WO2010039588A2 - Adjustable constant current source with continuous conduction mode ("ccm") and discontinuous conduction mode ("dcm") operation - Google Patents

Adjustable constant current source with continuous conduction mode ("ccm") and discontinuous conduction mode ("dcm") operation Download PDF

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Publication number
WO2010039588A2
WO2010039588A2 PCT/US2009/058298 US2009058298W WO2010039588A2 WO 2010039588 A2 WO2010039588 A2 WO 2010039588A2 US 2009058298 W US2009058298 W US 2009058298W WO 2010039588 A2 WO2010039588 A2 WO 2010039588A2
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Prior art keywords
current
inductor
power stage
converter power
converter
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PCT/US2009/058298
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French (fr)
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WO2010039588A3 (en
Inventor
John Laurence Melanson
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Cirrus Logic, Inc.
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Priority to CN200980147607.XA priority Critical patent/CN102232264B/en
Priority to GB1105424.4A priority patent/GB2475668B/en
Publication of WO2010039588A2 publication Critical patent/WO2010039588A2/en
Publication of WO2010039588A3 publication Critical patent/WO2010039588A3/en

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    • 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
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/02—Conversion of dc power input into dc power output without intermediate conversion into ac
    • H02M3/04—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters
    • H02M3/10—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • 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
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/02—Conversion of dc power input into dc power output without intermediate conversion into ac
    • H02M3/04—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters
    • H02M3/10—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • H02M3/158—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B45/00—Circuit arrangements for operating light-emitting diodes [LED]
    • H05B45/30—Driver circuits
    • H05B45/37—Converter circuits
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B45/00—Circuit arrangements for operating light-emitting diodes [LED]
    • H05B45/30—Driver circuits
    • H05B45/37—Converter circuits
    • H05B45/3725—Switched mode power supply [SMPS]
    • H05B45/375—Switched mode power supply [SMPS] using buck topology
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B45/00—Circuit arrangements for operating light-emitting diodes [LED]
    • H05B45/30—Driver circuits
    • H05B45/37—Converter circuits
    • H05B45/3725—Switched mode power supply [SMPS]
    • H05B45/38—Switched mode power supply [SMPS] using boost topology
    • 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
    • Y02B20/00—Energy efficient lighting technologies, e.g. halogen lamps or gas discharge lamps
    • Y02B20/30—Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Dc-Dc Converters (AREA)

Abstract

A converter system and method of operating a converter system are disclosed. The converter system comprises a converter power stage that can operate in a Discontinuous Conduction Mode (DCM) in a range of output currents and a Continuous Conduction Mods (CCM) hi another range of output currents, The converter power stage includes at least an inductor with an inductor value and & control switch, The converter power stage provides an average current. A current controller is coupled to the converter power stage. When the converter power stage operates in DCM, She converter power stage provides the average current and the current controller is configured to measure the inductor value of the inductor. Furthermore, the current controller can also he configured to measure an input-to-output conversion ratio from the converter power stage.

Description

ADJUSTABLE CONSTANT CURRENT SOURCE WITH CONTINUOUS CONDUCTION MODE ("CCM") AND DISCONTINUOUS CONDUCTION
MODE ("DCM") OPERATION
Cross-reference to Related Application
(1) This application is related to and cross-references U.S. Application Serial Number 12/107,613 entitled "Power Factor Correction (PFC) Controller and Method Using a Finite State Machine to Adjust the Duty Cycle of a PWM Control Signal" filed on April 22, 2008 (Inventor: John Melanson; Cirrus Docket No. 1684-IPD); U.S. Application Serial Number 12/110,714 filed on April 28, 2008 entitled "Discontinuous Conduction Mode (DCM) Using Sensed Current for a Switch-Mode Converter" (Inventor: John Melanson; Cirrus Docket No. 1679-IPD); and U.S. Application Serial Number
12/113,536 filed on May 1, 2008 entitled "Switch-Mode Converter Operating in a Hybrid Discontinuous Conduction Mode (DCM)/Continuous Conduction Mode (CCM) That Uses Double or More Pulses in a Switching Period" (Inventor: John Melanson; Cirrus Docket No. 1674-IPD).
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 apparatuses and methods for providing an adjustable constant current source which operates in both Discontinuous Conduction Mode (DCM) and Continuous Conduction Mode (CCM). DESCRIPTION OF THE RELATED ART
(3) Switch-mode systems are well known in the art. Figure 1 shows an exemplary switch-mode system 100. Switch-mode system 100 includes a switch-mode converter power stage 102, a converter current controller 104, and a load 106. Power 101 is fed into switch-mode converter power stage 102. Switch-mode system 100 utilizes switch- mode converter power stage 102 to convert alternating current (AC) voltages (such as line/mains voltages) to direct current (DC) voltages or DC-to-DC wherein the input current is proportional to the input voltage. Converter current controller 104 controls the current of switch-mode converter power stage 102, and switch-mode converter power stage 102 accordingly drives load 106. An exemplary switch-mode converter power stage 102 may be a buck converter or a boost converter. For switch-mode converter power stage 102, two modes of switching stage operation exist: Discontinuous Conduction Mode ("DCM") and Continuous Conduction Mode ("CCM").
(4) In CCM, the switch of switch-mode converter power stage 102 switches "ON" by converter current controller 104 when the inductor current iL of converter current controller 104 is non-zero, and the current in the energy transfer inductor of converter current controller 104 never reaches zero during the switching cycle. Figure 2 A shows exemplary target current iget (for inductor current u.) having a value of three (3) amp. Figure 2A further shows inductor current iL has a period often (10) microsecond and is always non-zero in value, hi CCM, the current swing is less than in DCM, which results in lower I2R power losses and lower ripple current for inductor current it, which results in lower inductor core losses. The lower voltage swing also reduces Electro Magnetic Interference (EMI), and a smaller input filter can then be used. Since the switch of switch-mode converter power stage 102 is turned "OFF" when the inductor current ύ, is not equal to zero, the diode of switch-mode converter power stage 102 needs to be very fast in terms of reverse recovery in order to minimize losses. In DCM, a switch of switch-mode converter power stage 102 is turned on (e.g., "ON") by converter current controller 104 when the inductor current it, of the inductor of switch-mode converter power stage 102 equals zero. Figure 2B shows exemplary target current itarget having a value of 0.8 amp. Figure 2B further shows inductor current iL has a period often (10) microsecond and does fall to the zero value at a portion of each period.
(5) As an example, for a switch-mode system 100 used to drive a Light Emitting Diode (LED) lighting system, it is important to have an accurate constant current output that is adjustable across a wide dynamic range, such as a range of one hundred-to-one (100:1). Such an accurate adjustable constant output requires a switch-mode converter power stage 102 that can smoothly transition between CCM and DCM and provide a controlled output in both CCM and DCM. For high target current values target that are set for inductor current iL, the current ripple needs to be minimized. Such low current ripple generally calls for operation of the switch-mode converter power stage 102 to be in CCM. Unless the inductor of switch-mode converter power stage 102 is greatly oversized, switch-mode converter power stage 102 will operate in DCM at a lower average current iaverage for inductor current iL. If the current of switch-mode converter power stage 102 in CCM mode is controlled in such a way that the time above target current iorget and the time below that target current itarget are equal, then the average current iaverage is equal to the target current itarget, assuming linear (non-saturating) operation of the inductor. CCM operation of switch-mode converter power stage 102 generally does not require knowing the inductor value L (or scaled inductor constant F * L product wherein F may be an on-time period divided by the count value of the on-time period) nor the input/output ratio D in order to provide such accurate constant average current output.
(6) However, providing a smooth transition between CCM and DCM for a converter power stage 102 has its challenges. For example, in DCM, the inductor value L (or scaled inductor F * L product) and input/output ratio D need to be known since they directly affect the current calibration. Any inaccuracy will cause a differential non- linearity ("DNL") error in the effective current Digital-to-Analog Converter ("DAC"). Thus, in order to provide at least a smoother transition between CCM and DCM, there are needs and desires to discover, observe, and/or derive the inductor value L (or scaled inductor constant F * L product) and the input/output ratio D of a switch-mode converter system, particularly when the switch-mode converter system operates in DCM. The attaining of such measurements allows the on-time or the total operating period for the switch of the switch-mode converter 102 to be controlled so that an accurate adjustable constant average current output for the inductor current iL is provided.
SUMMARY OF THE INVENTION
(7) A converter system and method of operating a converter system are disclosed. The converter system comprises a converter power stage that can operate in a Discontinuous Conduction Mode (DCM) in a range of output currents and a Continuous Conduction Mode (CCM) in another range of output currents. The converter power stage includes at least an inductor with an inductor value and a control switch. The converter power stage provides an average current. A current controller is coupled to the converter power stage. When the converter power stage operates in DCM, the converter power stage provides the average current and the current controller is configured to measure the inductor value of the inductor. Furthermore, the current controller can also be configured to measure an input-to-output conversion ratio from the converter power stage.
BRIEF INSCRIPTION OF THE DRAWINGS
(8) 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.
(9) Figure 1 depicts an exemplary switch-mode system.
(10) Figure 2 A depicts exemplary current waveforms of inductor current _L and target current itarget for switch-mode converter 102 operating in Continuous Conduction Mode ("CCM") shown at a time scale of 10 milliseconds.
(11) Figure 2B depicts exemplary current waveforms of inductor current JL and target current itarget for switch-mode converter 102 operating in Discontinuous Conduction Mode ("DCM") shown at a time scale of 10 milliseconds. (12) Figure 3 depicts details of an exemplary switch-mode buck converter power stage controlled by a Light Emitting Diode ("LED") current controller for driving LEDs.
(13) Figure 4 depicts details of an exemplary LED lighting controller that includes a target current generator and a LED current controller.
(14) Figure 5 depicts an exemplary current waveform for inductor current it of exemplary switch-mode buck converter that is used to illustrate a first exemplary technique to provide an accurate constant average inductor current output when exemplary switch-mode buck converter power stage operates in DCM to help allow for a smooth transition of switch-mode buck converter power stage between CCM and DCM.
(15) Figure 6 depicts details of another exemplary switch-mode buck converter power stage controlled by a LED current controller for driving LEDs.
(16) Figure 7 depicts exemplary current waveforms for control signal CSo, inductor current iL, and sense current isense of exemplary switch-mode buck converter power stage that are used to illustrate second and third exemplary techniques to each provide an accurate constant average inductor current output by exemplary switch-mode buck converter power stage operating in a hybrid Discontinuous Conduction Mode (DCM)/Continuous Conduction Mode (CCM) that uses double or more pulses in a switching period wherein the techniques help allow for a smooth transition of switch- mode buck converter power stage between CCM and DCM.
DETAILED DESCRIPTION
(17) Figure 3 depicts details of an Light Emitting Diode ("LED") lighting system 300 having an exemplary switch-mode buck converter power stage 301 controlled by a Light Emitting Diode ("LED") current controller 310 for driving LEDs 308. LED lighting system 300 is an exemplary system illustrating an embodiment of the present invention, and the present invention is not in any way limited to an LED lighting system nor the use of a buck converter, LED current controller, and LEDs. The present invention can also be used for other suitable applications as well as utilize other converters/converter power stages (e.g., boost converters) or controllers.
(18) Switch-mode buck converter power stage 301 comprises a control switch (e.g. , Field Effect Transistor ("FET")) 302 having a source and drain coupled in series with an inductor 304 as shown in Figure 3. The source of FET 302 is coupled to a positive side of input voltage Vin. Diode 306 is coupled across the input voltage Vin in which a first end of a diode 306 is coupled between the drain of FET 302 and inductor 304 while a second end of diode 306 is coupled to a negative side of the input voltage Vin. A string of LEDs 308 is coupled across the output voltage Vout (e.g., coupled from the positive side to negative side of output voltage Vout). The string of LEDs 308 may, for example, include twenty (20) to one hundred (100) LEDs coupled together in series.
(19) An end of sense resistor Rsense is coupled to the negative side of input voltage Vm, and the other end of sense resistor Rsense is coupled to the second end of diode 306. Sense resistor Rsense is utilized to detect the sense current We that is flowing through FET 302. For the sense current isense being provided to LED current controller 310 from a node that is at the drain of FET 302 as shown in Figure 3, the sense resistor Rsense can be located anywhere in the current loop 312. Alternatively, as shown in dotted lines, an end of sense resistor Rsense is coupled to the second end of diode 306, and the other end of sense resistor Rsense is coupled to the negative side of the output voltage Vout. For the sense current isense being provided to LED current controller 310 from a node that is at an input end of inductor 304 as shown in Figure 3, the sense resistor Rsense can be located anywhere in the current loop 314. LED current controller 310 outputs a switch control signal CS0 which is fed into the gate of FET 302 and controls activation and deactivation of FET 302 as a switch.
(20) For example, the output voltage Vout of exemplary LED lighting system 300 at full brightness intensity can be at or around four hundred milliamperes (400 mA). Switch-mode buck converter power stage 301 operates in CCM when the output voltage V0Ut is at least fifty (50) to one hundred (100) milliamperes (50 to 100 mA). When the output voltage Vout falls below 50 to 100 mA, switch-mode buck converter power stage 301 operates in DCM.
(21) In LED lighting system 300, the load inductor current iL is always measurable, that is, the high side switch of FET 302 is measurable. Referring now to Figures 3 and 4, a target current generator 412 is coupled to the LED current controller 310 for feeding a target current itarget into LED current controller 310. Target current generator 412 and LED current controller 310 together make up LED lighting controller 400 as shown in Figure 4. LED current controller 310 includes a local power supply 402 which provides power to the various components of LED current controller 310. LED current controller 310 further includes a state machine 410 which receives the target current itarget that is fed in from target current generator 412. State machine 410 provides a digital signal that is reflective or representative of the target current itarget to digital-to-analog converter 404. DAC 404 converts the representative digital signal into a corresponding analog signal. The analog signal and the sense current i^se are fed into comparator (COMP) 406 for comparison, and the result of the comparison is fed into state machine 410. LED current controller 310 further includes a clock (oscillator) 408, and clock (osc) 408 is coupled to and utilized by state machine 410. The techniques (e.g., first, second, and third techniques) of the present invention in providing an accurate adjustable constant average inductor current output iavg when a converter operates in DCM are implemented in state machine 410. Furthermore, LED controller 310 may be implemented on a single integrated circuit (IC) or single IC substrate. Target current generator 412 may also be part of the single IC or may be external to the IC.
(22) Referring now to Figures 3 and 5, when a clock period of clock (oscillator) 408 of LED current controller 310 is started, FET 302 is turned on. A reference current iref is set at a suitable value, which is some pre-selected current value between zero and the peak current ipeak- Reference current iref is set at a value that can be accurately measured but allows the load inductor current iL to ramp up to the peak current ipeak as well.
(23) Figure 5 depicts an exemplary current waveform 500 for inductor current _L of exemplary switch-mode buck converter power stage 301 that is used to illustrate a first exemplary technique to provide an accurate adjustable constant average inductor current output iavg when exemplary switch-mode buck converter operates in DCM. First exemplary technique help allow for a smooth transition of switch-mode buck converter power stage between CCM and DCM. As shown in Figure 5, when the load inductor current _L reaches the reference current iref at time TA, the first on time period T] is determined. In other words, time period Ti is the time from when FET 302 turns on and when the load inductor iL reaches the reference current iref. FET 302 is turned off at time n * TA. Thus, the second on time period T2 is determined from when the FET 302 is on at the time when the load inductor it reaches the reference current W (e.g., at time TA) to when the load inductor iL reaches the peak current ipeak (e.g., at time n * TA). n is a ratio and is preferably selected to be a ratio of 2 (e.g., 2:1). Load inductor current iL decreases in value passing through reference current i^ and falls to zero at time TB. The off time period T3 is defined from when the load inductor iL reaches the peak current ipeak (e.g., at time n * TA) until when Hie load inductor u. reaches zero (e.g., at time TB). The total period for inductor current i^ in Figure 5 is defined as time period TT. In this embodiment of LED lighting system 300, both the on time T011 (which is equal to time periods T1 + T2) and off time Toff (which is equal to time period T3) can be observed or measured, but only the on period T0n and total period TT can be controlled. Therefore, in implementing the LED lighting system 300, either the on period T0n or total period TT is controlled in order to provide an accurate constant average current output iaVg for inductor current iL.
(24) The input/output ratio D and the ratio Cl involving the inductor value (inductance) L for inductor 304 can be measured and/or determined from the following mathematical relationships:
Figure imgf000009_0001
Figure imgf000010_0001
(30) With respect to the present invention, the measuring and determination of inductor value (inductance) L for inductor 304 is not in any way limited to the measurement and determination of the actual inductance of inductor 304 (e.g., measured in milli-Henries) but can be a measurement or determination of any value that is representative or reflective of the inductance value. For example, such a representative or reflective value may be in conformity with a mathematical rate of increase related to the inductance, a scaled version of the inductance, a binary format of the inductance, or a direct, indirect or inverse proportional relationship to the inductance (e.g., L; 1/L, etc.).
(31) Ratio Cl provides a relationship in which the inductor value L is determined based on the rate of rise (e.g., WTi) of the current when FET 302 is switched on. The iαput-to-output conversion ratio D for converter 301 is calculated from an on time (ramp- up time) T0n (= Ti + T2) of inductor current iL and an off-time (ramp-down time) Tofr (= T3) of inductor current i^ Since the above values can be determined, the average constant output inductor current iAvα for inductor current iL is determined as follows:
Figure imgf000010_0002
(32) On time T0n can be determined and respectively controlled as follows:
Figure imgf000010_0003
(33) As shown in Equation G, on time T0n for FET 302 can be controlled for providing a given adjustable average constant output inductor current -AVG for inductor current ii, by using the measured, determined, and/or known values for the input/output ratio D, the ratio Cl, and the total period TT of inductor current it. (34) Figure 6 depicts details of another Light Emitting Diode ("LED") lighting system 600 having another exemplary switch-mode buck converter power stage 601 controlled by a Light Emitting Diode ("LED") current controller 310 for driving LEDs 308. Figure 6 also shows LED current controller 310 coupled to target current generator 412, and as mentioned before, when Figure 4 was discussed earlier, target current generator 412 and LED current controller 310 make up LED lighting controller 400. LED lighting system 600 is another exemplary system illustrating another embodiment of the present invention, and the present invention is not in any way limited to an LED lighting system nor the use of a buck converter power stage, LED current controller, and LEDs. The present invention can also be used for other suitable applications as well as utilize other converters/converter power stages (e.g., boost converters) or controllers.
(35) Switch-mode buck converter power stage 601 comprises LEDs 308, inductor 304, FET (control switch) 302, and sense resistor Rsense coupled in series together and across the output voltage V0Ut as shown in Figure 6. One end of diode 306 is coupled to a positive side of input voltage Vin, and the other end of diode 306 is coupled at a node between inductor 304 and FET 302 as shown, in Figure 6. Output current iout is shown flowing at the positive side of output voltage Vout. Inductor current iL flows through inductor 304 while sense current i^e flows through resistor R8611Se. Again, sense resistor Rsense is utilized to detect the sense current isense that is flowing through FET 302. LED current controller 310 outputs a switch control signal CSo which is fed into the gate of FET 302 and controls activation and deactivation of FET 302 as a switch. Switch-mode buck converter power stage 601 can only allow the measuring or detecting of the inductor current iL when FET 302 is on and cannot allow the measuring or detecting of inductor current ύ. when FET 302 is off. Thus, switch-mode buck converter power stage 601 requires sense current isense only when FET 302 is on, and the low side switch 302 can be used for sensing sense current isense.
(36) Referring now to Figure 7, exemplary current waveforms 700, 702, and 704 for respective control signal CSo, inductor current iL, and sense current iwnse of exemplary switch-mode buck converter power stage 601 that are used to illustrate second and third exemplary techniques to each provide an accurate adjustable constant average inductor current output iaVg by exemplary switch-mode buck converter 601 operating in a hybrid Discontinuous Conduction Mode (DCM)/Continuous Conduction Mode (CCM) that uses double or more pulses in a switching period. The techniques help allow for a smooth transition of switch-mode buck converter power stage between CCM and DCM. U.S. Application Serial Number 12/113,536 (hereafter '536 patent application) filed on May 1, 2008 entitled "Switch-Mode Converter Operating in a Hybrid Discontinuous Conduction Mode (DCM)/Continuous Conduction Mode (CCM) That Uses Double or More Pulses in a Switching Period" (Inventor: John Melanson; Cirrus Docket No. 1674-IPD) discusses in detail the operation of a switch-mode converter in such hybrid DCM/CCM that uses double or more pulses in a switching period, and the *536 patent application is hereby incorporated by reference.
(37) Referring now to waveforms 700, 702, and 704 of Figure 7, a second exemplary technique for providing an accurate adjustable constant average inductor current output iavg by exemplary switch-mode buck converter power stage 601 is discussed. Control signal CSo transitions to a high value and turns on FET 302 during time period T]. Inductor current iL ramps up and crosses through reference current iref and reaches peak current ipeak at the end of period T1. Sense current i^^ ramps up to a peak sense current value during time period Tj. During time period T., control signal CSo goes to a low value and turns off FET 302. During this time period T2, switch-mode buck converter 601 cannot allow the detection of the value of inductor current it, and sense current isense discharges to a zero value. Control signal CSo next goes back to a high value and turns on FET 302 during time period T3. Inductor current iL ramps back up and crosses through reference current iref and reaches peak current ipeak again. During this time period T3, switch-mode buck converter power stage 601 can allow the value of inductor current iL to be detected, and sense current isense ramps up to a peak sense current value. Control signal CSo then goes back to a low value and turns off FET 302 during time period T4. Inductor current ii, ramps down to zero during time period T4. During mis time period T4, switch-mode buck converter power stage 601 cannot allow for the detection of the value of inductor current it,, and sense current isense discharges to a zero value. (38) If time period T3 is less than time period T1 , switch-mode huck converter power stage 601 has then entered into the hybrid DCM/CCM that uses double or more pulses in a switching period. However, if time period T3 is approximately equal to time period Ti, then time period T2 needs to be adjusted (e.g., decreased) so that time period T3 will be less than time period T].
(39) Referring now to Figure 7, the total charge in a normal single pulse for inductor current ÷L would involve a normal switching time period that includes the time periods Ti and T4 only. The total charge for a single pulse would be the total charge Qi during time period T] and the total charge Q2 during time period T4. Thus, this relationship for the total charge of a normal single pulse is represented by the following mathematical relationship:
Figure imgf000013_0002
(40) However, inductor current ύ. cannot be observed or measured during time period T4. Thus,
Figure imgf000013_0001
(41) The double or more pulses of a switching period for inductor current IL as shown in current waveform 702 is basically an overlap of two single pulses (e.g., each involving time periods T] and T4 only). The overlap charge area Al being a triangular area as shown in current waveform 702. The left side length of the overlap charge area Al is reflective of the difference between time periods Ti and T3 while the right side length of the overlap charge area Al is reflective of the difference between time periods T4 and T2. Thus, the total charge QT under current waveform 702 is calculated as follows:
Total Charge Qτ = 2 * QsiDgk - A 1 Equation K
Overlap charge area Al = ((Ti - T3) / T1) * Qi + ((T4 - T2) / T4) * Q2)
(42) As shown in Figure 7, peak current -peak is set equal to 1 Amp, and in the exemplary waveforms of Figure 7, the geometry and triangular areas are set up to be the same as each other so that T1 = T4 and T3 = T2, and the mathematical relationships can be simplified.
Figure imgf000014_0001
(43) Since time period Ti is measured, time period T2 is preset (e.g., by the user), time period T3 is measured, the waiting time period T4 can be derived from time periods T,, T2, and T3, the peak current ipeak is known, the average current iavg can be calculated and determined by Equation N above. If the Ti / T2 ratio is chosen as a power of two, then the match is simple. From the time periods Ti, T2, and T3, the calculation of the total charge QT = (iavg * TT) becomes straight forward. Enough pulses based on the known time periods Ti, T2, and T3 can be created to set any value for average current iavg, and thus, control of a constant average output current iavg can be provided. (44) Since time period T4 can be derived and known, a number of single pulses (e.g., with ramρ-uρ time period Ti and ramp-down time period T4) can be used to provide respective average currents. Double or more pulses for a switching period can be used constantly, occasionally (to update the D = input/output ratio), or in any frequency manner with the single pulses.
(45) In this second exemplary technique, ratio Cl as discussed for the first exemplary technique provides the same relationship in which the inductor value L is determined based on the rate of rise (e.g., ire/Ti) of the current when FET 302 for converter 601 is switched on. The input-to-output conversion ratio D for converter 601 is calculated from a total on time (ramp-up time) TOn (= Ti + T3) of inductor current iL and a total off-time (ramp-down time) TOff (= T2 + T4 = T2 + Ti / T3 * T2) of inductor current iL. This second exemplary technique reflects the fact that the FET 302 is turned on again at least for a second time within the switching period TT before inductor current i^ decays to zero.
(46) Referring again to waveforms 700, 702, and 704 of Figure 7, a third exemplary technique for providing an accurate adjustable constant average inductor current output iavg by exemplary switch-mode buck converter power stage 601 is further discussed. The third exemplary technique is identical to the second exemplary technique except that at the end of timing period T4, an additional compensating pulse (shown in dotted line) having an on time of time period T5 = Ti - T3 is triggered for control signal CSo as shown in current waveform 700. A single triangular pulse with a known charge area of Al (e.g., identical to the overlap charge area Al) results since time periods T1 and T3 are known, and the single triangular pulse is added in the current waveform 702 for inductor current iL. The mathematical calculations become further simplified since the total charge QT is determined by:
Total Charge QT = 2 * Qsingle - A 1 + A 1 = 2 * Qsingle Equation O
(47) Therefore, the principles and techniques of the present invention help allow for a smooth transition of a converter power stage operate between CCM and DCM. When converter power stage 301 or 601 operates in DCM, converter power stage 301 or 601 is able to provide an average constant output current that is adjustably controlled by an inductor value that is measured and/or detected and further controlled by an input-to- output conversion, ratio that is measured and/or detected. The exemplary techniques of the present invention allow the inductor value (e.g., inductor value L) and the input-to- output conversion ratio (e.g., input-to-output ratio D) to be accurately measured, determined, or discovered. Accuracy in determining the inductor value and/or the input- to-output ratio for a converter directly affect the current calibration and will help avoid or minimize differential non-linearity ("DNL") errors in the effective current Digital-to- Analog Converter ("DAC"). Thus, it is important to provide an accurate adjustable constant average current output for the inductor current iL of a switch-mode converter, especially when the switch-mode converter is operating in DCM. The present invention provides ways to provide such a constant current output.
(48) 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 converter system, comprising: a converter power stage that can operate in a Discontinuous Conduction Mode (DCM) in a range of output currents and a Continuous Conduction Mode (CCM) in another range of output currents wherein the converter power stage includes at least an inductor with an inductor value and a control switch and the converter power stage provides an average current, and a current controller coupled to the converter power stage; and wherein when the converter power stage operates in DCM, the converter power stage provides the average current and wherein the current controller is configured to measure the inductor value of the inductor.
2. The converter system according to Claim 1 , wherein the inductor value is determined from a rate of rise of an inductor current through the inductor when the control switch is on.
3. The converter system according to Claim 1 wherein the current controller is configured to measure an input-to-output conversion ratio from the converter power stage.
4. The converter system according to Claim 3, wherein the input-to-output conversion ratio is determined from a ramp-up time of the inductor current and a ramp- down time of the inductor current.
5. The converter system according to Claim 3, wherein a sense current is detected at the control switch and wherein the input-to-output conversion ratio is determined by turning the control switch on at least a second time within a switching period before the inductor current decays to zero.
6. The converter system according to Claim 5, wherein at least one additional pulse is triggered after the inductor current decays to zero so that a total charge for the inductor current over the switching period is a simple multiple of a charge for a normal single pulse over a normal switching period for the inductor current.
7. The converter system according to Claim 1, wherein the converter power stage is a switch-mode buck converter power stage.
8. The converter system according to Claim 7, wherein an output of the switch-mode buck converter power stage is coupled to and drives a light emitting diode (LED) load.
9. A method of operating a converter system, comprising: operating a converter power stage in a Discontinuous Conduction Mode (DCM) in a range of output currents and a Continuous Conduction Mode (CCM) in another range of output currents in which the converter power stage includes at least an inductor with an inductor value and a control switch; providing, by the converter power stage, an average current; controlling, by a current controller, a current in the converter power stage; and when the converter power stage operates in DCM, providing, by the converter power stage, the average current and configuring the current controller to measure the inductor value of the inductor .
10. The method according to Claim 9, further comprising: determining the inductor value from a rate of rise of an inductor current through the inductor when the control switch is on.
11. The method according to Claim 9, further comprising: configuring the current controller to measure an input-to-output conversion ratio from the converter power stage.
12. The method according to Claim 11, further comprising: determining the input-to-output conversion ratio from a ramp-up time of the inductor current and a ramp-down time of the inductor current.
13. The method according to Claim 11 , further comprising: detecting a sense current at the control switch; and determining the input-to-output conversion ratio by turning the control switch on at least a second time within a switching period before the inductor current decays to zero.
14. The method according to Claim 13, wherein determining the input-to-output ratio further comprises: triggering at least one additional pulse after the inductor current decays to zero so that a total charge for the inductor current over the switching period is a simple multiple of a charge for a normal single pulse over a normal switching period for the inductor current.
15. The method according to Claim 9, wherein operating a converter power stage further comprises operating a switch-mode buck converter power stage.
16. The method according to Claim 1 S, further comprising: coupling an output of the switch-mode buck converter power stage to a light emitting diode (LED) load and driving the LED load.
17. A current controller for controlling an inductor current of a converter power stage wherein the converter power stage includes at least an inductor with an inductor value and a control switch and can operate in a Discontinuous Conduction Mode (DCM) in a range of output currents and a Continuous Conduction Mode (CCM) in another range of output currents; comprising: a local power supply, a state machine, a digital-to-analog converter, a comparator, and a clock coupled together in an operable manner, wherein the state machine receives a target current and the comparator compares a sense current from the converter with the target current, and the comparison is fed to the state machine to respectively provide a control signal to the switch; the state machine is able to receive and measure from the converter power stage the inductor value so that the converter power stage is able to provide an average current of the converter power stage when the converter power stage operates in DCM.
18. The current controller according to Claim 17, wherein the inductor value is able to be determined from a rate of rise of an inductor current through the inductor when the control switch is on.
19. The current controller according to Claim 17, the state machine is able to receive and measure from the converter power stage an input-to-output conversion ratio.
20. The current controller according to Claim 19, wherein the input-to-output conversion ratio is able to be determined from a ramp-up time of the inductor current and a ramp-down time of the inductor current.
21. The current controller according to Claim 19, wherein a sense current is able to be detected at the control switch and wherein the input-to-output conversion ratio is able to be determined by turning the control switch on at least a second time within a switching period before the inductor current decays to zero.
22. The current controller according to Claim 21, wherein at least one additional pulse is triggered after the inductor current decays to zero so that a total charge for the inductor current over the switching period is a simple multiple of a charge for a normal single pulse over a normal switching period for the inductor current.
23. The current controller according to Claim 17, wherein the current controller is a light emitting diode (LED) current controller.
24. The current controller according to Claim 17, wherein the current controller is implemented in a single integrated circuit.
PCT/US2009/058298 2008-09-30 2009-09-25 Adjustable constant current source with continuous conduction mode ("ccm") and discontinuous conduction mode ("dcm") operation WO2010039588A2 (en)

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