WO2008137652A1 - Power factor correction controller using a nonlinear delta- sigma modulator - Google Patents

Power factor correction controller using a nonlinear delta- sigma modulator Download PDF

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Publication number
WO2008137652A1
WO2008137652A1 PCT/US2008/062378 US2008062378W WO2008137652A1 WO 2008137652 A1 WO2008137652 A1 WO 2008137652A1 US 2008062378 W US2008062378 W US 2008062378W WO 2008137652 A1 WO2008137652 A1 WO 2008137652A1
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WIPO (PCT)
Prior art keywords
control signal
pulse width
factor correction
pfc
power converter
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PCT/US2008/062378
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French (fr)
Inventor
John L. Melanson
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Cirrus Logic, Inc.
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Publication of WO2008137652A1 publication Critical patent/WO2008137652A1/en

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/42—Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
    • H02M1/4208—Arrangements for improving power factor of AC input
    • H02M1/4225—Arrangements for improving power factor of AC input using a non-isolated boost converter
    • H—ELECTRICITY
    • H03—ELECTRONIC CIRCUITRY
    • H03M—CODING; DECODING; CODE CONVERSION IN GENERAL
    • H03M3/00—Conversion of analogue values to or from differential modulation
    • H03M3/30—Delta-sigma modulation
    • H03M3/458—Analogue/digital converters using delta-sigma modulation as an intermediate step
    • H03M3/476—Non-linear conversion systems
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B70/00—Technologies for an efficient end-user side electric power management and consumption
    • Y02B70/10—Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P80/00—Climate change mitigation technologies for sector-wide applications
    • Y02P80/10—Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier

Definitions

  • the present invention relates in general to the field of signal processing, and, more specifically, to a power control system that includes a nonlinear delta-sigma modulator with nonlinear power conversion process modeling.
  • Nonlinear processes to generate output signals.
  • plant systems such as servo control systems and power conversion systems, often utilize nonlinear processes.
  • Power control systems often utilize a switching power converter to convert alternating current (AC) voltages to direct current (DC) voltages or DC-to-DC.
  • Switching power converters often includes a nonlinear energy transfer process to provide power factor corrected energy to a load.
  • Power control systems provide power factor corrected and regulated output voltages to many devices that utilize a regulated output voltage.
  • Figure 1 represents a power control system 100, which includes a switching power converter 102.
  • Voltage source 101 supplies an alternating current (AC) input voltage V m (t) to a full, diode bridge rectifier 103.
  • the voltage source 101 is, for example, a public utility, and the AC voltage V 1n (X) is, for example, a 60 Hz/ 110 V line voltage in the United States of America or a 50 Hz/220 V line voltage in Europe.
  • the rectifier 103 rectifies the input voltage V m (t) and supplies a rectified, time -varying, line input voltage V x (t) to the switching power converter.
  • the switching power converter 102 includes power factor correction (PFC) stage 124 and driver stage 126.
  • PFC power factor correction
  • the PFC stage 124 is controlled by switch 108 and provides power factor correction.
  • the driver stage 126 is also controlled by switch 108 and regulates the transfer of energy from the line input voltage V x (t) through inductor 110 to capacitor 106.
  • the inductor current iL ramps 'up' when the switch 108 conducts, i.e. is "ON”.
  • the inductor current iL ramps down when switch 108 is nonconductive, i.e. is "OFF”, and supplies current ⁇ to recharge capacitor 106.
  • the time period during which inductor current i L ramps down is commonly referred to as the "inductor flyback time".
  • Diode 111 prevents reverse current flow into inductor 110.
  • the switching power converter 102 operates in discontinuous current mode, i.e. the inductor current i L ramp up time plus the inductor flyback time is less than the period of switch 108.
  • Input current i L is proportionate to the 'on-time' of switch 108, and the energy transferred to inductor 110 is proportionate to the 'on-time' squared.
  • control signal CSo is a pulse width modulated signal
  • the switch 108 is an n-channel field effect transistor that conducts when the pulse width of CSo is high.
  • the 'on-time' of switch 108 is determined by the pulse width of control signal CSo.
  • the energy transferred to inductor 110 is proportionate to a square of the pulse width of control signal CSo.
  • Capacitor 106 supplies stored energy to load 112.
  • the capacitor 106 is sufficiently large so as to maintain a substantially constant output voltage V c (t), as established by a power factor correction (PFC) and output voltage controller 114 (as discussed in more detail below).
  • the output voltage V c (t) remains substantially constant during constant load conditions. However, as load conditions change, the output voltage V c (t) changes.
  • the PFC and output voltage controller 114 responds to the changes in V c (t) and adjusts the control signal CSo to resume a substantially constant output voltage as quickly as possible.
  • the output voltage controller 114 includes a small capacitor 115 to filter any high frequency signals from the line input voltage V x (t).
  • the power control system 100 also includes a PFC and output voltage controller 114.
  • PFC and output voltage controller 114 controls switch 108 and, thus, controls power factor correction and regulates output power of the switching power converter 102.
  • the goal of power factor correction technology is to make the switching power converter 102 appear resistive to the voltage source 101.
  • the PFC and output voltage controller 114 attempts to control the inductor current i L so that the average inductor current i L is linearly and directly related to the line input voltage V x (t). Prodic, Compensator Design and Stability Assessment for Fast Voltage Loops of Power Factor Correction Rectifiers, IEEE Transactions on Power Electronics, Vol. 22, No. 5, Sept. 2007, pp.
  • PFC and output voltage controller 114 supplies a pulse width modulated (PWM) control signal CSo to control the conductivity of switch 108.
  • PWM pulse width modulated
  • switch 108 is a field effect transistor (FET)
  • control signal CSo is the gate voltage of switch 108.
  • the values of the pulse width and duty cycle of control signal CS 0 depend on two feedback signals, namely, the line input voltage V x (t) and the capacitor voltage/output voltage V c (t).
  • PFC and output controller 114 receives two feedback signals, the line input voltage V x (t) and the output voltage V c (t), via a wide bandwidth current loop 116 and a slower voltage loop 118.
  • the line input voltage V x (t) is sensed from node 120 between the diode rectifier 103 and inductor 110.
  • the output voltage V c (t) is sensed from node 122 between diode 111 and load 112.
  • the current loop 116 operates at a frequency f c that is sufficient to allow the PFC and output controller 114 to respond to changes in the line input voltage V x (t) and cause the inductor current i L to track the line input voltage to provide power factor correction.
  • the current loop frequency is generally set to a value between 20 kHz and 100 kHz.
  • the voltage loop 118 operates at a much slower frequency f v , typically 10-20Hz. By operating at 10-20Hz, the voltage loop 118 functions as a low pass filter to filter an alternating current (AC) ripple component of the output voltage V c (t).
  • AC alternating current
  • the PFC and output voltage controller 114 controls the pulse width (PW) and period (TT) of control signal CSo
  • PFC and output voltage controller 114 controls the nonlinear process of switching power converter 102 so that a desired amount of energy is transferred to capacitor 106.
  • the desired amount of energy depends upon the voltage and current requirements of load 112.
  • PFC and output voltage controller 114 varies the period of control signal CSo so that the input current i L tracks the changes in input voltage V x (t) and holds the output voltage Vc(t) constant.
  • PFC and output voltage controller 114 increases the period T of control signal CSo, and as the input voltage V x (t) decreases, PFC and output voltage controller 114 decreases the period of control signal CSo.
  • the pulse width PW of control signal CSo is adjusted to maintain a constant duty cycle (D) of controls signal CSo, and, thus, hold the output voltage Vc(t) constant.
  • the PFC and output voltage controller 114 updates the control signal CSo at a frequency much greater than the frequency of input voltage V x (t).
  • the frequency of input voltage V x (t) is generally 50-60 Hz.
  • the frequency 1/TT of control signal CSo is, for example, between 25 kHz and 100 kHz. Frequencies at or above 25 kHz avoid audio frequencies and frequencies at or below 100 kHz avoids significant switching inefficiencies while still maintaining good power factor correction, e.g. between 0.9 and 1, and an approximately constant output voltage V c (t).
  • FIG. 1 depicts a generalized representation of a power control system 200 described in Prodic.
  • the PFC and output voltage controller 202 of Prodic includes an error generator 204 to determine an error signal ea(t).
  • the error signal ed.t) represents a difference between the output voltage V c (t) and a reference voltage V REF -
  • the reference voltage V REF is set to the desired value of output voltage V c (t).
  • a comb filter 206 filters the error signal ea(t).
  • the comb filter 206 has significant attenuation at equally spaced frequencies (referred to as "notches") and has unity gain at other frequencies.
  • the comb filter 206 automatically tunes the notches to match twice the line frequency f L and harmonics of the line frequency.
  • the line frequency f L is the frequency of input voltage V m (t).
  • the comb filter 206 generates a "ripple free" error signal e vf (t).
  • Compensator 208 processes the filtered error signal, and input voltage feedback signal V x (t) generates a compensator output signal.
  • the pulse width modulator (PWM) 210 processes the compensator output signal to generate control signal CSo.
  • a power factor correction controller includes a processor to receive and process one or more switching power converter feedback signals and generate a pulse width control signal using each processed feedback signal.
  • the power factor correction controller also includes a pulse width modulator, coupled to the signal processor, having an input to receive the pulse width control signal and generate a pulse width modulated, power factor correction (PFC) control signal to control a switch that controls a power factor correction stage of the switching power converter.
  • PFC power factor correction
  • a method of controlling power factor correction of a switching power converter includes receiving one or more switching power converter feedback signals and processing each received feedback signal. The method further includes generating a pulse width control signal using each processed feedback signal and generating a pulse width modulated, power factor correction (PFC) control signal to control a switch that controls a power factor correction stage of the switching power converter.
  • PFC power factor correction
  • a pulse width of the PFC control signal varies approximately with a square root of the PWM control signal.
  • an apparatus to control power factor correction of a switching power converter includes means for receiving one or more switching power converter feedback signals.
  • the apparatus also includes means for generating a pulse width control signal using each processed feedback signal and means for generating a pulse width modulated, power factor correction (PFC) control signal to control a switch that controls a power factor correction stage of the switching power converter.
  • PFC power factor correction
  • a pulse width of the PFC control signal varies approximately with a square root of the PWM control signal.
  • Figure 1 (labeled prior art) depicts a power control system
  • Figure 2 (labeled prior art) depicts another embodiment of a power control system.
  • Figure 3 depicts a power control system with a nonlinear delta-sigma modulator.
  • Figure 4 depicts a PFC and output voltage controller with a nonlinear delta-sigma modulator.
  • Figure 5 depicts an embodiment of the nonlinear delta-sigma modulator of Figures 3 and 4.
  • Figure 6 depicts an embodiment of the nonlinear delta-sigma modulator of Figures 3, 4, and 5.
  • Figure 8 depicts an embodiment of the power control system of Figure 3
  • Figures 9-31 depict a program that emulates the power control system of Figure 8 and includes graphs depicting emulation results.
  • a power control system includes a switching power converter and a power factor correction (PFC) and output voltage controller.
  • the switching power converter utilizes a nonlinear energy transfer process to provide power to a load.
  • the PFC and output voltage controller generates a control signal to control power factor correction and voltage regulation of the switching power converter.
  • the PFC and output voltage controller includes a nonlinear delta-sigma modulator that models the nonlinear energy transfer process of the switching power converter.
  • the nonlinear delta-sigma modulator generates an output signal used to determine the control signal.
  • the PFC and output voltage controller By using the nonlinear delta-sigma modulator in a control signal generation process, the PFC and output voltage controller generates a spectrally noise shaped control signal.
  • noise shaping of the control signal improves power factor correction and output voltage regulation relative to conventional systems.
  • the PFC and output voltage controller control signal is a pulse width modulated signal.
  • the period of the pulse width modulated control signal controls output voltage regulation, and the duty cycle of the control signal controls power factor correction.
  • the period of the control signal is increased for lower power demands of the switching power converter and lower input voltages.
  • the period of the control signal can also be modulated in accordance with any number of modulation strategies.
  • the PFC and output voltage controller modulates the period of the control signal in accordance with a spread spectrum strategy to reduce electromagnetic interference of the power control system.
  • FIG. 3 depicts power control system 300, and power control system 300 includes a PFC and output voltage controller 302.
  • the PFC and output voltage controller 302 includes a pulse width (PW) and period control signal generator 304 to generate a pulse width control signal Qpw(n) and a period control signal Qp(n).
  • the PW and period signal generator 304 includes a nonlinear delta-sigma modulator 310.
  • the nonlinear delta-sigma modulator 310 models a nonlinear energy transfer process of switching power converter 306.
  • Switching power converter 306 includes a PFC stage 308 to provide power factor correction in accordance with control signal CSi.
  • the control signal CSi controls power factor correction by causing the inductor current i L to directly and linearly track changes in the line input voltage V x (t).
  • PFC stage 308 is identical to PFC stage 124.
  • Switching power converter 306 also includes a driver stage 316 to provide an approximately constant voltage and, thus, approximately constant power to load 112 in accordance with control signal CSi.
  • the control signal CSi controls output voltage regulation by causing the output voltage V c (t) to track a reference voltage V REF - In at least one embodiment, the reference voltage V REF is set to a desired output voltage of switching power converter 306.
  • a light emitting diode fixture may have a 400 V input voltage rating, and reference voltage V REF is set to 400 V.
  • the reference voltage can be manually or automatically modified to account for differing power demands as, for example, load 112 changes.
  • driver stage 316 is identical to driver stage 126. Unless explicitly indicated otherwise, the term “approximately” represents a nearly exact or an exact match. A value is “nearly exact” if the value achieves acceptable performance.
  • Power control system 300 also includes a pulse width modulator 312 to generate the pulse width modulated control signal CSi.
  • Pulse width modulator 312 modifies the pulse width and period of control signal CSi in accordance with the pulse width control signal Qpw(n) and modifies the period of control signal CSi in accordance with period input signal Qp(n).
  • pulse width control signal Qpw(n) and period control signal Qp(n) are discrete, quantization output signals of respective delta-sigma modulators.
  • Pulse width modulator 312 provides the control signal to switch 108, and control signal CSi controls the conductive state of switch 108.
  • switch 108 is a field effect transistor (FET), such as an n-channel, and control signal CSi is the gate voltage of switch 108.
  • FET field effect transistor
  • the PFC and output voltage controller 302 utilizes the line input voltage V x (t) and the output voltage V c (t) of switching power converter 306 to determine control signal CSi.
  • feedback signal(s) V FB(S) OO represents line input voltage V x (t), output voltage V c (t), a switch node voltage at switch node 314, or any combination thereof.
  • feedback signal V FB(S) OO is a single feedback signal representing the voltage at the switch node 314.
  • the PFC and output voltage controller 302 can determine both the line input voltage V x (t) and the output voltage V c (t) from the single feedback signal V FB (S)00 as, for example, described in U.S.
  • each signal represented by feedback signal(s) V FB(S) (O is scaled to a value that is useable by PFC and output voltage controller 302 without damaging PFC and output voltage controller 302.
  • PFC and output voltage controller 302 is implemented entirely as an integrated circuit or in combination with digital and/or analog components.
  • the integrated circuit has a maximum input signal voltage. Accordingly, each feedback signal(s) V FB(S) (0 is scaled as, for example, described in Melanson I and Melanson II.
  • the nonlinear delta-sigma modulator 310 processes an input signal, models the nonlinear energy transfer process of switching power converter 306, and provides a noise shaped output signal.
  • the nonlinear process of switching power converter 306 is identical to the nonlinear energy transfer process of switching converter 102.
  • the nonlinear delta-sigma modulator 310 can be used to provide spectral noise shaping of the control signal CSi.
  • the presence of noise in control signal CSi within a baseband frequency of control signal CSi allows the noise to influence the power factor correction and output voltage regulation of switching power converter 306.
  • the control signal CSi exercises improved control over switching power converter 306.
  • FIG. 4 depicts PFC and output voltage controller 400, which represents one embodiment of PFC and output voltage controller 302, and depicts PW and period control signal generator 402, which represents one embodiment of PW and period signal generator 304.
  • the PW and period signal generator 304 includes systems 404 and 406 to determine control signal CSi.
  • the period control system 404 determines the period of control signal CSi
  • the pulse width control system 406 determines the pulse width of the control signal CSi.
  • the PFC and output voltage controller 400 updates control signal CSi at a frequency between 25 kHz and 100 Mhz. Updating above 25 kHz avoids audible switching noises, and updating below 100 MHz results in a more efficient operation of switch 108.
  • the period control system 404 includes a period generator 408 to generate a period control signal TTC.
  • the period control signal TTC controls the period of control signal CSi.
  • the period generator 408 receives line input voltage V x (t), and period generator 408 generates period control signal TTC in response to line input voltage V x (t).
  • the line input voltage is sampled to generate a discrete value for use by period generator 408.
  • the period generator 408 generates a longer period of control signal CSo for lower power requirements of load 112 and as rectified, line input voltage V ⁇ (t) decreases.
  • the period generator 408 determines the period of control signal CSi in accordance with a spread spectrum strategy. The spread spectrum strategy adjusts the period of control signal CSi, and, thus, the frequency of control signal CSi, using a strategy that reduces electro-magnetic interference generated by, for example, switching power converter 306.
  • the period control system 404 also includes a delta-sigma modulator 409.
  • the delta-sigma modulator 409 receives the period control signal TTC and generates a period control signal Qp(n).
  • the period control signal Qp(n) is an output of a quantizer (not shown) of delta-sigma modulator 409.
  • the delta-sigma modulator 409 spectrally noise shapes the control signal TTC. Spectral noise shaping reduces the influence of noise on the control signal TTC and, thus, allows PFC and output voltage controller 400 to provide better power factor correction and output voltage regulation control for switching power converter 306.
  • the period control system 404 does not include the delta-sigma modulator 409, and the period generator 308 provides the period control signal TTC directly to the pulse width modulator 312.
  • Pulse width control system 406 determines a pulse width of control signal CSi so that control signal CSi tracks the line input voltage V x (t) and minimizes any difference between the output voltage V c (t) and the reference voltage V REF -
  • An error generator 410 determines an error signal e v between the reference voltage V REF and the output voltage V c (t) by subtracting the output voltage V c (t) from the reference voltage V REF -
  • a proportional integrator 412 processes the error signal e v to generate proportional-integral (PI) signal PIpw- The proportional integrator 412 adjusts the rate of response of PFC and output voltage controller 400 to changes in the output voltage V c (t).
  • the PI signal PI PW reflects the rate adjustment. If the response is too slow, then the output voltage V c (t) may fail to track changes in power demand of load 112 and, thus, fail to maintain an approximately constant value. If the response is too fast, then the output voltage V c (t) may react to minor, brief fluctuations in the power demand of load 112. Such fast reactions could cause oscillations in PFC and output voltage controller 400, damage or reduce the longevity of components, or both. Thus, the particular rate of response by proportional integrator 412 is a design choice. Setting the rate of response is subsequently discussed with reference to Figure 7.
  • the pulse width control system also includes a pulse width generator 414 to determine a pulse width control signal Tl.
  • the pulse width generator 414 generates the pulse width control signal Tl so that the duty cycle of control signal CSi tracks the line input voltage V x (t) and, thus, provides power factor correction.
  • the pulse width Ti of control signal CSi is determined in accordance with Equation [I]:
  • Tl is the pulse width of the control signal CSi as represented by period control signal Qp(n).
  • L represents an inductor value of PFC stage 308, such as inductor 110.
  • V rm s represents the root mean square of line input voltage V 1n (I;).
  • PIpw represents PI signal PIpw, which is the output of the proportional integrator 412.
  • TT is the period of control signal CSi as generated by period control system 404. In at least one embodiment, TT is the quantizer output signal Qp(n) of delta-sigma modulator 409.
  • TT is the period control signal TTC generated by period generator 408, if delta-sigma modulator 409 is not included in period control system 404
  • Vx is a sampled value of the current value of the line input voltage V x (t).
  • Vc is a sampled value of the output voltage V c (t) used to generate the PI output signal PIpw-
  • the switching power converter 306 operates in discontinuous current mode.
  • the period generator 408 ensures that the period of control signal CSi exceeds the ramp-up and ramp-down times of inductor current i L .
  • an inductor L of PFC stage 308, such as inductor 110 is set in accordance with Equation [2]:
  • V min is the root mean square (rms) minimum input voltage V 1n (I;).
  • P ma ⁇ is the maximum power demand of load 112.
  • J is an overdesign factor and any value greater than 1 indicates an overdesign. In at least one embodiment, “J” is 1.1.
  • f ma ⁇ is a maximum frequency of control signal CSi.
  • V cap is a nominal expected output voltage for load 112.
  • the switching power converter will operate in discontinuous current mode if the pulse width control signal satisfies Equation [3]:
  • Equation [3], [4], and [5] are the same as previously described.
  • the nonlinear portion of the energy transfer process is associated with the energy provided to an input inductor in the PFC stage, such as inductor 110 ( Figure 8).
  • the nonlinear delta-sigma modulator 310 is associated with power factor correction.
  • the pulse width of the control signal CSi and the relation of the pulse width to the period of control signal CSi, i.e. the duty cycle of control signal CSi controls power factor correction.
  • the nonlinear delta-sigma modulator 310 is used by pulse width control system 406 to spectrally noise shape the pulse width control signal Tl.
  • the nonlinear delta-sigma modulator 310 generates the pulse width control signal Qpw(n) as a quantizer output signal. By removing the influence of noise from a baseband of control signal CSi, the control signal CSi exercises improved control over switching power converter 306.
  • Figure 5 depicts a nonlinear delta-sigma modulator 500, which is one embodiment of nonlinear delta-sigma modulator 310.
  • the nonlinear delta-sigma modulator 500 includes a 'nonlinear system' feedback model 502 in a feedback path 504 of nonlinear delta-sigma modulator 500.
  • the feedback model 502 models nonlinearities of a nonlinear process, such as the nonlinear energy transfer process of switching power converter 306.
  • the feedback model 502 is represented by f(x).
  • the pulse width control signal Qpw(n) is fed back through a delay 506, and the feedback model 502 processes the delayed quantizer output signal Qpw(n-l) in accordance with f(Qpw(n-l)).
  • the error generator 508 determines a difference signal d(n) representing a difference between the feedback model 502 output f(Qpw(n-l)) and pulse width control signal Tl.
  • a k th order loop filter 510 filters the difference signal d(n) to generate a loop filter output signal u(n), where k is an integer greater than or equal to one and the value of Hs a design choice. Generally, increasing values oik decrease baseband noise and increase out-of-band noise.
  • the nonlinear delta-sigma modulator 500 includes a nonlinearity compensation module 512. However, in at least one embodiment, a nonlinearity compensation module is not included as part of the nonlinear delta-sigma modulator 500.
  • Quantizer 514 quantizes the output of compensation module 512 to determine pulse width control signal Qpw(n).
  • the compensation function f x (x) of compensation module 512 is an estimate of the inverse of the nonlinear system feedback model 502.
  • the compensation function f x (x) in the forward path 511 of nonlinear delta-sigma modulator 500 provides good noise shaping across all frequencies.
  • an imperfect compensation function i.e. approximate f x (x), allows more noise at all frequencies.
  • the compensation function f x (x) provides stability to nonlinear delta-sigma modulator 500.
  • the nonlinearity compensation module 512 is incorporated as part of the quantizer 514 rather than as a process separate from a quantization process.
  • the compensation module 512 causes the quantizer 514 to quantize the loop filter output signal u(n) in accordance with a quantization compensation function.
  • the quantizer compensation function determines pulse width control signal Qpw(n) in accordance with a derivative df(x) of the feedback model 502. For example, if the nonlinear system feedback model 502 function f(x) equals x 2 , then the quantizer compensation function is 2x.
  • the quantizer compensation function can be estimated as x. Decision points of the quantizer 514 are then x +/- 1 A.
  • Figure 6 depicts nonlinear delta-sigma modulator 600, which represents one embodiment of nonlinear delta-sigma modulator 310.
  • the nonlinear energy transfer process of switching power converter 306 can be modeled as a square function, x 2 .
  • Nonlinear delta-sigma modulator 600 includes a nonlinear system feedback model 602 represented by x 2 .
  • the nonlinear system feedback model represents one embodiment of nonlinear system feedback model 502.
  • the output of feedback model 602 is the square of the delay -by-one quantizer output signal Qpw(n), i.e. [Qpw(n-l)] 2 .
  • the nonlinear delta-sigma modulator 600 operates in the same manner as nonlinear delta-sigma modulator 300 and includes a compensation module 604 that is separate from quantizer 314.
  • the nonlinearity compensation module 604 processes output signal u(n) of the loop filter 310 with a square root function x 1 2 .
  • the output c(n) of compensation module 604 is quantized by quantizer 514to generate quantizer output signal Qpw(n).
  • FIG. 7 depicts a proportional integrator 700, which represents one embodiment of proportional integrator 412.
  • the proportional integrator 700 generates the PI output signal PIpw-
  • the PIpw varies as the difference between the reference voltage V REF and the output voltage V c (t), as represented by error signal e v from error generator 701, varies.
  • the difference between the The proportional integrator 700 includes an integral signal path 702 and a proportional signal path 704.
  • the integral signal path includes an integrator 706 to integrate the error signal e v , and a gain module 708 to multiple the integral of error signal e v by a gain factor g2 and generate the integrated output signal Ipw-
  • the proportional path 704 includes a gain module 710 to multiply the error signal e v by a gain factor gl and generate the proportional output signal P PW .
  • Adder 712 adds the integrated output signal I PW and the proportional output signal P PW to generate the PI signal PIpw-
  • the values of gain factors gl and g2 are a matter of design choice. The gain factors gl and g2 affect the responsiveness of PFC and output voltage controller 400.
  • Exemplary values of gain factors gl and g2 are set forth in the emulation code of Figures 8-31.
  • Faster response times of the PFC and output voltage controller 400 allow the control signal CSi to more rapidly adjust to minimize the error signal e v .
  • the output voltage V c (t) may fail to track changes in power demand of load 112 and, thus, fail to maintain an approximately constant value.
  • the output voltage V c (t) may react to minor, brief fluctuations in the power demand of load 112.
  • Such fast reactions could cause oscillations in PFC and output voltage controller 400, damage or reduce the longevity of components, or both.
  • the particular rate of response by proportional integrator 412 is a design choice.
  • FIG. 8 depicts power control system 800, which represents one embodiment of power control system 300.
  • Power control system includes a switching power converter 102, which is identical to the switching power converter of power control system 100.
  • PFC and output voltage controller 302 controls power factor correction and output voltage regulation of switching power converter 102.
  • Figure 9-31 depict a Mathematica® program that emulates power control system 800 and includes graphs depicting emulation results.
  • the Mathmatica® program is available from Wolfram Research, Inc. with office in Champaign, Illinois.
  • a PFC and output voltage controller includes a nonlinear delta-sigma modulator that models the nonlinear energy transfer process of a switching power converter.
  • the nonlinear delta-sigma modulator generates an output signal used to determine the control signal.
  • the PFC and output voltage controller uses the nonlinear delta-sigma modulator in a control signal generation process, the PFC and output voltage controller generates a spectrally noise shaped control signal.
  • noise shaping of the control signal improves power factor correction and output voltage regulation relative to conventional systems.
  • the nonlinear delta-sigma modulator includes a feedback model that models a nonlinear process being controlled and facilitates spectral shaping to shift noise out of a baseband in a spectral domain of a response signal of the nonlinear process.

Abstract

A power control system (300) includes a switching power converter (306) and a power factor correction (PFC) and output voltage controller (302). The switching power converter (306) utilizes a nonlinear energy transfer process to provide power to a load (112). The PFC and output voltage controller (302) generates a control signal (CSl) to control power factor correction and voltage regulation of the switching power converter (306). The PFC and output voltage controller (302) includes a nonlinear delta-sigma modulator (310) that models the nonlinear energy transfer process of the switching power converter (306). The nonlinear delta-sigma modulator (310) generates an output signal used to determine the control signal. By using the nonlinear delta-sigma modulator (310) in a control signal generation process, the PFC and output voltage controller (302) generates a spectrally noise shaped control signal. Noise shaping of the control signal improves power factor correction and output voltage regulation relative to conventional systems.

Description

POWER FACTOR CORRECTION CONTROLLER USING A NONLINEAR DELTA- SIGMA MODULATOR
Cross-reference to Related Application
(1) This application claims the benefit under 35 U.S.C. § 119(e) and 37 C.F.R. § 1.78 of U.S. Provisional Application No. 60/915,547, filed May 2, 2007, and entitled "Power Factor Correction (PFC) Controller Apparatuses and Methods," and is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
(2) The present invention relates in general to the field of signal processing, and, more specifically, to a power control system that includes a nonlinear delta-sigma modulator with nonlinear power conversion process modeling.
DESCRIPTION OF THE RELATED ART
(3) Many electronic systems utilize nonlinear processes to generate output signals. For example, plant systems, such as servo control systems and power conversion systems, often utilize nonlinear processes. Power control systems often utilize a switching power converter to convert alternating current (AC) voltages to direct current (DC) voltages or DC-to-DC. Switching power converters often includes a nonlinear energy transfer process to provide power factor corrected energy to a load. Power control systems provide power factor corrected and regulated output voltages to many devices that utilize a regulated output voltage.
(4) Figure 1 represents a power control system 100, which includes a switching power converter 102. Voltage source 101 supplies an alternating current (AC) input voltage Vm(t) to a full, diode bridge rectifier 103. The voltage source 101 is, for example, a public utility, and the AC voltage V1n(X) is, for example, a 60 Hz/ 110 V line voltage in the United States of America or a 50 Hz/220 V line voltage in Europe. The rectifier 103 rectifies the input voltage Vm(t) and supplies a rectified, time -varying, line input voltage Vx(t) to the switching power converter. (5) The switching power converter 102 includes power factor correction (PFC) stage 124 and driver stage 126. The PFC stage 124 is controlled by switch 108 and provides power factor correction. The driver stage 126 is also controlled by switch 108 and regulates the transfer of energy from the line input voltage Vx(t) through inductor 110 to capacitor 106. The inductor current iL ramps 'up' when the switch 108 conducts, i.e. is "ON". The inductor current iL ramps down when switch 108 is nonconductive, i.e. is "OFF", and supplies current ^ to recharge capacitor 106. The time period during which inductor current iL ramps down is commonly referred to as the "inductor flyback time". Diode 111 prevents reverse current flow into inductor 110. In at least one embodiment, the switching power converter 102 operates in discontinuous current mode, i.e. the inductor current iL ramp up time plus the inductor flyback time is less than the period of switch 108.
(6) Input current iL is proportionate to the 'on-time' of switch 108, and the energy transferred to inductor 110 is proportionate to the 'on-time' squared. Thus, the energy transfer process is one embodiment of a nonlinear process. In at least one embodiment, control signal CSo is a pulse width modulated signal, and the switch 108 is an n-channel field effect transistor that conducts when the pulse width of CSo is high. Thus, the 'on-time' of switch 108 is determined by the pulse width of control signal CSo. Accordingly, the energy transferred to inductor 110 is proportionate to a square of the pulse width of control signal CSo.
(7) Capacitor 106 supplies stored energy to load 112. The capacitor 106 is sufficiently large so as to maintain a substantially constant output voltage Vc(t), as established by a power factor correction (PFC) and output voltage controller 114 (as discussed in more detail below). The output voltage Vc(t) remains substantially constant during constant load conditions. However, as load conditions change, the output voltage Vc(t) changes. The PFC and output voltage controller 114 responds to the changes in Vc(t) and adjusts the control signal CSo to resume a substantially constant output voltage as quickly as possible. The output voltage controller 114 includes a small capacitor 115 to filter any high frequency signals from the line input voltage Vx(t).
(8) The power control system 100 also includes a PFC and output voltage controller 114. PFC and output voltage controller 114 controls switch 108 and, thus, controls power factor correction and regulates output power of the switching power converter 102. The goal of power factor correction technology is to make the switching power converter 102 appear resistive to the voltage source 101. Thus, the PFC and output voltage controller 114 attempts to control the inductor current iL so that the average inductor current iL is linearly and directly related to the line input voltage Vx(t). Prodic, Compensator Design and Stability Assessment for Fast Voltage Loops of Power Factor Correction Rectifiers, IEEE Transactions on Power Electronics, Vol. 22, No. 5, Sept. 2007, pp. 1719-1729 (referred to herein as "Prodic"), describes an example of PFC and output voltage controller 114. The PFC and output voltage controller 114 supplies a pulse width modulated (PWM) control signal CSo to control the conductivity of switch 108. In at least one embodiment, switch 108 is a field effect transistor (FET), and control signal CSo is the gate voltage of switch 108. The values of the pulse width and duty cycle of control signal CS0 depend on two feedback signals, namely, the line input voltage Vx(t) and the capacitor voltage/output voltage Vc(t).
(9) PFC and output controller 114 receives two feedback signals, the line input voltage Vx(t) and the output voltage Vc(t), via a wide bandwidth current loop 116 and a slower voltage loop 118. The line input voltage Vx(t) is sensed from node 120 between the diode rectifier 103 and inductor 110. The output voltage Vc(t) is sensed from node 122 between diode 111 and load 112. The current loop 116 operates at a frequency fc that is sufficient to allow the PFC and output controller 114 to respond to changes in the line input voltage Vx(t) and cause the inductor current iL to track the line input voltage to provide power factor correction. The current loop frequency is generally set to a value between 20 kHz and 100 kHz. The voltage loop 118 operates at a much slower frequency fv, typically 10-20Hz. By operating at 10-20Hz, the voltage loop 118 functions as a low pass filter to filter an alternating current (AC) ripple component of the output voltage Vc(t).
(10) The PFC and output voltage controller 114 controls the pulse width (PW) and period (TT) of control signal CSo Thus, PFC and output voltage controller 114 controls the nonlinear process of switching power converter 102 so that a desired amount of energy is transferred to capacitor 106. The desired amount of energy depends upon the voltage and current requirements of load 112. To regulate the amount of energy transferred and maintain a power factor correction close to one, PFC and output voltage controller 114 varies the period of control signal CSo so that the input current iL tracks the changes in input voltage Vx(t) and holds the output voltage Vc(t) constant. Thus, as the input voltage Vx(t) increases, PFC and output voltage controller 114 increases the period T of control signal CSo, and as the input voltage Vx(t) decreases, PFC and output voltage controller 114 decreases the period of control signal CSo. At the same time, the pulse width PW of control signal CSo is adjusted to maintain a constant duty cycle (D) of controls signal CSo, and, thus, hold the output voltage Vc(t) constant. In at least one embodiment, the PFC and output voltage controller 114 updates the control signal CSo at a frequency much greater than the frequency of input voltage Vx(t). The frequency of input voltage Vx(t) is generally 50-60 Hz. The frequency 1/TT of control signal CSo is, for example, between 25 kHz and 100 kHz. Frequencies at or above 25 kHz avoid audio frequencies and frequencies at or below 100 kHz avoids significant switching inefficiencies while still maintaining good power factor correction, e.g. between 0.9 and 1, and an approximately constant output voltage Vc(t).
(11) Figure 2 depicts a generalized representation of a power control system 200 described in Prodic. The PFC and output voltage controller 202 of Prodic includes an error generator 204 to determine an error signal ea(t). The error signal ed.t) represents a difference between the output voltage Vc(t) and a reference voltage VREF- The reference voltage VREF is set to the desired value of output voltage Vc(t). A comb filter 206 filters the error signal ea(t). The comb filter 206 has significant attenuation at equally spaced frequencies (referred to as "notches") and has unity gain at other frequencies. The comb filter 206 automatically tunes the notches to match twice the line frequency fL and harmonics of the line frequency. The line frequency fL is the frequency of input voltage Vm(t). According to Prodic, the comb filter 206 generates a "ripple free" error signal evf(t). Compensator 208 processes the filtered error signal, and input voltage feedback signal Vx(t) generates a compensator output signal. The pulse width modulator (PWM) 210 processes the compensator output signal to generate control signal CSo.
SUMMARY OF THE INVENTION
(12) In one embodiment of the present invention, a power factor correction controller includes a processor to receive and process one or more switching power converter feedback signals and generate a pulse width control signal using each processed feedback signal. The power factor correction controller also includes a pulse width modulator, coupled to the signal processor, having an input to receive the pulse width control signal and generate a pulse width modulated, power factor correction (PFC) control signal to control a switch that controls a power factor correction stage of the switching power converter. A pulse width of the PFC control signal varies approximately with a square root of the PWM control signal.
(13) In another embodiment of the present invention, a method of controlling power factor correction of a switching power converter includes receiving one or more switching power converter feedback signals and processing each received feedback signal. The method further includes generating a pulse width control signal using each processed feedback signal and generating a pulse width modulated, power factor correction (PFC) control signal to control a switch that controls a power factor correction stage of the switching power converter. A pulse width of the PFC control signal varies approximately with a square root of the PWM control signal.
(14) In a further embodiment of the present invention, an apparatus to control power factor correction of a switching power converter includes means for receiving one or more switching power converter feedback signals. The apparatus also includes means for generating a pulse width control signal using each processed feedback signal and means for generating a pulse width modulated, power factor correction (PFC) control signal to control a switch that controls a power factor correction stage of the switching power converter. A pulse width of the PFC control signal varies approximately with a square root of the PWM control signal.
BRIEF DESCRIPTION OF THE DRAWINGS
(15) The present invention may be better understood, and its numerous objects, features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference number throughout the several figures designates a like or similar element.
(16) Figure 1 (labeled prior art) depicts a power control system
(17) Figure 2 (labeled prior art) depicts another embodiment of a power control system.
(18) Figure 3 depicts a power control system with a nonlinear delta-sigma modulator.
(19) Figure 4 depicts a PFC and output voltage controller with a nonlinear delta-sigma modulator.
(20) Figure 5 depicts an embodiment of the nonlinear delta-sigma modulator of Figures 3 and 4.
(21) Figure 6 depicts an embodiment of the nonlinear delta-sigma modulator of Figures 3, 4, and 5.
(22) Figure 7 depicts a proportional integrator.
(23) Figure 8 depicts an embodiment of the power control system of Figure 3
(24) Figures 9-31 depict a program that emulates the power control system of Figure 8 and includes graphs depicting emulation results. DETAILED DESCRIPTION
(25) A power control system includes a switching power converter and a power factor correction (PFC) and output voltage controller. The switching power converter utilizes a nonlinear energy transfer process to provide power to a load. The PFC and output voltage controller generates a control signal to control power factor correction and voltage regulation of the switching power converter. The PFC and output voltage controller includes a nonlinear delta-sigma modulator that models the nonlinear energy transfer process of the switching power converter. The nonlinear delta-sigma modulator generates an output signal used to determine the control signal. By using the nonlinear delta-sigma modulator in a control signal generation process, the PFC and output voltage controller generates a spectrally noise shaped control signal. In at least one embodiment, noise shaping of the control signal improves power factor correction and output voltage regulation relative to conventional systems.
(26) In at least one embodiment, the PFC and output voltage controller control signal is a pulse width modulated signal. The period of the pulse width modulated control signal controls output voltage regulation, and the duty cycle of the control signal controls power factor correction. In at least one embodiment, the period of the control signal is increased for lower power demands of the switching power converter and lower input voltages. The period of the control signal can also be modulated in accordance with any number of modulation strategies. For example, in at least one embodiment, the PFC and output voltage controller modulates the period of the control signal in accordance with a spread spectrum strategy to reduce electromagnetic interference of the power control system.
(27) Figure 3 depicts power control system 300, and power control system 300 includes a PFC and output voltage controller 302. The PFC and output voltage controller 302 includes a pulse width (PW) and period control signal generator 304 to generate a pulse width control signal Qpw(n) and a period control signal Qp(n). The PW and period signal generator 304 includes a nonlinear delta-sigma modulator 310. The nonlinear delta-sigma modulator 310 models a nonlinear energy transfer process of switching power converter 306. Switching power converter 306 includes a PFC stage 308 to provide power factor correction in accordance with control signal CSi.
(28) The control signal CSi controls power factor correction by causing the inductor current iL to directly and linearly track changes in the line input voltage Vx(t). In at least one embodiment, PFC stage 308 is identical to PFC stage 124. Switching power converter 306 also includes a driver stage 316 to provide an approximately constant voltage and, thus, approximately constant power to load 112 in accordance with control signal CSi. The control signal CSi controls output voltage regulation by causing the output voltage Vc(t) to track a reference voltage VREF- In at least one embodiment, the reference voltage VREF is set to a desired output voltage of switching power converter 306. For example, a light emitting diode fixture may have a 400 V input voltage rating, and reference voltage VREF is set to 400 V. In at least one embodiment, the reference voltage can be manually or automatically modified to account for differing power demands as, for example, load 112 changes. In at least one embodiment, driver stage 316 is identical to driver stage 126. Unless explicitly indicated otherwise, the term "approximately" represents a nearly exact or an exact match. A value is "nearly exact" if the value achieves acceptable performance.
(29) Power control system 300 also includes a pulse width modulator 312 to generate the pulse width modulated control signal CSi. Pulse width modulator 312 modifies the pulse width and period of control signal CSi in accordance with the pulse width control signal Qpw(n) and modifies the period of control signal CSi in accordance with period input signal Qp(n). In at least one embodiment, pulse width control signal Qpw(n) and period control signal Qp(n) are discrete, quantization output signals of respective delta-sigma modulators. Pulse width modulator 312 provides the control signal to switch 108, and control signal CSi controls the conductive state of switch 108. In at least one embodiment, switch 108 is a field effect transistor (FET), such as an n-channel, and control signal CSi is the gate voltage of switch 108.
(30) The PFC and output voltage controller 302 utilizes the line input voltage Vx(t) and the output voltage Vc(t) of switching power converter 306 to determine control signal CSi. In at least one embodiment, feedback signal(s) VFB(S)OO represents line input voltage Vx(t), output voltage Vc(t), a switch node voltage at switch node 314, or any combination thereof. In at least one embodiment, feedback signal VFB(S)OO is a single feedback signal representing the voltage at the switch node 314. In this embodiment, the PFC and output voltage controller 302 can determine both the line input voltage Vx(t) and the output voltage Vc(t) from the single feedback signal VFB(S)00 as, for example, described in U.S. Patent Application entitled "Power Factor Correction Controller With Feedback Reduction", inventor John L. Melanson, assignee Cirrus Logic, Inc., and attorney docket number 1756-CA ("Melanson I") and U.S. Patent Application entitled "Power Factor Correction Controller With Switch Node Feedback", inventor John L. Melanson, assignee Cirrus Logic, Inc., and attorney docket number 1757-CA ("Melanson II"). Melanson I and Melanson II are incorporated herein by reference in their entireties.
(31) In at least one embodiment, each signal represented by feedback signal(s) VFB(S)(O is scaled to a value that is useable by PFC and output voltage controller 302 without damaging PFC and output voltage controller 302. For example, in at least one embodiment, PFC and output voltage controller 302 is implemented entirely as an integrated circuit or in combination with digital and/or analog components. The integrated circuit has a maximum input signal voltage. Accordingly, each feedback signal(s) VFB(S)(0 is scaled as, for example, described in Melanson I and Melanson II.
(32) As subsequently described in more detail, in at least one embodiment, the nonlinear delta-sigma modulator 310 processes an input signal, models the nonlinear energy transfer process of switching power converter 306, and provides a noise shaped output signal. In at least one embodiment, the nonlinear process of switching power converter 306 is identical to the nonlinear energy transfer process of switching converter 102. By modeling the nonlinear energy transfer process, in at least one embodiment, the nonlinear delta-sigma modulator 310 can be used to provide spectral noise shaping of the control signal CSi. The presence of noise in control signal CSi within a baseband frequency of control signal CSi allows the noise to influence the power factor correction and output voltage regulation of switching power converter 306. By removing the influence of noise from a baseband of control signal CSi, the control signal CSi exercises improved control over switching power converter 306.
(33) Figure 4 depicts PFC and output voltage controller 400, which represents one embodiment of PFC and output voltage controller 302, and depicts PW and period control signal generator 402, which represents one embodiment of PW and period signal generator 304. The PW and period signal generator 304 includes systems 404 and 406 to determine control signal CSi. The period control system 404 determines the period of control signal CSi, and the pulse width control system 406 determines the pulse width of the control signal CSi. In at least one embodiment, the PFC and output voltage controller 400 updates control signal CSi at a frequency between 25 kHz and 100 Mhz. Updating above 25 kHz avoids audible switching noises, and updating below 100 MHz results in a more efficient operation of switch 108.
(34) The period control system 404 includes a period generator 408 to generate a period control signal TTC. The period control signal TTC controls the period of control signal CSi. In at least one embodiment, the period generator 408 receives line input voltage Vx(t), and period generator 408 generates period control signal TTC in response to line input voltage Vx(t). In at least one embodiment, the line input voltage is sampled to generate a discrete value for use by period generator 408. In at least one embodiment, the period generator 408 generates a longer period of control signal CSo for lower power requirements of load 112 and as rectified, line input voltage Vχ(t) decreases. In at least one embodiment, the period generator 408 determines the period of control signal CSi in accordance with a spread spectrum strategy. The spread spectrum strategy adjusts the period of control signal CSi, and, thus, the frequency of control signal CSi, using a strategy that reduces electro-magnetic interference generated by, for example, switching power converter 306.
(35) In at least one embodiment, the period control system 404 also includes a delta-sigma modulator 409. The delta-sigma modulator 409 receives the period control signal TTC and generates a period control signal Qp(n). In this embodiment, the period control signal Qp(n) is an output of a quantizer (not shown) of delta-sigma modulator 409. The delta-sigma modulator 409 spectrally noise shapes the control signal TTC. Spectral noise shaping reduces the influence of noise on the control signal TTC and, thus, allows PFC and output voltage controller 400 to provide better power factor correction and output voltage regulation control for switching power converter 306. Exemplary conventional delta-sigma modulator design and operation is described in the book Understanding Delta-Sigma Data Converters by Schreier and Temes, IEEE Press, 2005, ISBN 0-471-46585-2. In at least one embodiment, the period control system 404 does not include the delta-sigma modulator 409, and the period generator 308 provides the period control signal TTC directly to the pulse width modulator 312.
(36) Pulse width control system 406 determines a pulse width of control signal CSi so that control signal CSi tracks the line input voltage Vx(t) and minimizes any difference between the output voltage Vc(t) and the reference voltage VREF- An error generator 410 determines an error signal ev between the reference voltage VREF and the output voltage Vc(t) by subtracting the output voltage Vc(t) from the reference voltage VREF- A proportional integrator 412 processes the error signal ev to generate proportional-integral (PI) signal PIpw- The proportional integrator 412 adjusts the rate of response of PFC and output voltage controller 400 to changes in the output voltage Vc(t). The PI signal PIPW reflects the rate adjustment. If the response is too slow, then the output voltage Vc(t) may fail to track changes in power demand of load 112 and, thus, fail to maintain an approximately constant value. If the response is too fast, then the output voltage Vc(t) may react to minor, brief fluctuations in the power demand of load 112. Such fast reactions could cause oscillations in PFC and output voltage controller 400, damage or reduce the longevity of components, or both. Thus, the particular rate of response by proportional integrator 412 is a design choice. Setting the rate of response is subsequently discussed with reference to Figure 7.
(37) The pulse width control system also includes a pulse width generator 414 to determine a pulse width control signal Tl. The pulse width generator 414 generates the pulse width control signal Tl so that the duty cycle of control signal CSi tracks the line input voltage Vx(t) and, thus, provides power factor correction. In at least one embodiment, the pulse width Ti of control signal CSi is determined in accordance with Equation [I]:
^w ^ W [I].
"Tl" is the pulse width of the control signal CSi as represented by period control signal Qp(n). "L" represents an inductor value of PFC stage 308, such as inductor 110. "Vrms" represents the root mean square of line input voltage V1n(I;). "PIpw" represents PI signal PIpw, which is the output of the proportional integrator 412. "TT" is the period of control signal CSi as generated by period control system 404. In at least one embodiment, TT is the quantizer output signal Qp(n) of delta-sigma modulator 409. In at least one embodiment, TT is the period control signal TTC generated by period generator 408, if delta-sigma modulator 409 is not included in period control system 404 "Vx" is a sampled value of the current value of the line input voltage Vx(t). "Vc" is a sampled value of the output voltage Vc(t) used to generate the PI output signal PIpw-
(38) In at least one embodiment, the switching power converter 306 operates in discontinuous current mode. When operating in discontinuous current mode, the period generator 408 ensures that the period of control signal CSi exceeds the ramp-up and ramp-down times of inductor current iL. In at least one embodiment to ensure that switching power converter 306 operates in discontinuous current mode, an inductor L of PFC stage 308, such as inductor 110 is set in accordance with Equation [2]:
L = Vmln2/ [(Pmax-J) • (2 -fmaχ) • I * V«W 4 [2] .
"L" is the value of the inductor of PFC stage 308. "Vmin" is the root mean square (rms) minimum input voltage V1n(I;). "Pmaχ" is the maximum power demand of load 112. "J" is an overdesign factor and any value greater than 1 indicates an overdesign. In at least one embodiment, "J" is 1.1. "fmaχ" is a maximum frequency of control signal CSi. "Vcap" is a nominal expected output voltage for load 112.
(39) For the inductor L value of Equation [2], in at least one embodiment, the switching power converter will operate in discontinuous current mode if the pulse width control signal satisfies Equation [3]:
= kl kZ - U \ -ττ hi
V, $ [3].
IT. kl ,ϊ( V*V<« *J [4]
k2 « (JL-SL j
"k3" is a power scale factor between 0 and 1. The remaining variables in Equations [3], [4], and [5] are the same as previously described.
(40) The nonlinear portion of the energy transfer process is associated with the energy provided to an input inductor in the PFC stage, such as inductor 110 (Figure 8). Thus, the nonlinear delta-sigma modulator 310 is associated with power factor correction. The pulse width of the control signal CSi and the relation of the pulse width to the period of control signal CSi, i.e. the duty cycle of control signal CSi, controls power factor correction. Accordingly, the nonlinear delta-sigma modulator 310 is used by pulse width control system 406 to spectrally noise shape the pulse width control signal Tl. The nonlinear delta-sigma modulator 310 generates the pulse width control signal Qpw(n) as a quantizer output signal. By removing the influence of noise from a baseband of control signal CSi, the control signal CSi exercises improved control over switching power converter 306.
(41) Figure 5 depicts a nonlinear delta-sigma modulator 500, which is one embodiment of nonlinear delta-sigma modulator 310. The nonlinear delta-sigma modulator 500 includes a 'nonlinear system' feedback model 502 in a feedback path 504 of nonlinear delta-sigma modulator 500. The feedback model 502 models nonlinearities of a nonlinear process, such as the nonlinear energy transfer process of switching power converter 306. In at least one embodiment, the feedback model 502 is represented by f(x). The pulse width control signal Qpw(n) is fed back through a delay 506, and the feedback model 502 processes the delayed quantizer output signal Qpw(n-l) in accordance with f(Qpw(n-l)). The error generator 508 determines a difference signal d(n) representing a difference between the feedback model 502 output f(Qpw(n-l)) and pulse width control signal Tl. A kth order loop filter 510 filters the difference signal d(n) to generate a loop filter output signal u(n), where k is an integer greater than or equal to one and the value of Hs a design choice. Generally, increasing values oik decrease baseband noise and increase out-of-band noise.
(42) The nonlinear delta-sigma modulator 500 includes a nonlinearity compensation module 512. However, in at least one embodiment, a nonlinearity compensation module is not included as part of the nonlinear delta-sigma modulator 500. The nonlinearity compensation module 512 compensates for nonlinearities introduced by the nonlinear feedback model 502. In at least one embodiment, the nonlinearity compensation module 512 processes the loop filter output signal u(n) using a compensation function of approximately f x(x), which is an inverse of the feedback model 502 function f(x), e.g. if f(x) = x2, then f x(x) = -x1 2. Quantizer 514 quantizes the output of compensation module 512 to determine pulse width control signal Qpw(n). In at least one embodiment, the compensation function f x(x) of compensation module 512 is an estimate of the inverse of the nonlinear system feedback model 502. In at least one embodiment, the compensation function f x(x) in the forward path 511 of nonlinear delta-sigma modulator 500 provides good noise shaping across all frequencies. In at least one embodiment, an imperfect compensation function, i.e. approximate f x(x), allows more noise at all frequencies. In at least one embodiment, the compensation function f x(x) provides stability to nonlinear delta-sigma modulator 500.
(43) In at least one embodiment, the nonlinearity compensation module 512 is incorporated as part of the quantizer 514 rather than as a process separate from a quantization process. The compensation module 512 causes the quantizer 514 to quantize the loop filter output signal u(n) in accordance with a quantization compensation function. In at least one embodiment, the quantizer compensation function determines pulse width control signal Qpw(n) in accordance with a derivative df(x) of the feedback model 502. For example, if the nonlinear system feedback model 502 function f(x) equals x2, then the quantizer compensation function is 2x. The quantizer compensation function can be estimated as x. Decision points of the quantizer 514 are then x +/- 1A.
(44) Figure 6 depicts nonlinear delta-sigma modulator 600, which represents one embodiment of nonlinear delta-sigma modulator 310. The nonlinear energy transfer process of switching power converter 306 can be modeled as a square function, x2. Nonlinear delta-sigma modulator 600 includes a nonlinear system feedback model 602 represented by x2. The nonlinear system feedback model represents one embodiment of nonlinear system feedback model 502. Thus, the output of feedback model 602 is the square of the delay -by-one quantizer output signal Qpw(n), i.e. [Qpw(n-l)]2. The nonlinear delta-sigma modulator 600 operates in the same manner as nonlinear delta-sigma modulator 300 and includes a compensation module 604 that is separate from quantizer 314. The nonlinearity compensation module 604 processes output signal u(n) of the loop filter 310 with a square root function x1 2. The output c(n) of compensation module 604 is quantized by quantizer 514to generate quantizer output signal Qpw(n).
(45) Figure 7 depicts a proportional integrator 700, which represents one embodiment of proportional integrator 412. The proportional integrator 700 generates the PI output signal PIpw- The PIpw varies as the difference between the reference voltage VREF and the output voltage Vc(t), as represented by error signal ev from error generator 701, varies. The difference between the The proportional integrator 700 includes an integral signal path 702 and a proportional signal path 704. The integral signal path includes an integrator 706 to integrate the error signal ev, and a gain module 708 to multiple the integral of error signal ev by a gain factor g2 and generate the integrated output signal Ipw- The proportional path 704 includes a gain module 710 to multiply the error signal ev by a gain factor gl and generate the proportional output signal PPW. Adder 712 adds the integrated output signal IPW and the proportional output signal PPW to generate the PI signal PIpw- The values of gain factors gl and g2 are a matter of design choice. The gain factors gl and g2 affect the responsiveness of PFC and output voltage controller 400. Exemplary values of gain factors gl and g2 are set forth in the emulation code of Figures 8-31. Faster response times of the PFC and output voltage controller 400 allow the control signal CSi to more rapidly adjust to minimize the error signal ev. As previously stated, if the response is too slow, then the output voltage Vc(t) may fail to track changes in power demand of load 112 and, thus, fail to maintain an approximately constant value. If the response is too fast, then the output voltage Vc(t) may react to minor, brief fluctuations in the power demand of load 112. Such fast reactions could cause oscillations in PFC and output voltage controller 400, damage or reduce the longevity of components, or both. Thus, the particular rate of response by proportional integrator 412 is a design choice.
(46) Figure 8 depicts power control system 800, which represents one embodiment of power control system 300. Power control system includes a switching power converter 102, which is identical to the switching power converter of power control system 100. In power control system 800, PFC and output voltage controller 302 controls power factor correction and output voltage regulation of switching power converter 102.
(47) Figure 9-31 depict a Mathematica® program that emulates power control system 800 and includes graphs depicting emulation results. The Mathmatica® program is available from Wolfram Research, Inc. with office in Champaign, Illinois.
(48) Thus, a PFC and output voltage controller includes a nonlinear delta-sigma modulator that models the nonlinear energy transfer process of a switching power converter. The nonlinear delta-sigma modulator generates an output signal used to determine the control signal. By using the nonlinear delta-sigma modulator in a control signal generation process, the PFC and output voltage controller generates a spectrally noise shaped control signal. In at least one embodiment, noise shaping of the control signal improves power factor correction and output voltage regulation relative to conventional systems.
(49) Thus, the nonlinear delta-sigma modulator includes a feedback model that models a nonlinear process being controlled and facilitates spectral shaping to shift noise out of a baseband in a spectral domain of a response signal of the nonlinear process.
(50) Although the present invention has been described in detail, it should be understood that various changes, substitutions and alterations can be made hereto without departing from the spirit and scope of the invention as defined by the appended claims.

Claims

WHAT IS CLAIMED IS;
1. A power factor correction controller comprising: a processor to receive and process one or more switching power converter feedback signals and generate a pulse width control signal using each processed feedback signal; and a pulse width modulator, coupled to the signal processor, having an input to receive the pulse width control signal and generate a pulse width modulated, power factor correction (PFC) control signal to control a switch that controls a power factor correction stage of the switching power converter; wherein a pulse width of the PFC control signal varies approximately with a square root of the PWM control signal.
2. The power factor correction stage of claim 1 wherein the processor comprises a nonlinear delta-sigma modulator that includes a quantizer, a loop filter, and a feedback path coupled between the quantizer and the loop filter, and the feedback path includes a square process that generates a square of quantizer output signals.
3. The power factor correction stage of claim 1 wherein the processor is configured to process each of the feedback signals to track a function associated with variations of a time- varying voltage input signal to the switching power converter.
4. The power factor correction stage of claim 3 wherein the PFC control signal includes a period, and the pulse width modulator is configured to modulate the period of the PFC control signal to track a function associated with variations of a time-varying voltage output signal of the switching power converter.
5. The power factor correction stage of claim 3 wherein the pulse width modulator is configured to determine a period of the PFC control signal in accordance with a root mean square of the time-varying voltage input signal to the switching power converter.
6. The power factor correction stage of claim 3 wherein the pulse width modulator is configured to modulate a period of the PFC control signal in accordance with variations in a load coupled to the switching power converter.
7. The power factor correction stage of claim 1 wherein the pulse width modulator is configured to include random modulations over time to periods of the PFC control signal.
8. The power factor correction stage of claim 1 wherein the processor is configured to process each of the feedback signals to track a function associated with variations of a time- varying output voltage of the switching power converter.
9. The power factor correction stage of claim 1 wherein the pulse width modulator is configured to generate a digital pulse width modulated power factor correction (PFC) control signal.
10. The power factor correction stage of claim 1 wherein the processor is further configured to process the one or more feedback signals of the power converter to control a period of the PFC control signal.
11. A method of controlling power factor correction of a switching power converter, the method comprising: receiving one or more switching power converter feedback signals; processing each received feedback signal; generating a pulse width control signal using each processed feedback signal; and generating a pulse width modulated, power factor correction (PFC) control signal to control a switch that controls a power factor correction stage of the switching power converter; wherein a pulse width of the PFC control signal varies approximately with a square root of the PWM control signal.
12. The method of claim 1 wherein generating a pulse width control signal using each processed feedback signal further comprises: generating the pulse width control signal using a nonlinear delta-sigma modulator that includes a quantizer, a loop filter, and a feedback path coupled between the quantizer and the loop filter, and the feedback path includes a square process that generates a square of quantizer output signals.
13. The method of claim 1 further comprising: processing each of the feedback signals to track a function associated with variations of a time-varying voltage input signal to the switching power converter.
14. The method of claim 1 wherein the PFC control signal includes a period, the method further comprising: modulating the period of the PFC control signal to track a function associated with variations of a time-varying voltage output signal of the switching power converter.
15. The method of claim 1 further comprising: determining a period of the PFC control signal in accordance with a root mean square of the time-varying voltage input signal to the switching power converter.
16. The method of claim 1 further comprising: modulating a period of the PFC control signal in accordance with variations in a load coupled to the switching power converter.
17. The method of claim 1 further comprising: randomly modulating periods of the PFC control signal.
18. The method of claim 1 further comprising: processing each of the feedback signals to track a function associated with variations of a time-varying output voltage of the switching power converter.
19. The method of claim 1 further comprising: generating a digital pulse width modulated power factor correction (PFC) control signal.
20. The method of claim 1 further comprising: processing the one or more feedback signals of the power converter to control a period of the PFC control signal.
21. An apparatus to control power factor correction of a switching power converter, the apparatus comprising: means for receiving one or more switching power converter feedback signals; means for generating a pulse width control signal using each processed feedback signal; and means for generating a pulse width modulated, power factor correction (PFC) control signal to control a switch that controls a power factor correction stage of the switching power converter; wherein a pulse width of the PFC control signal varies approximately with a square root of the PWM control signal.
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PCT/US2008/062387 WO2008137656A2 (en) 2007-05-02 2008-05-02 Power factor correction controller with feedback reduction
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PCT/US2008/062381 WO2008137654A1 (en) 2007-05-02 2008-05-02 System and method with inductor flyback detection using switch gate charge characteristic detection
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PCT/US2008/062381 WO2008137654A1 (en) 2007-05-02 2008-05-02 System and method with inductor flyback detection using switch gate charge characteristic detection
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