voltage fluctuations and maintain consistent output ripple at the output. The system also includes a digital controller connected to the DC-DC converter and configured to manage adaptive phase shedding and switching frequency. The digital controller further comprises a voltage controller, positioned at the outer voltage loop and configured to regulate output voltage by generating a reference current based on load conditions, an adaptive phase shedding controller configured to enable or disable phases by gradually adjusting the reference current, ensuring balanced load sharing and consistent voltage ripple, an independent current controllers for each phase, positioned at the inner current loop and configured to ensure current balance and prevent current imbalance due to circuit parasitic, an adaptive phase and frequency selector configured to dynamically adjust switching phase and frequency angles between active phases, and a PWM generator connected to each phase and configured to generate the necessary control signals for phase switching.
[0022] In one embodiment, the WBG devices are selected for their high efficiency and low switching loss properties compared to conventional silicon-based devices, improving overall converter efficiency.
[0023] In one embodiment, the digital controller is further configured to dynamically adjust the phase angle difference between active phases according to load conditions, enhancing output ripple stability.
[0024] In one embodiment, the adaptive phase shedding controller is configured to increase reference current for adding a phase and decrease it in steps for dropping a phase to maintain balanced current distribution among active phases.
[0025] In one embodiment, the adaptive phase shedding controller is configured to monitor load current and trigger phase activation or deactivation based on a predefined threshold to optimize efficiency.
[0026] In one embodiment, the system further comprises a phase rotation technique that activates phases in a round-robin manner when fewer active phases are needed, thereby enhancing thermal management.
[0027] In one embodiment, the independent current controllers are configured to monitor and adjust the individual phase currents to maintain balanced load distribution, independent of circuit parasitic effects.
[0028] In one embodiment, the adaptive phase and frequency selector is configured to modify the switching frequency inversely with the number of active phases, thereby maintaining consistent output voltage ripple across different load conditions.
[0029] In one embodiment, the PWM generator generates duty cycles for each phase based on the reference currents received from the independent current controllers , ensuring seamless phase addition or removal.
[0030] In light of the above, in another aspect of the present disclosure, a method for adaptive phase shedding and switching frequency control based on load current using the multiphase DC-DC converter system. The method comprises operating with individual phases connected in parallel via a DC-DC converter. The method also includes filtering voltage fluctuations at the input via an input capacitor. The method also includes filtering output voltage fluctuations and maintain consistent output ripple at the output via an output capacitor. The method also includes managing adaptive phase shedding and switching frequency, wherein the digital controller further comprises via a digital controller. The method also includes regulating output voltage by generating a reference current based on load conditions via a voltage controller. The method also includes enabling or disabling phases by gradually adjusting the reference current, ensuring balanced load sharing and consistent voltage ripple via an adaptive phase shedding controller. The method also includes ensuring current balance and preventing current imbalance due to circuit parasitic via independent current controllers. The method also includes dynamically adjusting phase angles and switching frequency between active phases via an adaptive phase and frequency selector. The method also includes generating the necessary control signals for phase switching via a PWM generator.
[0031] These and other advantages will be apparent from the present application of the embodiments described herein.
[0032] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments.
[0033] The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
[0034] These elements, together with the other aspects of the present disclosure and various features are pointed out with particularity in the claims annexed hereto and form a part of the present disclosure. For a better understanding of the present disclosure, its operating advantages, and the specified object attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] To describe the technical solutions in the embodiments of the present disclosure or in the prior art more clearly, the following briefly describes the accompanying drawings required for describing the embodiments or the prior art. Apparently, the accompanying drawings in the following description merely show some embodiments of the present disclosure, and a person of ordinary skill in the art can derive other implementations from these accompanying drawings without creative efforts. All of the embodiments or the implementations shall fall within the protection scope of the present disclosure.
[0036] The advantages and features of the present disclosure will become better understood with reference to the following detailed description taken in conjunction with the accompanying drawing, in which:
[0037] FIG. 1 illustrates a block diagram of a multiphase DC-DC converter system, in accordance with an exemplary embodiment of the present disclosure;
[0038] FIG. 2 illustrates a block diagram of a multiphase DC-DC converter system, in accordance with an exemplary embodiment of the present disclosure;
[0039] FIG. 3 illustrates a system flow chart, outlining the sequential steps involved in the multiphase DC-DC converter system, in accordance with an exemplary embodiment of the present disclosure; and
[0040] Like reference, numerals refer to like parts throughout the description of several views of the drawing.
[0041] The multiphase DC-DC converter system is illustrated in the accompanying drawings, which like reference letters indicate corresponding parts in the various figures. It should be noted that the accompanying figure is intended to present illustrations of exemplary embodiments of the present disclosure. This figure is not intended to limit the scope of the present disclosure. It should also be noted that the accompanying figure is not necessarily drawn to scale.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0042] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.
[0043] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the present disclosure. It may be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without some of these specific details.
[0044] Various terms as used herein are shown below. To the extent a term is used, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0045] The terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
[0046] The terms "having", "comprising", "including", and variations thereof signify the presence of a component.
[0047] Referring now to FIG. 1 to FIG. 3 to describe various exemplary embodiments of the present disclosure. FIG. 1 illustrates a block diagram of a multiphase DC-DC converter system 100, in accordance with an exemplary embodiment of the present disclosure.
[0048] The system 100 may include a DC-DC converter 102, individual phases 106, an input capacitor 104, an output capacitor 108, a digital controller 110, a voltage controller 112, an adaptive phase shedding controller 114, an independent current controllers 116, an adaptive phase and frequency selector 118 , a PWM generator 120, and a DC source 122.
[0049] The DC-DC converter 102 is a critical component of the system designed to convert direct current from one voltage level to another efficiently. It ensures that the appropriate voltage is supplied to the load under various operating conditions. In this invention, the DC-DC converter 102 works in a multiphase architecture, where each phase operates interleaved to provide a stable and reliable power supply. This multiphase setup allows for better load distribution, reduces output ripple, and enhances overall efficiency. The converter includes several individual phases 106, each managed by a controller that ensures load balancing and minimizes parasitic losses. In the preferred embodiment of the present invention, the DC-DC converter 102 is a multiphase buck converter that adjusts the number of active phases based on the load requirements. The use of wide bandgap (WBG) devices further improves its efficiency by minimizing switching losses compared to conventional silicon devices.
[0050] In one embodiment of the present invention, WBG devices are selected for their high efficiency and low switching loss properties compared to conventional silicon-based devices, improving overall converter efficiency. These devices allow the system to operate at higher switching frequencies without incurring significant losses, thereby enabling the design of smaller and more efficient power conversion systems. By using WBG devices, the invention achieves better thermal performance, reduces energy loss, and allows for faster switching times, which contribute to enhanced performance in high-load or high-frequency applications. This directly impacts the system's ability to add or drop phases smoothly, maintaining a consistent voltage ripple and improving overall reliability.
[0051] The individual phases 106 are essential building blocks of the multiphase DC-DC converter 102. Each phase consists of an inductor and switching elements, operating interleaved to share the load current and reduce the overall current ripple. These phases work in parallel, and their interleaved operation allows the system to deliver smoother output while distributing the thermal load across multiple phases, enhancing efficiency and reliability. In the preferred embodiment of the present invention, the individual phases 106 are part of a multiphase buck converter topology. Each phase is independently controlled by a digital controller 110, which regulates its duty cycle to balance the current across all active phases.
[0052] The output capacitor 108 is a critical component in the DC-DC converter system 100, tasked with smoothing and stabilizing the output voltage after the conversion process. It acts to filter any high-frequency voltage ripples that may result from the switching of the individual phases 106, ensuring that the output voltage is steady and within the desired range. This not only improves the quality of the power supplied to the load but also helps maintain system stability under varying load conditions. In the preferred embodiment of the present invention, the output capacitor 108 is designed to handle the high switching frequencies typical of the multiphase DC-DC converter 102.
[0053] The digital controller 110 is the central processing unit of the multiphase DC-DC converter system 100. It is responsible for managing and controlling the overall operation of the converter by regulating both the output voltage and current. The digital controller 110 monitors key parameters, such as phase currents and load conditions, and adjusts the converter's behavior to optimize performance. It coordinates the independent current controllers 116 for each phase and ensures smooth phase transitions when adding or shedding phases, thereby maintaining a stable output voltage and consistent load sharing across all active phases. In the preferred embodiment of the present invention, the digital controller 110 is a sophisticated microcontroller-based unit that communicates with various sensors and control loops within the system.
[0054] In one embodiment of the present invention, the digital controller 110 is further configured to dynamically adjust the phase angle difference between active phases according to load conditions, enhancing output ripple stability. It uses advanced algorithms to optimize the switching frequency and phase angle based on the number of active phases, which minimizes ripple and reduces power loss. This dynamic adjustment ensures that even when the number of active phases changes, the system can continue to operate efficiently, providing stable power delivery without compromising performance. By continuously fine-tuning the phase and frequency settings, the digital controller 110 contributes to both the reliability and efficiency of the multiphase converter system.
[0055] The voltage controller 112 is a crucial component within the multiphase DC-DC converter system, responsible for regulating the output voltage. It continuously compares the output voltage with a reference voltage and generates the necessary control signals to maintain the desired voltage level. By adjusting the current reference of the individual phases, the voltage controller 112 ensures that the system meets the required voltage output under varying load conditions.
[0056] The adaptive phase shedding controller 114 is a key component in the multiphase DC-DC converter system 100, responsible for dynamically adjusting the number of active phases based on the real-time load conditions. It monitors the system's load and determines whether to activate or deactivate individual phases 106 to optimize the converter's efficiency. This controller ensures that only the necessary number of phases are active, thus reducing energy losses during low-load conditions while ensuring sufficient power delivery during high-load conditions. By controlling the number of active phases, it helps balance the power distribution across the phases and minimizes the overall switching losses.
[0057] In one embodiment of the present invention, the adaptive phase shedding controller 114 is configured to increase the reference current for adding a phase and decrease it for dropping a phase in steps to maintain balanced current distribution among active phases. It ensures a smooth transition when phases are added or removed by gradually adjusting the reference current, preventing any sudden spikes or drops in the output voltage. This feature helps maintain balanced operation across all active phases, reducing the risk of current imbalances or thermal stress on individual phases 106.
[0058] In one embodiment of the present invention, the adaptive phase shedding controller 114 is configured to monitor the load current and trigger phase activation or deactivation based on a predefined threshold to optimize efficiency. It continuously evaluates the load demand and determines whether additional phases need to be activated to handle increased load or whether phases can be deactivated during low-load conditions to reduce switching losses. This adaptive control mechanism allows the system to operate at maximum efficiency across a wide range of load conditions, ensuring that power delivery is matched to demand while minimizing unnecessary energy consumption.
[0059] In one embodiment of the present invention, the system further comprises a phase rotation technique that activates phases in a round-robin manner when fewer active phases are needed, thereby enhancing thermal management. This technique ensures that the thermal load is evenly distributed across all phases, preventing any single phase from overheating due to continuous operation. By cycling through different phases during periods of low demand, the system allows each phase to share the thermal burden, extending the life of components and improving overall reliability.
[0060] The independent current controllers 116 are crucial for ensuring that each phase in the multiphase DC-DC converter 102 operates with balanced current distribution. These controllers independently regulate the current flowing through each phase, preventing any one phase from carrying a disproportionate load. This independent control is essential in managing the uneven distribution of current that can arise due to circuit parasitic effects, such as differences in inductance or resistance between phases, which could otherwise lead to inefficiencies or potential damage to the system. In the preferred embodiment of the present invention, the independent current controllers 116 are digital controller 110, each dedicated to a specific phase of the converter. These controllers monitor the current in their respective phases and adjust the duty cycle of the phase accordingly, ensuring that the total current is shared evenly across all active phases. This configuration helps prevent current imbalance, which is a common issue in conventional converters that rely on a single controller for all phases.
[0061] In one embodiment of the present invention, the independent current controllers 116 are configured to monitor and adjust the individual phase currents to maintain balanced load distribution, independent of circuit parasitic effects. It ensures that the current through each phase is regulated in real-time, allowing the system to compensate for any variations in circuit parameters. By continuously adjusting the current in each phase, the controllers help achieve optimal efficiency and ensure that the load is evenly shared, which enhances system reliability and prevents phase-specific overheating or overloading. This independent regulation also contributes to the smooth operation of the adaptive phase shedding process, as the system can maintain balanced operation even when phases are added or removed based on load conditions.
[0062] The adaptive phase and frequency selector 118 is a vital component in the system, responsible for determining the optimal phase angle and switching frequency based on the number of active phases and the current load conditions. Its primary role is to ensure that the system operates at maximum efficiency while maintaining consistent output voltage ripple, regardless of how many phases are active at any given time. The selector dynamically adjusts the phase shift between active phases and the switching frequency to match the system's real-time requirements, optimizing the performance of the DC-DC converter 102.
[0063] In one embodiment of the present invention, the adaptive phase and frequency selector 118 is configured to modify the switching frequency inversely with the number of active phases, thereby maintaining consistent output voltage ripple across different load conditions. It dynamically increases the switching frequency when fewer phases are active and reduces it when more phases are active. This inverse relationship between the number of active phases and the switching frequency ensures that the output voltage ripple remains within acceptable limits, regardless of changes in the load or the number of active phases. By adapting the frequency and phase angles, the selector contributes to the system's ability to deliver stable and efficient power, even under varying operating conditions.
[0064] The PWM generator 120 is a fundamental component responsible for generating the control signals that regulate the switching of the individual phases 106 in the multiphase DC-DC converter 102. By generating precise duty cycles for each phase, the PWM generator 120 controls how long each phase remains active during a switching cycle, directly influencing the converter's output voltage and current. The accuracy of the PWM signals is crucial to the converter's ability to maintain stable operation under varying load conditions. It converts the control signals from the current controllers into duty cycles that drive the switching devices in each phase of the converter. The PWM generator 120 ensures that the switching of the phases occurs in a coordinated manner, preventing overlap or irregularities that could lead to inefficiencies or ripple in the output voltage.
[0065] In one embodiment of the present invention, the PWM generator 120 generates duty cycles for each phase based on the reference currents received from the independent current controllers 116, ensuring seamless phase addition or removal. It dynamically adjusts the duty cycles to match the reference current for each phase, allowing the system to smoothly add or drop phases without causing voltage spikes or dips. This coordination ensures that when new phases are added, the transitions are gradual, preventing any disturbances in the output. Similarly, when phases are removed, the duty cycles are decreased in steps to avoid sudden drops in current, maintaining system stability. The PWM generator 120, thus, plays a key role in the efficient and reliable operation of the DC-DC converter 102.
[0066] FIG. 2 illustrates a block diagram of a multiphase DC-DC converter system 100, in accordance with an exemplary embodiment of the present disclosure.
[0067] FIG. 2.1 illustrates the core architecture of the multiphase DC-DC converter system 100, which operates with several individual phases to convert input voltage efficiently into a stable output. The system incorporates an input capacitor 104 that filters the incoming voltage, ensuring a smooth and stable DC voltage is fed into the converter. The DC-DC converter 102 comprises multiple phases (Phase 1 to Phase N), each responsible for handling a portion of the load current. These currents from all phases are then combined and filtered by the output capacitor 108 to deliver a stable output. The system dynamically manages the number of active phases based on load requirements, which allows it to deactivate unused phases during low-load conditions. This adaptive phase control improves the overall efficiency of the system while maintaining a consistent output ripple.
[0068] Each phase operates independently, addressing challenges like current imbalance, which can arise due to circuit parasitic elements. The digital controller 110 plays a crucial role in regulating the current across all phases, ensuring that the load is evenly shared. This regulation enhances the system's efficiency and long-term reliability, as it mitigates the performance degradation that can result from imbalanced current distribution.
[0069] FIG. 2.2 provides a detailed view of the digital controller 110, which is responsible for the overall management of the multiphase system. The voltage controller 112 monitors the output and compares it with a reference value, generating a reference current. This reference current is passed to the adaptive phase shedding controller 114, which adjusts the number of active phases based on the system's load requirements. This controller enables or disables individual phases as necessary to optimize performance.
[0070] The adaptive phase shedding controller 114 works in tandem with independent current controllers, each associated with a specific phase. These controllers generate the required duty cycles to modulate the power delivered by each phase. The PWM generator 120 converts these duty cycles into switching signals, which are sent to control the power semiconductor devices, ensuring precise operation.
[0071] The system also incorporates an adaptive phase and frequency selector 118, which adjusts both the switching frequency and phase angles between active phases. This feature is essential for maintaining consistent performance and minimizing output ripple, regardless of the number of active phases. By dynamically adjusting the frequency based on the load, the system optimizes efficiency across various operating conditions, reducing unnecessary energy losses when fewer phases are required. Additionally, the adaptive frequency selection helps in maintaining stable output ripple, allowing for the use of smaller and more efficient capacitors.
[0072] Overall, the figures highlight a sophisticated multiphase DC-DC converter system that is designed for flexibility and efficiency. By dynamically managing the active phases and adjusting the switching frequency in real-time, the system ensures both high efficiency and consistent output performance under varying load conditions. The unique approach of using independent current compensators for each phase also enhances load sharing and system balance, improving thermal management and overall reliability.
[0073] The flowchart in FIG. 3 outlines the sequential steps involved in the multiphase DC-DC converter system 100, which manages the dynamic adjustment of active phases based on the load current. This system 100 is designed to optimize efficiency and maintain stability by adding or removing phases according to the load requirements. Below is a detailed explanation of each step and how the system operates:
[0074] At 302, the system is initialized, marking the start of the process. This step serves as the beginning of the phase control mechanism for the multiphase DC-DC converter, which aims to dynamically adjust the number of active phases based on the load conditions.
[0075] At 304, the system measures the load current to determine how much power is required. This measurement is crucial because it directly affects how many phases should be active to efficiently distribute power without overloading any individual phase.
[0076] At 306, the system determines the required number of phases based on the measured load current. This decision ensures that the system activates the optimal number of phases to meet the power demand while maintaining high efficiency.
[0077] At 308, the system checks whether the number of active phases is less than the required number of phases as determined in the previous step.
[0078] If the active phases are fewer than required, at 310, the system initiates the phase addition process. This step is designed to increase the system's capacity by bringing more phases online to handle the increasing load. This process must be done smoothly to avoid abrupt changes that could destabilize the converter.
[0079] At 314, the reference input current for the new phase is gradually increased. This step ensures that the current gradually rises to meet the required reference current. The system does this incrementally to avoid surges in power that could cause instability or inefficiencies. The system checks if the increased reference input current equals the required reference current. If the input reference current is not yet equal to the required level, the system continues increasing the input current. Once the current matches the required level, the system moves forward to activate the phase.
[0080] At 318, when the reference input current matches the required reference current, the new phase is activated. This phase addition helps distribute the load more efficiently across multiple phases, improving the system's overall performance and power management.
[0081] At 320, the process ends after the required phase has been activated. This marks the successful completion of the phase addition process, and the system can continue operating with the newly activated phases.
[0082] On the other hand, if the number of active phases is greater than the required number (step 308), the system initiates the phase removal process at 312. This step is taken to deactivate phases when the load decreases, helping to optimize the converter's efficiency by minimizing unnecessary active phases.
[0083] At 316, the system starts decreasing the reference output current for the phase that is set to be removed. This gradual reduction prevents abrupt changes in the system that could cause imbalances or inefficiencies. The system checks whether the reference output current for the phase to be removed has reached zero. If it has not, the system continues to reduce the current until it is zero. Once the current reaches zero, the phase is ready to be deactivated 322.
[0084] Once the reference output current reaches zero, the phase is deactivated, and it is no longer active in the system. This reduction in active phases ensures that the system runs efficiently, adjusting to the lower load without unnecessary power consumption.
[0085] Finally, at 320, the process ends after deactivating the required phases, marking the conclusion of the phase removal process. This step ensures the system operates with the optimal number of active phases based on the current load.
[0086] The system initiates by operating individual phases of a multiphase DC-DC converter connected in parallel. These phases are responsible for delivering power based on the current load demand. As the load varies, the system dynamically adjusts the number of active phases to maintain efficiency. To stabilize the input and output voltage fluctuations, the system employs capacitors at both ends: an input capacitor to filter input voltage fluctuations and an output capacitor to ensure consistent voltage ripple, keeping the output stable.
[0087] The heart of the process lies in the adaptive phase shedding and switching frequency management, controlled by a digital controller. This controller continuously monitors the load conditions and adjusts the output voltage by generating a reference current through a voltage controller. Based on the load, the system enables or disables phases by gradually adjusting the reference current of each phase, rather than directly changing the duty cycle. This gradual adjustment ensures smooth transitions and balanced load sharing, preventing sudden changes that could disrupt the output voltage.
[0088] To further optimize performance, the system includes independent current controllers for each phase. These controllers address one of the significant challenges in conventional multiphase converters: phase current imbalance caused by parasitic in the circuit. By maintaining individual control over each phase's current, the system prevents imbalances and ensures even current distribution, which enhances the long-term performance and reliability of the converter.
[0089] As the load on the system changes, the adaptive phase and frequency selector dynamically adjusts both the switching frequency and the phase angles between the active phases. This dynamic adjustment is critical for maintaining a consistent output ripple and distributing the load efficiently across all active phases. By modifying the switching frequency when phases are added or removed, the system ensures that the converter operates at optimal efficiency under varying conditions.
[0090] The system also incorporates a PWM (Pulse Width Modulation) generator, which generates the necessary control signals to manage the switching of phases. This ensures that each phase transitions smoothly in and out of operation, avoiding abrupt shifts that could compromise performance.
[0091] What sets this invention apart is its novel approach to phase management. Unlike conventional methods that modify the duty cycle directly, this system adjusts the reference current during phase addition or removal, ensuring smooth transitions while maintaining overload protection. This method not only enhances reliability but also reduces switching losses by using wide bandgap (WBG) power semiconductor devices instead of traditional silicon-based switches, thereby improving overall system efficiency.
[0092] Additionally, the system employs a phase rotation technique when fewer phases are active. In this mode, phases are activated in a round-robin manner, distributing the thermal load evenly across all phases, improving the system's thermal management over time. This feature prevents overheating and extends the operational lifespan of the converter.
[0093] Overall, the system's adaptive phase shedding and frequency control enable it to dynamically manage the number of active phases based on load requirements, ensuring high efficiency, consistent voltage ripple, and balanced load sharing under varying conditions. This innovative approach addresses the limitations of traditional DC-DC converters, offering a more efficient, reliable, and thermally balanced solution for power management.
[0094] While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it will be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
[0095] A person of ordinary skill in the art may be aware that, in combination with the examples described in the embodiments disclosed in this specification, units and algorithm steps may be implemented by electronic hardware, computer software, or a combination thereof.
[0096] The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described to best explain the principles of the present disclosure and its practical application, and to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the present disclosure.
[0097] Disjunctive language such as the phrase "at least one of X, Y, Z," unless specifically stated otherwise, is otherwise understood with the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and/or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain embodiments require at least one of X, at least one of Y, or at least one of Z to each be present.
[0098] In a case that no conflict occurs, the embodiments in the present disclosure and the features in the embodiments may be mutually combined. The foregoing descriptions are merely specific implementations of the present disclosure, but are not intended to limit the protection scope of the present disclosure. Any variation or replacement readily figured out by a person skilled in the art within the technical scope disclosed in the present disclosure shall fall within the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure shall be subject to the protection scope of the claims.
, Claims:I/We Claim:
1. A multiphase DC-DC converter (102) system (100) for adaptive phase shedding and switching frequency control based on load current, the system comprising:
a DC-DC converter (102) configured to operate with individual phases (106) connected in parallel, each phase comprising wide bandgap power semiconductor devices designed to minimize switching losses;
an input capacitor (104) connected to the DC-DC converter (102) configured to filter voltage fluctuations at the input;
an output capacitor (108) connected to the DC-DC converter (102) configured to filter output voltage fluctuations and maintain consistent output ripple at the output;
a digital controller (110) connected to the DC-DC converter (102) and configured to manage adaptive phase shedding and switching frequency, wherein the digital controller (110) further comprises:
a Voltage controller (112), positioned at the outer voltage loop and configured to regulate output voltage by generating a reference current based on load conditions;
an adaptive phase shedding controller (114) configured to enable or disable phases by gradually adjusting the reference current, ensuring balanced load sharing and consistent voltage ripple;
an independent current controllers (116) for each phase, positioned at the inner current loop and configured to ensure current balance and prevent current imbalance due to circuit parasitic;
an adaptive phase and frequency selector (118) configured to dynamically adjust switching phase and frequency angles between active phases; and
a PWM generator (120) connected to each phase and configured to generate the necessary control signals for phase switching.
2. The system as claimed in claim 1, wherein the WBG devices are selected for their high efficiency and low switching loss properties compared to conventional silicon-based devices, improving overall converter efficiency.
3. The system as claimed in claim 1, wherein the digital controller (110) is further configured to dynamically adjust the phase angle difference between active phases according to load conditions, enhancing output ripple stability.
4. The system as claimed in claim 1, wherein the adaptive phase shedding controller (114) is configured to increase reference current incrementally for adding a phase and decrease it incrementally for dropping a phase to maintain balanced current distribution among active phases.
5. The system as claimed in claim 1, wherein the adaptive phase shedding controller (114) is configured to monitor load current and trigger phase activation or deactivation based on a predefined threshold to optimize efficiency.
6. The system as claimed in claim 1, wherein the system further comprises a phase rotation technique that activates phases in a round-robin manner when fewer active phases are needed, thereby enhancing thermal management.
7. The system as claimed in claim 1, wherein the independent current controllers (116) are configured to monitor and adjust the individual phase currents to maintain balanced load distribution, independent of circuit parasitic effects.
8. The system as claimed in claim 1, wherein the adaptive phase and frequency selector (118) is configured to modify the switching frequency inversely with the number of active phases, thereby maintaining consistent output voltage ripple across different load conditions.
9. The system as claimed in claim 1, wherein the PWM generator (120) generates duty cycles for each phase based on the reference currents received from the independent current controllers (116), ensuring seamless phase addition or removal.
10. A method for adaptive phase shedding and switching frequency control based on load current using the multiphase DC-DC converter (102) system (100), the method comprising:
operating with individual phases (106) connected in parallel via a DC-DC converter (102);
filtering voltage fluctuations at the input via an input capacitor (104);
filtering output voltage fluctuations and maintain consistent output ripple at the output via an output capacitor (108);
managing adaptive phase shedding and switching frequency, wherein the digital controller (110) further comprises via a digital controller (110):
regulating output voltage by generating a reference current based on load conditions via a Voltage controller (112);
enabling or disabling phases by gradually adjusting the reference current, ensuring balanced load sharing and consistent voltage ripple via an adaptive phase shedding controller (114);
ensuring current balance and preventing current imbalance due to circuit parasitic via independent current controllers (116);
dynamically adjusting switching phase and frequency angles between active phases via an adaptive phase and frequency selector (118); and
generating the necessary control signals for phase switching via a PWM generator (120).

Documents

NameDate
202441087011-FORM-26 [30-11-2024(online)].pdf30/11/2024
202441087011-Proof of Right [30-11-2024(online)].pdf30/11/2024
202441087011-COMPLETE SPECIFICATION [12-11-2024(online)].pdf12/11/2024
202441087011-DECLARATION OF INVENTORSHIP (FORM 5) [12-11-2024(online)].pdf12/11/2024
202441087011-DRAWINGS [12-11-2024(online)].pdf12/11/2024
202441087011-EVIDENCE FOR REGISTRATION UNDER SSI(FORM-28) [12-11-2024(online)].pdf12/11/2024
202441087011-FORM 1 [12-11-2024(online)].pdf12/11/2024
202441087011-FORM FOR SMALL ENTITY(FORM-28) [12-11-2024(online)].pdf12/11/2024
202441087011-REQUEST FOR EARLY PUBLICATION(FORM-9) [12-11-2024(online)].pdf12/11/2024

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